Technical Documentation - M - 3108 - TD

System:
PURE STEAM GENERATOR
Equipment: CPSG ST 1000
Document Code: M_3108_TD
Job No.: 11880
Serial No.: 3108
SUMMARY

Section 1. Section 4.
General documentation and constructive Piping, fittings and welding
specification documentation
1.1. Design qualification 4.1. Material list and certificates
1.2. Risk assessment 4.2. Welding documentation
1.3. P&ID reading key
1.4. P&ID
Section 5.
1.5. Tie‐in drawing Manuals and spare parts
1.6. Conformity declaration of the equipment 5.1. Use and maintenance manual
1.7. Quality declarations 5.2. Operating manual
5.3. Suggested Spare Parts list

Section 2.
Components documentation
2.1. Part list
2.2. Technical dossiers
2.3. Components certification
2.4. Instruments used for internal test

Section 3.
Electrical, Hardware and Software
documentation
3.1. Electrical and pneumatic scheme
3.2. Electrical insulation test and control board
conformity declaration
3.3. Hardware design specification
3.4. Input / Output list
3.5. PLC/HMI Software identification form
3.6. Alarms list and actions
3.7. PLC / HMI software recovery procedures

TECHNICAL DOCUMENTATION – M_3108_TD SUMMARY/FOREWORD

FOREWORD

A good understanding of the contents of this Documentation ‐ through careful reading of all
sections ‐ is essential for the correct, safe use and operation of the equipment.

No one should operate or perform maintenance on this equipment without first having read
and understood the Instructions for Use & Maintenance which are provided for all critical
components and for the whole equipment in the correspondent sections.

Wrong manipulations or unsuitable or missing maintenance may jeopardize the correct
operation of the equipment and its warrantee.

HOW TO USE THE SYSTEM DOCUMENTATION

The whole System Documentation is mainly composed by:
‐ Technical Documentation (contained in one or more books ‐ depending on the equipment
type)
‐ Technical Dossiers (contained in one or more books ‐ depending on the equipment type)
‐ Components Datasheets & Manuals (contained in one or more books ‐ depending on the
equipment type).

The “Technical Documentation” contain the main information of the system: system specification,
drawings, components certificates etc.
The “Technical Dossiers” refer only to the equipment main components (column vessels,
exchangers, etc.) and provide specific information about them.
In case of electronic files only, the Technical Dossier are attached inside the Technical
Documentation file.
The “Components Datasheets & Manuals” contain only the manuals or datasheets of each system
component.

To find a specific topic/document, use the summary at the beginning of the relevant documentation.

HOW TO QUICK‐FIND DOCUMENTS IN THE HARD COPIES
Technical Documentation
To find a specific component certificate, use the equipment Part List (contained in the TECHNICAL
DOCUMENTATION).
The Part List column “Certificates filed in” indicates where to find the required certificate (Section
No. and Attachment No.).
A title page precedes each attachment.
See example below:


The title page shows the list of deliverables for each component, which are attached in sequence
and preceded by a separator as in the example below:


Components Datasheets & Manuals
To find a specific component datasheet and/or manual, use the equipment Part List (contained in
the TECHNICAL DOCUMENTATION) and identify the component supplier using the relevant Part List
column “Supplier”.
Now open the COMPONENTS MANUALS & DATASHEETS book and find, using the summary, the
correct supplier section.
A title page precedes each supplier section.
See example below:


HOW TO USE THE DOCUMENTATION PDF FILES
The Documentation PDF files are supplied through CD‐ROM or FTP Link.
Click on the Documentation folder to visualize the PDF files:
Technical Documentation and Components Datasheets and Manuals.
See example below:


HOW TO QUICK‐FIND DOCUMENTS IN THE PDF FILE
Technical Documentation
Open the PDF file.
Click on the flag menu (on the left side of the screen) to visualize the file content.
Then, click on the desired section/attachment to open the corresponding title page.
On equipment components title pages, in order to simplify the research of each certificate, different
links are present. Use them to open the relevant certificate.
See example below:

Another way to find a specific component certificate, is through the equipment Part List (contained
in the TECHNICAL DOCUMENTATION).
The Part List column “Certificates filed in” indicates where to find the required certificate (Section
No. and Attachment No.). Section and attachment number appear in the form of clickable link that
refer directly to the desired title page.
On components title pages, in order to simplify the research of each certificate, different links are
present. Use them to open the relevant certificate.
See example below:


Components Datasheets & Manuals
Open the PDF file of Components Manuals & Datasheets.
Then, click on the desired section to open the corresponding title page.
On title pages, in order to simplify the research of each certificate, different links are present. Use
them to open the relevant datasheet or manual.
See example below:

Open the PDF file of Components Manuals & Datasheets.
Now, open the summary. The supplier section number appear in the form of clickable link that refer
directly to the desired title page.
On title pages, in order to simplify the research of each certificate, different links are present. Use
them to open the relevant datasheet or manual.
See example below:


Section 1
General documentation and constructive specification

1.1. Design qualification
1.2. Risk assessment
1.3. P&ID reading key
1.4. P&ID
1.5. Tie‐in drawing
1.6. Conformity declaration of equipment
1.7. Quality declarations

TECHNICAL DOCUMENTATION ‐ M_3108_TD

SECTION 1.1.
Design qualification
▹▹▷

CUSTOMER FARMALOGICA S.A.
LOCATION COLOMBIA
DOCUMENT NAME DESIGN QUALIFICATION
BRAM-COR
DOCUMENT CODE M_3108_DQ_0
Ref. No. P.I. 4394.4.A
SYSTEM PURE STEAM GENERATOR
EQUIPMENT TYPE CPSG ST 1000

SERIAL No. 3108
JOB No. 11880
BASIC TECHNICAL DATA
POWER SUPPLY
(VOLTAGE AND FREQUENCY) 440 V - 60 Hz / 3 PH + G
REVISION HISTORY
Rev. Description Date Issued Verified Approved
0 First issue 06/06/2018 C. Opl A. Scala A. Negri
BRAM-COR S.p.A.
Via Mercalli 12/A ‐ 43122 Parma
Tel. +39 0521 538711
Fax: +39 0521 538770
e‐mail: info@bram‐cor.com
UNI EN ISO 9001:2015 Certified Company
TABLE OF CONTENTS
1. OVERVIEW ......................................................................................................................................................... 4
1.1. DQ PROTOCOL RATIONALE ................................................................................................................................ 4
1.2. SCOPE AND APPLICATION .................................................................................................................................. 4
1.3. CHANGE CONTROL ............................................................................................................................................. 5
1.4. RESPONSIBILITIES ............................................................................................................................................... 5
1.5. PROTOCOL APPROVAL ....................................................................................................................................... 5
1.6. TERMINOLOGY AND ABBREVIATIONS................................................................................................................ 5
1.7. REGULATORY STANDARDS ................................................................................................................................. 6
1.8. BRAM-COR S.p.A. QUALITY SYSTEM PROCEDURES............................................................................................ 7
2. REFERENCE DOCUMENTATION .......................................................................................................................... 8
3. FUNCTIONAL DESIGN SPECIFICATION ................................................................................................................ 9
3.1. DESIGN ASSUMPTIONS FOR PS QUALITY ........................................................................................................... 9
3.2. UTILITIES REQUIREMENTS, CONSUMPTIONS AND PERFORMANCE ................................................................ 10
3.2.1. UTILITIES AND CONSUMPTIONS ............................................................................................................. 10
3.2.1.1. FEEDWATER ................................................................................................................................... 10
3.2.1.2. INDUSTRIAL STEAM SUPPLY REQUIREMENTS................................................................................ 10
3.2.1.3. ELECTRICAL SUPPLY REQUIREMENTS ............................................................................................ 11
3.2.1.4. COMPRESSED AIR SUPPLY REQUIREMENTS................................................................................... 11
3.2.1.5. DRAINAGE ...................................................................................................................................... 11
3.2.2. PERFORMANCE ....................................................................................................................................... 11
3.2.3. PURE STEAM GENERATION PROCESS ..................................................................................................... 12
3.2.4. PS GENERATOR STERILIZATION PROCESS ............................................................................................... 12
3.3. MECHANICAL COMPONENTS DESCRIPTION .................................................................................................... 13
3.3.1. PURE STEAM GENERATOR ...................................................................................................................... 13
3.3.2. FEED WATER PUMP [P-2001] ................................................................................................................. 14
3.3.3. EVAPORATION EXCHANGER [E-2001] ..................................................................................................... 15
3.3.4. EVAPORATION and DECONTAMINATION CHAMBER [C-2001] ............................................................... 15
3.3.5. VALVES .................................................................................................................................................... 16
3.3.5.1. INLET VALVE ................................................................................................................................... 16
3.3.5.2. MODULATING VALVE ..................................................................................................................... 16
3.3.5.3. MANUAL MEMBRANE VALVES....................................................................................................... 16
3.3.5.4. PNEUMATIC MEMBRANE VALVES ................................................................................................. 16
3.3.5.5. SAFETY VALVE ................................................................................................................................ 16
3.3.5.6. PIPING AND FITTINGS .................................................................................................................... 16
3.3.5.7. INSULATION MATERIAL.................................................................................................................. 16
3.4. ELECTRICAL COMPONENTS DESCRIPTION ....................................................................................................... 17
3.4.1. WIRING ................................................................................................................................................... 17
3.4.2. CONTROL BOARD .................................................................................................................................... 17
3.4.2.1. EMERGENCY CIRCUIT ..................................................................................................................... 17
3.4.3. INSTRUMENTS ........................................................................................................................................ 17
3.4.3.1. PRESSURE TRANSDUCER ................................................................................................................ 18
3.4.3.2. LEVEL TRANSMITTER ...................................................................................................................... 18
3.4.3.3. PRESSURE SWITCH ......................................................................................................................... 18
4. HARDWARE DESIGN SPECIFICATION .................................................................................................................19
4.1. OVERVIEW ....................................................................................................................................................... 19
4.1.1. ENVIRONMENTAL CONDITIONS.............................................................................................................. 19
4.2. SYSTEM ARCHITECTURE ................................................................................................................................... 19
4.3. PLC AND USER INTERFACE CONFIGURATION .................................................................................................. 20
4.3.1. AUTOMATION UNIT - PLC ....................................................................................................................... 20
4.3.2. STORAGE ................................................................................................................................................. 20
4.3.3. INPUT – OUTPUT SYSTEM ....................................................................................................................... 20
4.3.4. HUMAN-MACHINE INTERFACE ............................................................................................................... 21
5. SOFTWARE DESIGN SPECIFICATION ..................................................................................................................22
5.1. SEQUENCES ...................................................................................................................................................... 22
5.2. COMMANDS .................................................................................................................................................... 22
5.2.1. CPSG EMPTYING ..................................................................................................................................... 22
5.3. FUNCTIONS ...................................................................................................................................................... 23
DESIGN QUALIFICATION - M_3108_DQ_0 PAGE 2 of 40

5.4. USER FUNCTIONS ............................................................................................................................................. 28
5.4.1. MANUAL START / STOP .......................................................................................................................... 28
5.4.2. SYSTEM OPERATION MONITORING ........................................................................................................ 28
5.4.3. ALARMS RESET........................................................................................................................................ 28
5.4.4. SYSTEM PARAMETERS SCREEN ............................................................................................................... 28
5.5. PLC FUNCTIONAL SPECIFICATIONS .................................................................................................................. 29
5.5.1. STARTUP SEQUENCE ............................................................................................................................... 29
5.5.2. RUNNING SEQUENCE .............................................................................................................................. 29
5.5.3. SHUTDOWN SEQUENCE .......................................................................................................................... 29
5.5.4. ALARM TASK ........................................................................................................................................... 30
5.6. INTERFACES...................................................................................................................................................... 32
5.6.1. USER INTERFACE WITH THE PLC/HMI SYSTEM ....................................................................................... 33
5.6.2. ALARM WINDOW ................................................................................................................................... 33
5.6.3. PARAMETERS SCREEN............................................................................................................................. 33
5.6.3.1. FUNCTIONAL PARAMETERS SCREEN .............................................................................................. 33
5.6.3.2. PID PARAMETERS SCREEN ............................................................................................................. 33
5.7. PASSWORDS..................................................................................................................................................... 34
5.8. INTERFACE WITH EXTERNAL INPUTS AND OUTPUTS ....................................................................................... 34
5.8.1. DIGITAL INPUTS ...................................................................................................................................... 34
5.8.2. ANALOG INPUTS ..................................................................................................................................... 34
5.8.3. DIGITAL OUTPUTS ................................................................................................................................... 35
5.8.4. ANALOG OUTPUTS .................................................................................................................................. 35
5.9. INTERFACE WITH OTHER SYSTEMS .................................................................................................................. 35
5.10. INTERFACE WITH INSTRUMENTATION ............................................................................................................ 35
5.11. NON-FUNCTIONAL ATTRIBUTES ...................................................................................................................... 35
5.11.1. AVAILABILITY (POWER FAILURE RECOVERY) .......................................................................................... 35
5.11.1.1. RESTART AFTER A POWER FAILURE .............................................................................................. 35
5.11.1.2. PROGRAM RETENTION DURING A POWER FAILURE ..................................................................... 35
5.12. ERROR CHECKING ............................................................................................................................................ 36
5.12.1. PLC/HMI SYSTEM .................................................................................................................................... 36
5.12.2. ANALOGICAL INPUT / OUTPUT ............................................................................................................... 36
5.12.3. STANDBY OPERATION ............................................................................................................................. 36
5.13. MAINTAINABILITY ............................................................................................................................................ 36
5.13.1. EXPANSION / SPARE CAPACITY ............................................................................................................... 36
5.13.2. BACKUP ................................................................................................................................................... 36
6. DOCUMENTATION AND TESTING......................................................................................................................37
6.1. TECHNICAL DOCUMENTATION INCLUDED IN THE SUPPLY. ............................................................................. 37
6.1.1. TECHNICAL DOCUMENTATION CONTENTS ............................................................................................. 37
6.1.2. DATASHEETS & MANUALS BOOK ............................................................................................................ 38
6.2. VALIDATION DOCUMENTATION ...................................................................................................................... 38
6.2.1. QUALIFICATION PROTOCOLS PREPARATION .......................................................................................... 38
6.2.2. INSTALLATION QUALIFICATION PROTOCOL ............................................................................................ 38
6.2.3. OPERATIONAL QUALIFICATION PROTOCOL ............................................................................................ 38
7. EXCLUSIONS .....................................................................................................................................................39
8. DELIVERY ..........................................................................................................................................................39
9. WARRANTY ......................................................................................................................................................39
10. APPROVAL PAGE ..............................................................................................................................................40
• Attachments: see section 2

1. OVERVIEW
This document contains the Design Specifications of the Pure Steam Generator CPSG ST 1000
developed for FARMALOGICA.
The Design Qualification is the documented verification that the design of the equipment matches
the Customer’s URS and/or the contract agreements. The Design Qualification is the first step of the
validation process in the Good Automated Manufacturing Practice of the PS production system.
The technical specifications herein are meant to be verified during the Installation Qualification and
the Operational Qualification of the equipment.
1.1. DQ PROTOCOL RATIONALE
The DQ protocol is composed of this basic document, which includes in its text following
specifications:
 Functional Design Specification (with design assumptions, utilities specification, process description,
equipment and mechanical components specification)
 Preliminary Hardware Design Specification
 Preliminary Software Design Specification
 Documentation Specification
and of a series of attachments specified in section 2, which are an integrating and fundamental part
of the whole protocol.
Wherever possible, datasheets of commercial components are provided as clickable links to the
manufacturer’s website, to complete the information. Connection to the components
manufacturers’ website may take a few seconds.
1.2. SCOPE AND APPLICATION
This document defines the functional objects towards the design solutions for all system
components:
1. mechanical components
2. electrical hardware,
3. embedded software.
BRAM-COR scope of supply includes:

 detailed design (constituted by this document with its attachments) of the system
 manufacturing of the system as per contractual terms
 issue of the Technical Documentation complete with manuals, components documentation,
materials certification, instruments calibration certificates and welding documentation (see section
6 for details)
 issue of Installation Qualification, Operational Qualification protocols.

1.3. CHANGE CONTROL
Any comment, note, implementation on the original DQ protocol shall be entered by the Customer
beside the relevant chapter/sentence. The commented document shall be forwarded in due time to
BRAM-COR Project Manager for assessment and review, implying a new revision of the DQ
protocol.
This document will reflect all integrations made in progress to the original project. The chronological
traceability of the project evolution is provided by the revision index and by the true dates in the
revisions history shown in the front page.
1.4. RESPONSIBILITIES
According to contract agreements:

 BRAM-COR develops this Design Qualification Protocol;
 FARMALOGICA shall check and approve this DQ protocol before equipment construction;
 BRAM-COR starts the construction of the equipment as soon as this DQ protocol has been officially
approved and signed by the Customer.
1.5. PROTOCOL APPROVAL
This document shall be approved prior to implementation of any component purchase. Upon
approval by both parties, this Design Qualification becomes an element of a legal contract which is
binding on the Supplier and the Customer. Customer’s signature for approval indicates that the
documentation and information contained herein has been reviewed and complies with the User
Requirement Specification.
Once approved by the Customer, the design solutions described in this document overcome any
prior or preliminary notice and are applied for system construction.
To respect the project schedule, the deadline for DQ approval is 10 working days from DQ file
shipment in electronic format. If no comment or no approval is transmitted by the Customer
within this date, BRAM-COR will hold this DQ to be officially approved and will start the
construction of the equipment.
1.6. TERMINOLOGY AND ABBREVIATIONS
AI = Analogic Input OP= Operator Panel

AO = Analogic Output OQ = Operational Qualification
CQA = Quality Critical Attribute P&ID= Piping and Instrumentation Diagram
CSV = Comma-Separated-Value PW= Purified Water
DI = Digital Input PS = Pure steam = CS = Clean Steam
DO= Digital Output SAT = Site Acceptance Test
DQ = Design Qualification SCADA = Supervisory Control and Data Acquisition
DTS = Double Tube Sheet SOP = Standard Operating Procedure
Eu. Ph= European Pharmacopoeia SW = Software
FAT = Factory Acceptance Test TIE IN=Utilities & boundaries connections diagram
FW = Feed Water TOC= Total Organic Carbon
GMP = Good Manufacturing Practice UPS = Uninterruptible Power Supply
HDPE = High density Polyethylene URS= User Requirement Specification
HW = Hardware USB= Universal Serial Bus
HMI= Human-Machine Interface USP =United States Pharmacopoeia
IQ = Installation Qualification WFI= Water for Injection
MMC = Micro Memory Card ZDL = Zero Dead Leg

1.7. REGULATORY STANDARDS
BRAM-COR S.p.A. design, production and testing activities are performed in compliance to the
following standards:
 ISPE Guideline: "Sterile Manufacturing facilities" Vol. 3
 ISPE Guideline: "Water & steam systems" – Vol. 4
 GAMP 5: “A risk-based approach to compliant GXP computerized systems”
 GAMP Guideline: "Testing GXP"
 ISPE Guideline: "Calibration Management"
 ISPE Guideline: "Commissioning and Qualification of Water and Steam Systems" Vol. 5
ISPE GPG: “Approaches to Commissioning and Qualification of Pharmaceutical Water and Steam System” 2nd

Ed.
 USP 40 <1231>
 European Pharmacopeia 9th edition
 ASME BPE-2016 “Bioprocessing Equipment”
 2006/42/CE European Directive for Machinery
EudraLex -The Rules Governing Medicinal Products in the European Union -Volume 4

Good Manufacturing Practice-Medicinal Products for Human and Veterinary Use
 PIC/S PI 009-2 “Aide memoire: Inspection of utilities”
 PIC/S PI 006-2 “Recommendations on Qualification and Validation””
 21CFR Part 11
 21CFR Part 210
 21CFR Part 211 - Subpart D - Equipment
 EN ISO 9606:2013 “Qualification of welders" - Manual welding
 EN 14732:2013 “Qualification of welders" - Automatic welding
 ASTM A -270 “Standard Specification for Seamless and Welded Austenitic Stainless Steel Sanitary Tubing”
 ASTM A 967-01 “Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts”
 CEI EN 60204-1:“Electrical safety of machinery”
 IEC 61439: “Low-voltage switchgear and controlgear assemblies”
 IEC 1131-1: “Programmable Controllers - General Information
 UNI 10893: "Technical Documentation of Product"
 EN 10204: “Metallic Products: type of inspection documents”
ASTM C- 795 –“ Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless

Steel”
 ASME A13.1 “Scheme for the identification of piping"
ASTM A 380-99 “Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts,

Equipments and Systems”
 FDA Guide to Inspection of High Purity Water System

1.8. BRAM-COR S.p.A. QUALITY SYSTEM PROCEDURES
BRAM-COR S.p.A. activities are regulated by BRAM-COR Corporate Quality System and described in
the Quality Manual, detailed by the relevant Standard Operating procedures.
The following list defines BRAM-COR certified Quality System Procedures and main Operating
Instructions regulating Design, Construction, Testing and Project Managing activities.
Activity Procedure Title Operating Title

Instruction
PO 73_01 Design Management IO 73_01_01 Software development
Design
PO 74_01 Purchase Management - -
Purchase
Supplier’s Assessment - -
PO 75_01 Job Management - -
PO 75_02 Customer’s Properties - -
PO 75_03 Assistance - -
PO 75_04 Identification and IO 75_04_01 Coding

Traceability
PO 75_05 Process Control IO 75_05_01 Thickness measurement
IO 75_05_02 Roughness test

Production
PO 75_06 Delivery and - -
and
Commissioning
Installation
PO 75_08 Machines Construction - -
IO 75_09_01 Piping Cleaning
IO 75_09_02 Pickling and passivation
IO 75_09_03 Coupons-weld identification

PO 75_09 Sanitary Piping
IO 75_09_04 Hydrostatic test
IO 75_09_05 Drainability test
PO 76_01 Measuring Instruments Operating procedures for calibration

Inspection & Management
Monitoring PO 83_01 CAPA Management - -

2. REFERENCE DOCUMENTATION
This document includes following reference documentation:
ATTACHMENT NO. DOCUMENT DESCRIPTION

1 Reading key
2 PS Generator Piping and Instrumentation Diagram (P&ID) # 23749
3 PS Generator TIE-IN drawing # 23751
4 PS Generator Part List # M_3108_PL
 The P&ID drawing describes the equipment in terms of flow and components. All components in the
P&ID drawing are marked with their TAG number for traceability to the part-list of the equipment.
 The TIE-IN drawing provides information about equipment size and necessary connections.
 The part-list is composed of several columns as follows:
COLUMN SPECIFICATION
Unit Identification No. of the equipment - e.g. 20 = Pure Steam Generator
TAG Identification No. of the component - e.g. PT-001 = pressure transducer
Description Description of the component
Supplier Brand
Model Model of the component
Position Position of the component in the equipment
Certification Type of certificate supplied with the item

Attachment number of the documentation of the component (e.g. datasheet,
manual, certificate where applicable) to the final Technical Documentation
Annex to TD
delivered at FAT. This column is usually filled-in only after construction of the
equipment.
Item rev Indicating subsequent changes to the component (if any)
The whole Technical Documentation of the equipment is delivered with the equipment in as built
version.
For further details about the contents of BRAM-COR Technical Documentation, see the relevant
section in this document.

3. FUNCTIONAL DESIGN SPECIFICATION

3.1. DESIGN ASSUMPTIONS FOR PS QUALITY
BRAM-COR develops the project according to:
 Eu. Ph./ USP requirements for Pure Steam

 Specifications in BRAM-COR Offer
 Technical information and requirements from the Customer
 Current GMP regulatory standards for Pure Steam production equipment as specified in section 1.7.
Pharmacopoeias requirements and compliance to EN 285 for Pure Steam (condensate) are
resumed in following table:
PARAMETER
USP 39 9 th Eu.Ph.
Physical/chemical
Conductivity ≤ 1,3 μS/cm@25°C Not defined
TOC ≤ 0.50 mg/L Not defined
Microbiological
≤ 10 CFU/100 ml
Bacterial count Not defined
< 0.25 EU/ml
Bacterial endotoxins Not defined
CLEAN STEAM PHYSICAL PROPERTY DESIGN VALUE (EN 285) 1
Non-condensable gasses < 3.5 ml/100 ml condensate
Superheated < 25 °C 2
Dryness > 0,9-0,95
Notes:
1. Physical properties of Pure Steam , according to EN 285, if applicable, should be tested on the worst
case point of the local PS distribution line (i.e. on the end-user point, which is usually an autoclave).
Steam Quality Testing is not included in BRAM-COR supply.
2. The amount of superheat present in the steam should be no more than 25° C above the temperature
in free expansion into atmosphere at the current atmospheric pressure. This corresponds to an
upper limit of 125°C in the measurement (i.e. the temperature of the steam is considered to be
acceptable if it is less than 25°C above that of the local temperature of boiling water, which is
altitude dependent).

3.2. UTILITIES REQUIREMENTS, CONSUMPTIONS AND PERFORMANCE
3.2.1. UTILITIES AND CONSUMPTIONS

UTILITY PARAMETER VALUE - UNIT NOTES
Flow Rate 1000 l/h

Compendial PW with conductivity
Feed Water
Temperature 15°C <1.1 µS/cm @ 20°C
(Purified Water)
Pressure 1 barg
The plant steam lines must be
Flow Rate 1160 kg/h
protected against overpressure.
Industrial Steam The industrial steam inlet group
Pressure 6 barg
shall be installed by the customer.
Since power surges may seriously
Voltage 440 V
damage hardware components, a
Electric Supply steady electrical supply shall be
Frequency 60 Hz
ensured by the Customer by means
(CB-3010)
of a voltage stabilizer/UPS
Total Power 1.0 kW unit/surge arrester.
Compressed Air to the Dry, oil free compressed air. The
Flow Rate 2 Nl/min
control board Customer’s compressed air supply
To actuate the control line shall be ready for pneumatic
Pressure Min. 6 bar quick connection in Teflon pipe.
valves
Blow-down Flow Rate 100 l/h

From the evaporation See section 3.2.1.5.
column Temperature 144°C
This parameter depends from the
Flow Rate To be defined setting of the safety valve installed
Vent on the column of the Pure Steam
Generator. Condense from the vent
Pressure 4.9 barg shall be conveyed out of the room.
Note: The battery limits for BRAM-COR supply are clearly defined in the enclosed P&ID drawings.
3.2.1.1. FEEDWATER
Feedwater should be Purified Water compliant to pharmacopoeial standards (conductivity <1.3
µS/cm @ 25°C, TOC ≤ 0.50 mg/L).
Feed water lack is alarmed, stopping the equipment.
3.2.1.2. INDUSTRIAL STEAM SUPPLY REQUIREMENTS

The Pure Steam Generator requires industrial steam for the double-tube-sheet exchanger heating.
The industrial steam supply line shall be capable of delivering steam at a flow-rate corresponding to
the consumption. The Customer’s industrial steam supply line shall be configured as described in the
P&ID drawing of the equipment. The industrial steam inlet group with manual valve and Y filter shall
be provided and installed by the customer. The plant steam lines must be protected against
overpressure. The design pressure of the plant steam side of BRAM-COR equipment is 9.0 barg, so
the safety valve on the boiler should have a set pressure below 8.9 barg (better below 8.5 barg).
The generator can accept inlet pressure fluctuation between 7 to 8 barg without any additional
accessory.
The Customer’s supply steam line shall include condense separators and steam traps to keep the line
drained. Industrial steam lack is alarmed, stopping the equipment.

3.2.1.3. ELECTRICAL SUPPLY REQUIREMENTS

The Clean Steam Generator requires a single-point electrical supply to operate all control
components and to feed the heater,
The Customer’s electrical supply circuit shall provide power as specified in section 3.2. The electrical
supply of the Customer shall prevent power surges to avoid damages to hardware components. The
supply connection points shall be configured as described in the equipment drawings.
3.2.1.4. COMPRESSED AIR SUPPLY REQUIREMENTS

The Clean Steam Generator requires compressed air supply to actuate the control valves.
The Customer’s compressed air supply line shall be capable of delivering a minimum flow rate as
specified in the P&ID drawing and shall be configured for quick pneumatic connection with nylon
pipe.
Oil free, dry compressed air is strictly recommended.
Compressed air lack is alarmed, stopping the equipment.
3.2.1.5. DRAINAGE
Blowdown temperature is very hot.
It is recommended to construct local drain lines with temperature resistant materials.
Waste water quantity and temperature are shown in P&ID drawing of the equipment.
3.2.2. PERFORMANCE
Product Parameter Value / Unit Note
Flow Rate 900 Kg/h

-
Pressure 3 barg
Conductivity ≤ 1,3 μS/cm@25°C In-line measurement
Laboratory tests on the condensed

Pure Steam
TOC < 0.50 mg/l sample (not included in BRAM-COR
supply)
Endotoxins level <0.25 EU/ml sample (not included in BRAM-COR
supply)
Total viable Organisms <10 CFU/100 ml sample (not included in BRAM-COR
supply)

3.2.3. PURE STEAM GENERATION PROCESS

The Pure Steam production process consists of feedwater evaporation followed by pure steam
separation according to following process steps, with reference to the enclosed P&ID of the system
and to following picture:
1) Feed water is pressurized by a centrifugal pump (P-2001) ❶ to the evaporation column through the inlet valves
(one of the two valves is equipped with a closing stroke limiter to limit the feed water flow during normal
running). Water level inside the column is continuously checked by the level control 20 LT-001 ❼. This system
allows the CPSG to produce Pure Steam with a content of un-condensable gasses lower than 3,5 %.
2) Feed-water enters into the evaporator column from the bottom ❺, filling the evaporator column itself and
the exchanger tubes (the exchanger is piped “in parallel” with the evaporator column).
3) Industrial steam ❸ enters the shell side of the heat exchanger ❷ causing water boiling and evaporation.
4) The vapor or clean steam enters the upper half of the evaporator column ❹. The height of the evaporator
column, the low velocity of the clean steam inside it, and a baffle demister installed in the upper part of the
column effect the separation of the pyrogens and other contaminants and of the water droplets from the clean
steam, yielding pyrogen-free pure steam.
5) The contaminants removed return to the feed-water in the lower half of the evaporator column. A small
quantity of the feed-water will be removed through intermittent blow-down, averting any exceeding
concentration of contaminants. The blow-down flow-rate will be set during Factory Testing.
6) When the pressure into the evaporator reaches the set-point (tolerance ± 0,2 barg), the modulating valve 20
PV-001 (industrial steam regulation valve) ❻ starts closing, according to the signal coming from pressure
transducer PT-001.
Pure Steam is controlled and maintained at the desired pressure, through the algorithm which controls the
industrial steam modulating valve (20 PV-001) ❻.
4
7 6
3.2.4. PS GENERATOR STERILIZATION PROCESS

The System works at temperatures higher than 121°C. It is therefore self-sterilized during normal
operation.

3.3. MECHANICAL COMPONENTS DESCRIPTION
3.3.1. PURE STEAM GENERATOR

The Pure Steam Generator is assembled as a single, skid-mounted unit that includes all components
and a shunt board. Product contact surfaces are in AISI 316L
stainless steel with Ra < 0.5 µm and product contact
components are conceived for sanitary use.
All commands can be activated from the HMI.
All components (main items, valves, instruments, etc.) are
 tagged with engraved metal plates in aluminum stuck with a
stainless steel chain to ensure full traceability
 listed in the attached PART LIST
 described in details in the TECHNICAL DOCUMENTATION, to be
collected throughout the manufacturing process and submitted
during FAT activities.
The equipment skid is in AISI 304 stainless steel, as well as the
insulating jackets and control board.
Gaskets are manufactured in FDA-compliant PTFE or EPDM.
Construction details about the equipment are provided in the
P&ID and TIE-IN drawings, attached to this document. The
equipment is constructed in compliance to the current GMP,
ensuring
 full drainability of the lines
 DTS construction of the exchanger 3
 installation of a safety valve
 manufacturing by certified welders.
Data sheets and certifications for product critical 2
components (including material certificates) are
provided in the technical documentation of the
equipment, as well as the welding documentation.
Positions and models of the components are
detailed in the part list attached to the technical 4
documentation of the equipment.
1. Feed water pump

2. Evaporation exchanger 5
3. Evaporation chamber
4. Industrial steam modulating valve
5. Steam trap.
Equipment size and weight is specified in the Tie-In

drawing appended in attachment 3.
1

3.3.2. FEED WATER PUMP [P-2001]

Water is sucked from the feed water line and sent to the evaporation chamber by a multistage pump
at a pressure at least 1 bar greater than the pressure in the evaporation chamber itself.
The in-line design of the pump enables installation in the horizontal pipe system where
the suction and discharge ports are in the same horizontal level.
The feedwater line includes a conductivity meter (20 AE-002), transmitting a 4-20 mA
to the transmitter on the control board.
The PW user point feeding the equipment shall be equipped with an isolation valve (by
customer).
Flow control is managed through the pneumatic valves on pump delivery and through
the level sensor (20 LT-001) of the evaporation chamber.
The Feed water pump discharge line is provided with manual membrane valve (20 HV-
001) on the drain line.
Interconnecting piping is fabricated in SS
316L, internally polished and fittings are
sanitary (tri-clover) type.
The technical specifications and
characteristics of this multistage pump will be
included in the technical documentation of
the equipment; the pump model and
technical features are detailed in part list
(attachment 4).
Product-contact parts of the pump are in AISI
316 stainless steel, with ceramic seals.
Pump overload is alarmed, stopping the
equipment.
The feedwater pump is turned off any time
the equipment is stopped for an alarm
occurrence.
The pump is supplied with Installation and
Operating Instructions, conformity
declaration.
Pump materials for model CRN are specified
in the picture aside.

3.3.3. EVAPORATION EXCHANGER [E-2001]

The Pure Steam Generator is endowed with a heating system to increase water temperature.
The feed-water entering the Evaporation Chamber is heated through a double tube heat exchanger
in parallel to the Evaporation and Decontamination Chamber. Hot
surfaces are insulated with Rockwool clad with an AISI 304 stainless steel
jacket, satin finish. Product-contact surfaces are in AISI 316L stainless
steel with Ra <0.5 µm. Gaskets are in PTFE.
Max. design temperature: 180°C, max design pressure: 9.0 barg
The evaporation exchanger is supplied with
 material certificates with traceability to the construction drawing,
 complete welding documentation including WPQ certificates for the
welder, welding procedure specifications (WPS) and welding procedures
qualification records (WPQR)
 filler material certificate
 non-destructive test report
 pickling and passivation certificate
3.3.4. EVAPORATION and DECONTAMINATION CHAMBER [C-2001]

The core of the equipment is the Evaporation and Decontamination Chamber, in parallel to the
Evaporation Heater. In this chamber feed water, heated in the Evaporation Heater, is turned into
vapour. A pressure control regulates the entrance of industrial steam into the heater in order to keep
a constant pressure in the Evaporation chamber. The height of the Evaporation Chamber is designed
to enhance Clean Steam separation from the retained Water Droplets, by means of the demister
[DM-001] - a mesh in stainless steel effecting the physical separation. The water level in the column
is monitored through a level transmitter [20 LT-001], inside a dedicated external housing, which is
connected to C-2001 through appropriate fittings, and is running through
the principle of communicating vessels.
The evaporation column is equipped with a pressure transducer monitoring
process pressures and a pneumatic membrane valve for automatic
discharge of the blow-down to the sewage line.
Hot surfaces are insulated with Rockwool clad with an AISI 304 stainless
steel jacket, satin finish.
Product-contact surfaces are in AISI 316L stainless steel with Ra <0.5 µm.
Gaskets are in PTFE.
Max. design temperature: 180°C, max design pressure: 5.0 barg
The evaporation column is supplied with

 material certificates with traceability to the construction drawing,
 complete welding documentation including WPQ certificates for the
welder, welding procedure specifications (WPS) and welding procedures qualification records
(WPQR)
 filler material certificate
 non-destructive test reports
 pickling and passivation certificate
 roughness certificates

3.3.5. VALVES
Different types of valves regulate water/steam/condensate passage in the system. As a rule, all
valves in product contact are certified sanitary valves. All valves are specified in the attached Part-
list .
A detailed valves documentation with the material certificates is included in the Technical
Documentation supplied with the equipment.
3.3.5.1. INLET VALVE

The equipment is endowed with two sanitary membrane valves on the pump outlet for fast
automatic water filling by GEMU.
3.3.5.2. MODULATING VALVE

A modulating valve allows the modulation of industrial steam passage in the system. 2-ways valves
have 1 inlet +1 outlet; modulating valves on utilities lines (i.e. industrial steam) are in cast iron.
3.3.5.3. MANUAL MEMBRANE VALVES

Manual membrane valves are sanitary valves with PTFE/EPDM gaskets. The opening device is driven
manually by the User. The valve body in product contact is in AISI 316 L stainless steel.
3.3.5.4. PNEUMATIC MEMBRANE VALVES

Pneumatic membrane valves are automatic sanitary valves with PTFE/EPDM gaskets. The opening
device is driven by oil-free compressed air supplied to the valve actuator. The valve body in product
contact is in AISI 316 L stainless steel.
3.3.5.5. SAFETY VALVE

The safety valve is a mechanical valve used to prevent the overpressure phenomena and the
explosion risk. This device opens when the pressure inside is over the maximum spring set point. The
valve body in product contact is in AISI 316 L stainless steel.
3.3.5.6. PIPING AND FITTINGS

Pure steam piping will be executed in accordance to regulatory standards for PS pharmaceutical
equipment and for sanitary piping.
All piping and fittings, in contact with the product, are in certified AISI 316L stainless steel.
All welds will be executed by qualified welders following BRAM-COR PO 75_09 “Sanitary Piping”
procedure.
The finished piping will be pickled and passivated following BRAM-COR Quality System procedure.
To ensure proper drainage, all horizontal lines will be pitched at min. 1 % slope. D
3.3.5.7. INSULATION MATERIAL

Vessel sides and exchanger are insulated with asbestos-free and chloride-free Rockwool with thermal
conductivity = 0,035 W/(m·K), supplied with the manufacturer’s conformity declaration, and clad in
AISI 304 stainless steel. Components that cannot be insulated (such as modulating valves) are labelled
with a warning label for hot contact.

3.4. ELECTRICAL COMPONENTS DESCRIPTION
All hardware components are listed in the Electrical scheme supplied in the final technical
documentation and detailed in the same documentation.
3.4.1. WIRING
The Pure Steam Generator is wired in accordance with established and distributed electrical
schematics and applicable national standards in order to ensure safe and reliable operation.
All wiring is bundled using “cable ties” and/or wire-ways. Each conductor is identified at each
termination point (i.e.: at both ends). All wiring conforms to approved schematics. Wire sizes
conforms to current UL standards.
3.4.2. CONTROL BOARD

The control board (CB-2010) is manufactured in AISI 304 stainless steel, according to regulatory
standards. Standard Protective grade is IP 54. Air vents and the acoustic horn (siren) are installed on
the board side.
The front panel includes:
 HMI
 Main switch HMI
 Emergency pushbutton
 “Power ON” light
 Emergency reset button
 Siren Reset button
A filter air regulator (20 PCV-001) is installed on the Emergency

board side to reduce and filter compressed air inlet. pushbutton, light
indicators, main
The front panel is locked by a safety lock. Control voltage switch
24 V DC.
The cabinet is CE certified and identified by a label in English with
technical data of the plant, according to the European Directive for
machinery.
CE Electrical components in the control board are installed to allow easy maintenance.
3.4.2.1. EMERGENCY CIRCUIT

The emergency circuit, prompted by the emergency pushbutton, is designed to immediately stop the
equipment, as per European Directive of Machinery 2006/42/EC.
3.4.3. INSTRUMENTS
All instruments necessary for the equipment are listed in Part list of the equipment attached to this
DQ document, specifying components, instruments, and valves.
All instruments are conceived for sanitary use. Product-contact components are in AISI 316L stainless
steel.
Gaskets are manufactured in GMP-compliant materials (EPDM or PTFE).
Critical instruments are supplied with the manufacturer’s certificate and material certificates.
Instruments are considered product-critical when their accuracy may impact on final product (PS)
quality and patient safety.
For critical instruments, the user shall implement his own calibration SOPs, based on the instrument
manufacturer’s instruction and common Calibration Practices.
Yearly periodicity for critical instruments calibration is recommended.
In general, the validity of the manufacturer’s calibration certificates is to be intended as follows:
 Dry sensors (pressure, level): 1 year from equipment start-up

Site calibration by experts of the measuring chains (transmitter + cable + probe) is always
recommended before validation.
Annual calibration of critical instruments is recommended.
3.4.3.1. PRESSURE TRANSDUCER

Pressure in the evaporation column shell is monitored by means of a pressure transducer, specified
in the part-list of the equipment appended in attachment 3.
The transducer is constructed with an inside spacer suitable for high temperatures.
For further details see:
http://www.jumo.de/products/as-per-approvals/metrological-certification/402050/jumo-dtrans-
p31---pressure-transmitter-for-higher-medium-temperatures-402050.html
JUMO pressure transducers are supplied with
 Technical data sheet
 Instructions manual
 Calibration certificate
 Conformity declaration.
Out-of-specification values are alarmed, stopping the equipment.
3.4.3.2. LEVEL TRANSMITTER

Water level in the evaporation chamber is monitored through a level transmitter, which is detailed
in the part-list in attachment 3 and provided with material certificates and conformity declaration by
the manufacturer.
The instrument is supplied with following documents:

 Operating instructions
 Inspection (3.1. material) certificate
 Final inspection report
Out-of-specification values are alarmed, stopping the equipment.

For further details see:
https://portal.endress.com/wa001/dla/5000545/6651/000/03/TI00401FEN_1412.pdf
3.4.3.3. PRESSURE SWITCH

A digital pressure switch to detect air lack is installed inside the control board.
Rated pressure -0.100 to 1.000 MPa. The LED displays current air pressure, set mode and error code.
Instrument accuracy: 0.2% F.S. ± 1 digit.
Compressed air lack is alarmed, stopping the equipment.
The instrument is supplied with the manufacturer’s operating instructions and calibration certificate.
See also:
https://content2.smcetech.com/pdf/ZSE10F-ISE10_EU.pdf

4. HARDWARE DESIGN SPECIFICATION

4.1. OVERVIEW
This Hardware Design Specification (HDS) section specifies in details the following:
 General architecture of the system
 Components features
The hardware required for monitoring and control all the systems is based on a number of standard
apparatus currently in worldwide use.
4.1.1. ENVIRONMENTAL CONDITIONS

All BRAM-COR systems, with special regard to all computerized systems and control boards, are
meant to work under following room conditions:
 Indoor location with dry surfaces and walls

 No direct or indirect exposure to sunlight
 Min. / max. operating temperature between 0 °C and + 30°C
 Maximum humidity: 70%
4.2. SYSTEM ARCHITECTURE
The control system of the Pure Steam generator is constituted by the HMI + CPU with I/O modules +
Ethernet cable.
The Human-Machine Interface is constituted by a touchscreen operator panel installed on the door
of the control cabinet.
Following table describes main hardware architecture. Functional specifications are provided in
following chapters
PURE STEAM GENERATOR CB-2010

CPU ET200S
Operator Panel
ETHERNET
KTP700 PN 7”

4.3. PLC AND USER INTERFACE CONFIGURATION
4.3.1. AUTOMATION UNIT - PLC

Hardware characteristics of the PLC - CPU are described in following table:
Description Supplier
SIMATIC ET 200S distributed I/O with integrated CPU and Ethernet communication SIEMENS
Further information is provided in following link:

http://www.automation.siemens.com/salesmaterial-as/brochure/en/brochure_simatic-
et200_en.pdf
The control system operates independently from the user interface, i.e. the system can continue to
operate even if the user interface fails.
Standard features of the CPU include:
 Memory 128 KB
 Transmission rates up to 12 Mbit/s
 63 I/O.
Following functions are performed by the PLC:
 Automatic Sequences ( i.e. CS Production, Stand-by)
 Control Functions (e.g. PID control valves )
 Input of measured values and setting of limit values
 Output commands for digital and analogic values
The operative system is in English language.

The control system operates independently from the HMI i.e. the system can continue to operate
even if the user interface fails.
4.3.2. STORAGE
The PLC program is saved to MMC memory upon completion of commissioning and testing. When
the system is started for the first time following installation of the memory, the program is loaded
from the MMC to the RAM of the PLC. This prevents program loss in the event of power failure
affecting the RAM.
The control system with operator panel does not perform any data storage, show audit trails or
parameters trends.
4.3.3. INPUT – OUTPUT SYSTEM

The inputs and outputs required for the process are integrated in the PLC.
The I/O modules are the interface to the process level for measurements and activation of actuators
and can be of different type:
 Analogic inputs (from sensors)
 Analogic outputs (to pump, modulating valve)
 Digital inputs (from emergency circuit, thermal protection of the pump, level gauge, etc.)
 Digital outputs (to pneumatic membrane valves and pump start).
The I/O list provided with the as built documentation during FAT activities.

4.3.4. HUMAN-MACHINE INTERFACE

The Human-Machine Interface (HMI) is constituted by a 7” touchscreen operator panel by SIEMENS
installed on the door of the control cabinet.
Description Supplier
SIMATIC HMI, KTP700 BASIC, BASIC PANEL, KEY AND TOUCH OPERATION, 7" TFT SIEMENS
DISPLAY, 65536 COLORS, PROFINET INTERFACE, CONFIGURATION FROM WINCC BASIC
V13/ STEP7 BASIC V13
The HMI provides supervision management for the PS generation system.

KT700 is a 7” touch panel (214 x 158 mm) with function keys with
 colors display
 Ethernet interface
All users are independent with individual login (see section 5.6
for passwords management and access policy).

5. SOFTWARE DESIGN SPECIFICATION

The software is configured upon a Siemens WinCC automation package for the PLC and for the HMI.
The software is configured to allow:
 Alarming, alarm reset
 Setting of limit values
 Manual Control
 Activation of sequences
 Indication of measured values
 Users management
Interventions are controlled by authorized access levels This means each access can only be executed
by authorized personnel. The PC works with password access log levels.
All users are independent with individual login.
5.1. SEQUENCES
The possible macro-sequences for the Pure Steam Generator are:

- Production (Automatic)
- Emptying (Manual)
STAND-BY
PB_PRD
PB_PRD
PRODUCTION
NOTE:
PB_PRD : Push button production = 1
PB_PRD : Push button production = 0
PB_PRD Reset PB_SMP
5.2. COMMANDS
Possible commands:
1. PRODUCTION
2. EMPTYING.
The sequences are interlocked
5.2.1. CPSG EMPTYING

The emptying sequence in the equipment is manual.
Manual emptying can be performed by the user with the manual valve.
The Pure Steam Generator emptying shall be performed when the machine is in stand-by for safety
reasons.

5.3. FUNCTIONS
The Pure Steam Generator is capable of continuous operation under all load conditions. The PLC/HMI
is programmed and configured to enable the user to perform all functions necessary to start, stop
and monitor all system parameters. The HMI is programmed to allow system parameters to be
changed. A security system is included to restrict the ability to change system parameters to
supervisors.
The software ensures continuous operation using the physical inputs and outputs to control the
equipment. The software design provides full automation, with minimal user input between unit start
and unit shut-down, as long as the process remains within the set parameters. The software design
ensures the safe shut-down of the equipment, as soon as the process deviates from critical
parameters.
The PLC/HMI will be programmed and configured so that data from the user are input through the
HMI and transferred to memory locations in the CPU module. The value of the outputs will be
determined according to the ladder logic program. These values will be transferred to the
corresponding output addresses and/or memory locations. The HMI will read the values of the
memory locations and update its displays, screens, or graphics accordingly.
The PLC/HMI program and configuration provide two categories of functions:
 Functions performed or initiated by the user.

 Functions performed or initiated by the PLC.
PLC STRUCTURE
1) Cyclic Program 2) Event Program
• First Scan • Interrupt

• Main Program • Diagnostic Alarm
PLC Schema – 1) Cyclic Program

(1)
(0)
Sistem and
First Scan
Diagnostics
(2)
Read Inputs
CYCLIC
(4)
PROGRAM
Write
Outputs
(3)
Program
Execution
PLC Schema – 1) Cyclic Program - Specification
• OB1, FC from 0 to 99,DB from 0 to 99

SYSTEM • FC from x01 to x30,DB from x01 to x30
• FC x40
INPUT • FC from x91 to x99
• FC from x50 to x69

PROGRAM • FC from x71 to x79
• FC x42
OUTPUT • FC x90

How the PLC operates
The PLC is a purpose-built machine control computer designed to read digital and analog inputs
from various sensors, execute a user defined logic program, and write the resulting digital and
analog output values to various output elements like hydraulic and pneumatic actuators, indication
lamps, solenoid coils etc.
Scan cycle
Exact details vary between manufacturers, but most PLCs follow a 'scan-cycle' format.
Overhead
Overhead includes testing I/O module integrity, verifying the user program logic hasn't changed, that
the computer itself hasn't locked up (via a watchdog timer), and any necessary communications.
Communications may include traffic over the PLC programmer port, remote I/O racks, and other
external devices such as HMIs (Human Machine Interfaces).
Input scan
A 'snapshot' of the digital and analog values of the input cards is saved to an input memory table.
Logic execution
The user program is scanned element by element, then rung by rung until the end of the program,
and resulting values are written on an output memory table.
Output scan
Values from the resulting output memory table are written on the output modules.
Once the output scan is complete the process repeats itself until the PLC is powered down.
The time it takes to complete a scan cycle is, appropriately enough, the "scan cycle time", and
ranges from hundreds of milliseconds (on older PLCs, and/or PLCs with very complex programs) to
only a few milliseconds on newer PLCs, and/or PLCs executing short, simple code.
BLOCKs DESCRIPTION:
Organization blocks (OBs) represent the interface between the operating system and the user
program. They are invoked by the operating system and control the program with cyclic interrupt,
the startup behavior of the automation system and error handling. Planning organization blocks can
determine the behavior of the CPU.
Functions (FCs) belong to the blocks programmed by the user. The function is a block of code "free
memory". The temporary variables are stored in the FC stack local data. For storing data, functions
can use global data blocks. Since a FC does not have any memory, you must always specify the
actual parameters. Local data of a FC cannot be given any initial value.
Data blocks (DBs) do not contain instructions STEP 7, but are used to store user data. The data
blocks are used to store user data that can be used by all the other blocks. The DB size is variable.
To the maximum size, see the description of the CPU. The structure of the data blocks can be freely
determined.

PLC Schema – 2) Event (clock) Program
EVENT PROGRAM
Interrupt Interrupt Interrupt Interrupt

Time t Time 2t Time ….. Time …xt
The INTERRUPT signal can pause the execution of basic instructions so that the CPU can execute
instructions that are found in other sub-programs called "interrupt subroutine".
Following an interrupt signal, cyclic program is interrupted to perform another subroutine. When this
subroutine has finished processing, the CPU returns to the original point of the cyclic program and
continues with its processing.

PLC Schema – 3) Diagnostic Alarm
DIAGNOSTIC
ALARM
PROGRAM
Alarm1
Alarm…
Normal
Operation
The CPU operating system calls OB and Diagnostic FC, and for the ones it has an enabled diagnostic
interrupt, it detects the presence of an error, and also if the error has been eliminated (in case of an
incoming or outgoing call).
PLC Schema – Interrupt – Diagnostic

Specification
• Istance DB for PID

Clock • FB41......FB43
• OB from 80 to 129
Alarm • FC from x15 to x29
Spare
Spare

5.4. USER FUNCTIONS
The HMI system is programmed and configured to enable the user to perform the following
functions:
• Manual start of the system;
• Manual stop of the system;
• System operation monitoring;
• Alarms reset;
• System current parameters view and setting.
The PLC and HMI will be programmed and configured to enable the user to change screens and input
necessary data or command to perform the listed functions. In the HMI screen changes can be
initiated by pressing clearly defined keys on the HMI keyboard. From all screens the user can have
the possibility to return to the previous screen through an “ESC” key or a “BACK ARROW” pushbutton.
The PLC program will override any screen page called by the user in case of an alarm condition and
display an appropriate alarm message.
The red led indicating the presence of an alarm will remain until the alarm is reset.
5.4.1. MANUAL START / STOP

According to the sequence to activate, the user can initiate/shutdown the Pure Steam Generator by
pressing the relative running mode key in the “COMMANDS PAGE” screen. This will prompt the PLC
program to begin the start/stop sequence.
The command features (such as sampling) may be activated from the HMI panel and under specific
conditions.
5.4.2. SYSTEM OPERATION MONITORING

The SYSTEM RUNNING screen displays the default parameters required for the user to verify proper
and safe operation of the Pure Steam Generator. Depending upon the supplied optional, additional
screens may be used to display additional parameters. The PLC overrides the selection of the
additional screens and the HMI displays the ALARM screen in the event of an alarm.
5.4.3. ALARMS RESET

When an alarm is initiated, the PLC will force the HMI to display the Alarm window. The user shall
reset the alarm by pressing the RESET key on the Alarm screen.
5.4.4. SYSTEM PARAMETERS SCREEN

The User can view the system operating parameters on the HMI screen by entering the Menu screen,
which will then provide access to the Pure Steam Generator screens. The user can change any of the
information displayed from these screens only after entering a password (see also section 5.6.3).

5.5. PLC FUNCTIONAL SPECIFICATIONS

Once operation is started, the PLC shall automatically handle all tasks associated with the operation
of the Pure Steam Generator, without any further action by the user.
The PLC performs following functions or tasks automatically without any action required by the user
(beyond initiating the startup or shutdown sequence of the Pure Steam Generator and monitoring
the operating conditions).
5.5.1. STARTUP SEQUENCE

Control system outputs, prompting all devices corresponding to the phase, will be activated when
turning ON the system . The system will proceed automatically step by step according to PLC program
The startup sequence consists in following steps:
1. Restore the emergency circuit.
2. Check and remove all current critical alarms.
3. Turn on the necessary devices.
4. Press the push buttons as described above.
5.5.2. RUNNING SEQUENCE

The running sequence is not a discrete operating mode. The term “running sequence” is used to
describe the actions required after the system has been started and has executed the startup
sequence. The running sequence starts as soon as all functions listed in the startup sequence have
been completed. The transition from startup to running is seamless and transparent to the user.
5.5.3. SHUTDOWN SEQUENCE

System operation shall stop when the “OFF” button is pressed .
All the running control system outputs will be stopped in a safe way.
The shutdown sequence consists in following steps:
1. Bring the system to a safe position
2. By disabling the current sequence, the equipment stops.

5.5.4. ALARM TASK

The control system is configured to prompt
 Messages, as pop-ups on the HMI, which do not require an action by the user
 Warnings for anomalies, with acoustic signals + pop-ups displayed on the HMI, which are auto-reset
(canceled) as soon as the original operating conditions are restored
 Alarms with acoustic signal + pop-up on the HMI, which require an action (manual reset) by the user
after restoration of the original operating conditions.
An acoustic alarm is triggered when the related alarm message is displayed on the HMI.
System operations stop to keep the equipment in a safe condition.
When an alarm occurs (the critical alarms are all the ones listed in the Alarm List of the equipment,
which is included in the Technical Documentation), the outputs which control the acoustic alarm and
the resuming alarm relay are activated. All the outputs related to the control devices which were
activated will be disabled.
When the alarm is accepted and the anomaly solved, the process can continue with actual cycles.
The Alarm Task consists of following operations:

1. Monitor all inputs and outputs
2. Determine whether an alarm condition exists, based on the ladder logic program.
3. If an alarm condition exists, take following actions:
a. Activate the alarm horn and the common alarm relay (only when the user action is required).
b. Switch on a signal (like a red alarm light) on the HMI.
d. Transfer the alarm code to the HMI and display the alarm message.
e. Maintain this status until the alarm is reset by the user.
f. Shut-off the siren when the alarm is reset or the siren is disabled with the appropriate pushbutton
on the control board.
g. Maintain this status until the alarm is reset by the user or by the auto-reset.
4. After the alarm is reset, command the HMI to display the previous screen and continue operation as
normal.
A detailed alarm list for each equipment , containing information about
 Alarm CODE
 TAG of related instrument
 Alarm description
 Plant stop YES or NO
 Action (or behavior of the equipment)
 Delay time and set-points
is supplied in the Technical Documentation and submitted at FAT.
The alarm list will include:

 Alarms concerning utilities supply (compressed air lack, industrial steam lack, feedwater)
 Alarm for process pressure
 Alarms for level in the column
 Alarms related to electrical safety (thermal protections)
Alarms are tested during FAT and OQ activities.

Following table provides a preliminary list of CPSG alarms:
EQUIPMENT
ASSOCIATED
ALARM CODE ALARM DESCRIPTION STOP
DEVICE (YES OR NO)
G_004 - PLC INTERNAL ERROR YES
G_010 - CIRCUIT 230 VAC - INTERVENTION PROTECTION YES
G_012 - CIRCUIT 24 V DC - INTERVENTION PROTECTION (24VP FAILURE) YES
G_014 - EMERGENCY CIRCUIT NOT RESTORABLE YES
G_016 - EMERGENCY BUTTON PRESSED YES
G_018 20PS001 COMPRESSED AIR LACK YES
G_032 P-2001 FEED WATER PUMP - ENGINE PROTECTION YES
G_034 P-2002 FEED WATER PUMP - ENGINE PROTECTION YES
G_040 20PS002 MISSING INDUSTRIAL STEAM YES
G_063 20PT001 PURE STEAM - PRESSURE (bar) - HH YES
G_070 20LT001 COLUMN C-2001 MINIMUM LEVEL YES
G_072 20LT001 COLUMN C-2001 MAXIMUM LEVEL YES
G_074 20LT001 PURE STEAM - PRODUCTION - FILLING FAILED C-2001 YES
G_120 - FEED WATER INLET NOT AVAILABLE YES
G_122 - PURE STEAM EXTERNAL START SIGNAL NOT PRESENT YES

5.6. INTERFACES
Interfaces with the User shall ensure safe, reliable, continuous, and automatic operation and/or
configuration. HW and SW grant a GMP compliant security level.
KTP 700 ARCHITECTURE

CPU
INTERNAL
PLC Machine DB Actual data
• Ethernet
HMI
HMI
Security Access
OPC

5.6.1. USER INTERFACE WITH THE PLC/HMI SYSTEM

The PLC/HMI system includes interfaces with the User ensuring easy, safe, and reliable operation.
The User can access HMI screens to perform following activities:
1. start and stop all the sequences of the Pure Steam Generator,
2. reset alarms,
3. view and set the system parameters,
4. view the current status of the equipment,
5. view the current status of the analogical variables.
The User can check set-point values and other parameters against known correct values before
starting the system. The User can change any incorrect values, under access policy.
Limited access to the configuration screens enhances safety.
The prompts displayed on the screens include all instructions necessary for a User with limited
technical training to start operation, stop operation and reset alarms, ensuring easy operation.
5.6.2. ALARM WINDOW

The ALARM “screen” is a window displayed on HMI panel. This ALARM window remains active until
the user resets the alarm. The ALARM RESET key will be active if any alarm is present.
5.6.3. PARAMETERS SCREEN

The “parameters” screen consists in several screens, displaying the system parameters in related
groups.
5.6.3.1. FUNCTIONAL PARAMETERS SCREEN

The PARAMETERS screen displays following information:
 PARAMETERS set-point
 PARAMETERS timeout delay set-point
 PARAMETERS process value
 PARAMETERS timeout delay process value
5.6.3.2. PID PARAMETERS SCREEN

The PID screen displays following information:
 The SET-POINTS for PID regulation (temperature , pressure)
 Proportional (P) term (Gain);
 Integral (I) term (Reset time);
 Derivative (D) term (Derivative time);
 Input value (Process Value );
 Output value (in percent).

5.7. PASSWORDS
Access security is ensured by 3 Password levels for the Customer:

 OPERATOR (for start/stop operations);
 SUPERVISOR (parameters modification);
 MAINTENANCE (upper level for maintenance, backup and password management).
The modification of critical data/set points is allowed on dedicated HMI pages only.
Changes to these data sets will be possible through a login procedure only. When trying to change
any value on the screen, a window will appear with a cursor line waiting for the password code.
For security reason the dialed number will not be displayed. Subsequently, the HMI displays the
previous screen allowing the change of the selected parameters.
BRAM-COR access configuration provides following standard settings:

 User shall log-in by digiting user ID + password, the combination of which is unique and may be
changed by the Customer in runtime.
 No password aging.
 Unlimited number of access attempts.
 Minimum password length: 3 normal characters.
 Log-out time: 5 minutes.
 Passwords Import/Export on encrypted file.
 Only a user of the “Maintenance” level can add, modify, cancel passwords and users.
5.8. INTERFACE WITH EXTERNAL INPUTS AND OUTPUTS

The PLC/HMI system shall include interfaces with external equipment to ensure safe, continuous,
and automatic operation.
The PLC can accept inputs from external switches and sensors and can produce outputs to control
external devices such as control relays and solenoids.
5.8.1. DIGITAL INPUTS

Digital inputs have a value of 0 (Off) or 1 (On). A “0” represents voltage absence, such as an open
circuit or switch. A “1” represents voltage presence, such as a closed circuit or switch.
5.8.2. ANALOG INPUTS

Analog inputs have values changing in relation to physical variables. Analog inputs use following input
range: 4-20 mA DC. The analog input card contains an A/D converter converting the current or voltage
signal to an integer value within the PLC. The PLC ladder logic program scales the analog inputs to
engineering units used by PLC and HMI.

5.8.3. DIGITAL OUTPUTS

Digital outputs have a value of 0 (Off) or 1 (On). A “0” represents voltage absence, thus the
component connected to the output is de-energized. A “1” represents voltage presence, thus the
component connected to the output is powered-on. The following digital output data are generated
by the PLC according to the inputs.
5.8.4. ANALOG OUTPUTS

The PLC AO-Card directly generates analog outputs. This electronic card contains D/A converters that
convert the integer data value generated by the program algorithm to an analog signal (typically 4-
20 mA) at the module’s terminals. These analog outputs are configured as mA or VDC signals and
command the actuators
The interfaces are furthermore specified in the electrical scheme of the equipment.
5.9. INTERFACE WITH OTHER SYSTEMS

Exchange (electrical) signals are configured as follows:
 One digital input signaling water presence at the system inlet
 Two digital outputs: the first one prompts water from the local utility; the second one is available
for special user requirements.
The interfaces are furthermore specified in the electrical scheme, delivered with the equipment.
5.10. INTERFACE WITH INSTRUMENTATION

All data measured by the in-line instrumentation are acquired in real time through the analogic
inputs.
5.11. NON-FUNCTIONAL ATTRIBUTES
5.11.1. AVAILABILITY (POWER FAILURE RECOVERY)

5.11.1.1. RESTART AFTER A POWER FAILURE
The Pure Steam Generator shall manually be restarted after recovery from a power failure with
appropriate setting procedures.
The PLC/HMI system is configured so that, after recovery from a power failure, the original system
conditions must be manually restored.
5.11.1.2. PROGRAM RETENTION DURING A POWER FAILURE

The PLC/HMI system includes provisions to prevent loss or corruption of the ladder logic program
during a power failure. Upon restoration of electrical power, all operating parameters are restored
automatically, and all running modes except for feature commands are maintained; whereas the run
mode shall be restarted by the user.

5.12. ERROR CHECKING
5.12.1. PLC/HMI SYSTEM

The PLC/HMI system includes automatic error-checking functions.
Upon the application of power, and continuously thereafter, the PLC/HMI system will run self-
diagnostic routines which have been specified, designed, and programmed by the PLC and HMI
manufacturer.
5.12.2. ANALOGICAL INPUT / OUTPUT

All analogical input/output signals are checked for valid input range (typically 4-20 mA or 0-10 V).
Analog I/O signals are automatically checked by the I/O card of the PLC (when the I/O Module
includes this function). The current value will be checked and, if this is out of the range, the value
will be not accepted and an alarm is displayed.
5.12.3. STANDBY OPERATION

The PLC/HMI system is configured so that the “ready” state any time power is applied is identical to
the “ready” state after normal shutdown. In order to start the Pure Steam Generator, the only action
required of the user shall be to initiate the startup sequence.
5.13. MAINTAINABILITY
5.13.1. EXPANSION / SPARE CAPACITY

The PLC/HMI system is configured so that function upgrades may be accomplished without physical
redesign of the system.
The PLC/HMI system will be provided with an adequate number of spare I/O point for each type of
I/O for possible expansion.
5.13.2. BACKUP
After equipment start-up, the software RUNTIME backup (for PLC and HMI) will be handed over to
the user, together with the corresponding software recovery procedures, in order to restore the
system to the original as-left settings in case of failure.

6. DOCUMENTATION AND TESTING

6.1. TECHNICAL DOCUMENTATION INCLUDED IN THE SUPPLY.
BRAM-COR supply includes one printout copy and one electronic copy on CD-ROM in English.
The equipment documentation is constituted by:
 A GMP collection of plant-specific drawings, technical specifications, materials certificates,
calibration certificates, hardware and software specifications, welding documentation, plant
manuals (TECHNICAL DOCUMENTATION # M_3108_TD);
 A GMP collection of datasheets and manuals of components, instruments and valves (DATASHEETS
& MANUALS BOOK # M_3108_D&M)
6.1.1. TECHNICAL DOCUMENTATION CONTENTS (final numeration may vary during issue)
Section 1: General documentation and constructive specifications:

1.1 Design qualification
1.2 Risk Assessment
1.3 P&ID reading key
1.4 P&ID
1.5 Tie-In drawing
1.6 Conformity declaration of equipment
1.7 Quality declaration
Section 2: Components; Valves & Instruments documentation

2.1. Components , Valves & Instruments list and description
2.2. Materials & roughness certificates (where applicable), Manufacturer’s
calibration certificates for the critical instruments
Section 3: Hardware and Software documentation

3.1. Electrical and pneumatic drawing
3.2. Electrical insulation test and control board conformity declaration
3.6. PLC /HMI software recovery procedures
Section 4: Piping, fittings and welding documentation

4.1. Material list and certificates
4.1.1. Materials list
4.1.2. Materials certificates
4.2. Welding documentation
4.2.1. WPS: Welding procedure specification
4.2.2. WPQR: Welding procedure qualification record
4.2.3. WPQ: Welding performance qualification
4.2.4. Pickling and Passivation Report
4.2.5. Filler material (for manual welding)
4.2.6. Gas ARGON certificate
Section 5: Equipment Manuals and Spare Parts list

5.1. Use and maintenance manual

5.2. Operating manual

5.3. Suggested spare parts
6.1.2. DATASHEETS & MANUALS BOOK

The D&M Book includes datasheets and manuals of all components, valves and instruments for
quick consultation.
6.2. VALIDATION DOCUMENTATION

Our Scope of Work will cover the following activities:
 Preparation of DQ protocol (this document)
 Preparation of Qualification Protocols (IQ, OQ).
6.2.1. QUALIFICATION PROTOCOLS PREPARATION

BRAM-COR S.p.A. will prepare a customized validation protocol for each validation phase (i.e.
Installation, Operational and Performance Qualification) in blank format.
The protocols will be issued in English following our standard.
The Protocols will take into account all the requirements coming from reference GMPs standards.
The protocols will be reviewed by the Validation Manager and approved by the Customer’s key
Representatives (usually from Manufacturing, Quality Assurance, Engineering Departments) before
“field” activities can start.
A list of typical verifications for each Qualification phase includes:
6.2.2. INSTALLATION QUALIFICATION PROTOCOL

- Test IQ01: Documentation verification
- Test IQ02: AS BUILT verification
- Test IQ03: Components verification
- Test IQ04: Instrument verification
- Test IQ05: Hardware verification
- Test IQ06: Software installation verification
- Test IQ07: Materials in product contact verification
- Test IQ08: Safety aspects verification
- Test IQ09: Utilities & boundaries connection verification
6.2.3. OPERATIONAL QUALIFICATION PROTOCOL

- Test OQ01: HMI verification
- Test OQ02: Access levels verification
- Test OQ03: Alarms verification
- Test OQ04: Functional and critical operating values verification
- Test OQ05: Power failure verification
- Test OQ10: Training verification

7. EXCLUSIONS
As per contract agreements, following item/services are excluded from the supply:
 Recommended PS Condenser including test instrument (Conductivity Meter) for metering PS quality
 Recommended Quenched Waste Water Collector & Cooler with Spray Valve
 Multi Channels Digital Recorder
 Ethernet Card for communication with client's central system(to be confirmed after have received data/specs about the
client's remote PC)
 Expediting costs to reduce the standard delivery time
 FAT/SAT protocols (blank forms in english)
 FAT test in our italian factory of Parma for max TWO Customer's inspectors, two working days
 Set of 5 days/man of absence from our offices for Supervision to Commissioning, Start Up & Training of the equipment
 Civil Works
 Any utility at site, such as electrical energy, compressed air, steam, welding gasses, pickling & passivation acids, VAT,
Taxes/Duties/Permissions
 Drainages
 Connections and Cabling upto the battery limits of our equipment
 Pressure Vessels Certification by Third Parties & Certified external Bodies
 Unpacking, lifting, moving and positioning the equipment in their final destination
 Any AIR TICKET, local/international board, travel, lodging expense, VISA charges of Customer's personnel or inspectors
 Any AIR TICKET, local/international board, travel, lodging expense, VISA charges of our Personnel
 Any fees, tax, clearance, expenses also of the banks included the LC confirmation
 Any raw material or consumable
 Disposal of cleaning and passivation acids according to local environment regulations
 Disposal of yard rubbish according to local environment regulations
 Pre-shipment inspection by Certified Authorities
 Any item, service, quantity not expressely indicated by our offer
8. DELIVERY
The equipment is supplied within contractual terms if times for approval and feedback to this DQ
are respected by the customer. Any structural or functional change to the equipment with respect
to the contract may delay delivery time and imply additional costs. The equipment is delivered Ex-
Works, in wood package with pluriball protection.
9. WARRANTY
As per contractual terms: 12+ 6 = 18 months from shipping date.

SECTION 1.2.
Risk assessment
▹▹▷

LOCATION COLOMBIA
DOCUMENT NAME RISK ASSESSMENT
DOCUMENT CODE M_3108_RA_0
SERIAL No. 11880
JOB No. 3108
REVISION HISTORY
Rev. Description Date Issued by Verified by Approved by
0 First issue 27/07/2018 C. Opl A. Scala A. Negri

BRAM‐COR S.p.A.
Tel. +39 0521 538711
Fax: +39 0521 538770


CONTENTS

1. INTRODUCTION ............................................................................................................................................ 3
1.1. SCOPE AND APPLICATION .................................................................................................................................. 3
1.2. STANDARD REFERENCES .................................................................................................................................... 3
1.3. TERMINOLOGY AND ABBREVIATIONS ................................................................................................................ 4
2. KEY PARAMETERS FOR RISK ASSESSMENT ..................................................................................................... 5
2.1. SEVERITY INDEX ASSIGNMENT CRITERIA ........................................................................................................... 5
2.2. OCCURRENCE INDEX ASSIGNMENT CRITERIA .................................................................................................... 6
2.3. DETECTION INDEX ASSIGNMENT CRITERIA ........................................................................................................ 6
3. RISK ASSESSMENT METHOD ......................................................................................................................... 6
4. CONTROL STRATEGY ..................................................................................................................................... 7
5. RISK ASSESSMENT ........................................................................................................................................ 8
5.1. UTILITIES .................................................................................................................................................. 8
5.2. PS GENERATION ....................................................................................................................................... 9
5.3. CONSTRUCTION/INSTALLATION ............................................................................................................. 11
5.4. HARDWARE & ELECTRICAL COMPONENTS .............................................................................................. 14
5.5. SOFTWARE ............................................................................................................................................. 16
5.6. SAFETY ................................................................................................................................................... 17
5.7. DOCUMENTATION ................................................................................................................................. 18
5.8. CLEANING AND MAINTENANCE .............................................................................................................. 19

RISK ASSESSMENT ‐ M_3108_RA_0 PAGE 2 OF
20

1. INTRODUCTION
This document is issued by BRAM‐COR Technical Department for Risk Assessment of the Pure Steam
Generator CPSG ST 1000, as a primary step for automation design, testing and validation strategies.
The plant is described in Design Qualification protocol # M_3108_DQ_0.
The scope of this document is to provide a careful preventive evaluation of all product‐ , process‐ and safety‐
critical issues which may occur in the operating lifecycle of the equipment.
The aim of this Risk Assessment is to identify those process steps, critical subsystems or major component in
the equipment that need to be tested and kept under control and to avoid useless repetitions in testing,
improving the system reliability. This assessment focuses on GMP risks. GMP risks are those related to
patient’s health, final product quality and data integrity.
1.2. STANDARD REFERENCES
 ISO 9001:2015
 ISPE Guideline: "Sterile Manufacturing Facilities" Vol. 3 2nd ed.
FDA Guidance for Industry : “Sterile Drug Products Produced by Aseptic Processing — Current Good

Manufacturing Practice” ‐ 2004
 PIC/S PI007‐06: “Recommendation on the Validation of Aseptic Processes” ‐ 2011
PIC/S PE 009‐11 (Part I): “Guide to Good Manufacturing Practice For Medicinal Products” ‐2014
 ISPE Guideline: "Water & Steam Systems" – Vol. 4 2nd ed.
ISPE Guideline “Product Quality Lifecycle Implementation (PQLI®) from Concept to Continual

Improvement ‐ 2011
 European Pharmacopoeia 9th edition
 2006/42/CE European Directive for Machinery
 2014/68/EU Pressure Equipment Directive
EudraLex ‐The Rules Governing Medicinal Products in the European Union‐Volume 4

Good Manufacturing Practice‐Medicinal Products for Human and Veterinary Use
 USP 40
 ICH Guidelines Q8(R2): Pharmaceutical Development
 ICH Guidelines Q9: Quality Risk Management
 ICH Guidelines Q10: Pharmaceutical Quality System
 GAMP 5: “A risk‐based approach to compliant GXP computerized systems”
 ASME BPE‐2016 “Bioprocessing Equipment”
 UNI EN ISO 9606:2013 “Qualification of welders" ‐ Manual welding
 UNI EN 14732:2013 “Qualification of welders" ‐ Automatic welding
ASTM A ‐270 “Standard Specification for Seamless and Welded Austenitic Stainless Steel Sanitary

Tubing”
 ASTM A 967‐01 “Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts”
 CEI EN 60204‐1:“Electrical Safety of Machinery”
 IEC 61439: “Low‐voltage switchgear and controlgear assemblies”
 IEC 1131‐1: “Programmable Controllers ‐ General Information”
 GAMP Guideline: "Testing GXP" 2005
 GAMP Guideline: “A Risk‐based Approach to GXP Process Control Systems” 2nd ed.
20

 ISPE GPG: “Applied Risk Management to Commissioning and Qualification”
 ISPE Baseline Guide: “Commissioning and Qualification” ‐ 2001
 ISPE Guideline: "Commissioning and Qualification of Water and Steam Systems" Vol. 5
WHO TRS 937 2006 ‐ Annex 4: “ Supplementary Guidelines on Good Manufacturing Practices ‐

Validation”
 ISPE Guideline: "A risk‐ based Approach to Calibration Management ‐ 2nd Ed.”
 UNI 10893: "Technical Documentation of Product"
 UNI EN 10204: “Metallic Products: type of inspection documents”
ASTM C‐ 795 –“ Standard Specification for Thermal Insulation for Use in Contact with Austenitic

Stainless Steel”
 UNI 5634 “Identification of piping for fluids"
ASTM A 380‐99 “Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts,

Equipments and Systems”
 21CFR Part 11
ASME = American Society of Mechanical Engineers ISPE = International Society of Pharmaceutical
CFR = Code of Federal Regulation Engineering
CIP = Clean‐in‐Place OQ = Operational Qualification
CP = Calibration Protocol P&ID= Piping and Instrumentation Diagram
CS = Clean Steam PL = Part List
CSV = Comma‐Separated Value PS = Pure Steam
DQ = Design Qualification PLC = Programmable Logic Controller
EP= European Pharmacopoeia PQ = Performance Qualification
FAT = Factory Acceptance Test PW = Purified Water
FDA = Food and Drugs Administration QA = Quality Assurance
DQ = Functional Design Specification RA = Risk Assessment
FMEA = Failure Mode and Effect Analysis RPM = Revolutions per Minute
GAMP = Good Automated Manufacturing Practice SAT = Site Acceptance Test
GDP = Good Documentation Practice SCADA = Supervisory Control and Data Acquisition
GMP = Good Manufacturing Practice DQ = Software Design Specification
HDS = Hardware Design Specification SIP = Sterilization‐in‐Place
HMI= Human‐Machine Interface SOP = Standard Operating Procedure
I/O = Input/Output URS= User Requirement Specification
IQ = Installation Qualification USP =United States Pharmacopoeia
WFI= Water for Injection

20

2. KEY PARAMETERS FOR RISK ASSESSMENT
S = Severity ‐ rating from 1 (no danger) to 10 (critical)
O = Occurrence (probability) ‐ rating from 1 (low probability) to 10 (high probability)
D = Detection ‐ measuring the risk that the failure will escape detection, rating from 1
(low chances that the failure will escape detection) to 10 (high probability that the failure will escape detection)
RPN= Risk Priority Number: a threshold value calculated by multiplying S x O x D.

STEP 1: detect
a failure
mode

STEP 5: Risk STEP 2:
Priority No. : Severity
RPN Number: S

STEP 4 : STEP 3:
Detection Probability
Number: D Number: O

FMEA ASSESSMENT PROCESS

2.1. SEVERITY INDEX ASSIGNMENT CRITERIA
Severity refers to the possible consequence of a hazard, for its impact on patient safety, product quality and
data integrity.
Affecting levels Category Index

Immediately
affecting other Process deviation affecting performance of other 10
process because of dependent processes with extreme severity
Catastrophic
the delivered Anomalies as a result of process deviations relevantly 8‐9
product affect performance of other dependent processes
6‐7
Anomalies as a result of process deviations affect in very

little extent performance of other dependent processes
Major
Restrictedly Deviation with relevant consequences for process 4‐5
affecting process performance
performance in Perceptible deviation with slight consequences for 2‐3
short, middle or Minor
process performance
long term
Deviations that are imperceptible or practically with no 1
Negligible
consequences for process performance

RISK ASSESSMENT ‐ M_3108_RA_0 PAGE 5 OF 20

2.2. OCCURRENCE INDEX ASSIGNMENT CRITERIA

Occurrence refers to hazard/failure probability during the equipment lifecycle.
Occurrence Probability Index

rare low 1‐3
occasional medium 4‐7
possible high 8‐10
2.3. DETECTION INDEX ASSIGNMENT CRITERIA
Detection is related to risk of unnoticed failures.
Detection Chances that the failure will escape detection Index

easy low 1‐3
occasional medium 4‐7
difficult high 8‐10
3. RISK ASSESSMENT METHOD
Risk management aims to establish controls such that the combination of severity, occurrence and detectability
of failures is reduced to an acceptable level.
For every system subcomponent or process step (COLUMN B), possible failures are listed (COLUMN C) and
evaluated by means of the FMEA method (section E).
The Risk Priority Number (RPN) obtained focuses attention on process/product critical issues, in order to
design and provide appropriate controls.
The relevant analysis is shown in COLUMN F and preventive and corrective actions are indicated in section G,
with general measures, monitoring instruments and alarms, as well their traceability in Specification protocols
and Commissioning/Qualification protocols (COLUMN H) .
The risk level related to the resulting RPN is resumed in following table:

RISK LEVEL SCORE MITIGATION MEASURES

Tolerable. It not necessary to carry out additional
LOW 1 to 10
measures for mitigation.
The risk can be easily kept under control with
Standard Operating Procedures or local
MEDIUM
11 to 30 measurement on instruments with direct reading
(like manometers).
The risk shall be mitigated by an appropriated
control strategy, including digital instruments

HIGH sending signals to the PLC, alarms for immediate
>30 reaction by the operator in case of failure, alarms
testing, calibration plan.



4. CONTROL STRATEGY
Risk assessment results are taken into account for design, construction, installation and maintenance purposes
of the equipment, in order to act the best control strategy.
Controls are aimed at:
 Eliminating risk through system design (through GMP /GAMP/ compliant design)
 Reducing risk by reducing the probability of failure (through GMP/GAMP/ compliant manufacturing)
 Reducing risk by increasing the in‐process detectability of a failure (Process Analytical Technology ‐ alarms
policy).

Where applicable, for GMP RISKS with RPN > 30, control strategies include constant monitoring by one or more
instruments + alarm.
Please refer to the ALARM LIST of the equipment, to be provided with the Software Design Specification, for
alarms identification


5. RISK ASSESSMENT
A B C D E F G. CONTROL STRATEGY H
Process step / Possible failure GMP Risk FMEA Risk Effect Tests / Measures Trac. / Spec.
#
Machine component Evaluation

G1 G2 G3
S O D RPN General measures Monitoring Alarms
Instrument (YES/NO/NA)
5.1. UTILITIES
1. Feed water inlet No external water or YES 6 3 2 36 Feed water pump cannot Monitoring device on Dry contact YES Alarm list, OQ
signal presence start the upstream treatment

unit.
2. Feed water quality Feed water quality is YES 8 4 2 64 Feed water quality for the The Pure Steam DQ

not suitable for system PS generator does not generator shall be fed
operation meet Purified Water with water purified by
an upstream treatment
quality; possible
unit.
microbiological
contamination. Sampling of feed water Conductivity YES
on the distribution loop meter on the
must be possible and PW from the PW
representative. distribution distributions
system (by system (by
Sampling SOPs by customer)
customer)
Customer.
Monitoring Instruments
on the upstream
treatment unit
3. Compressed air Compressed air lack YES 6 3 2 36 Malfunction of pneumatic Check air pressure Pressure YES Alarm list, SAT,

valves switch for air IQ
Functional test: low
lack (20 PS‐
pressure alarm,
001)
equipment stops.

Create SOP “Operation”,
define pressure setpoint

#

G1 G2 G3
4. Compressed air No or wrong air filter YES 6 3 2 36 Poor air quality can cause Check installation of air Pressure YES Alarm list, SAT,

malfunction of pneumatic filter. Compressed air switch for air IQ
Air filter breakthrough must be dry and oil‐free. lack
valves.
(20PS‐001)
Create SOP for regular

checks.
5. Industrial steam Industrial steam YES 6 3 2 36 Malfunction if the industrial Check specification. Pressure YES Alarm list, OQ

pressure is too low steam pressure drops Plant stop in case of switch

below the set value. failure. (20PS‐002)
6. Industrial steam Poor plant steam YES 5 2 2 20 Piping corrosion. Check steam quality NA NA DQ, IQ

quality regularly.
7. Electrical supply Power failure, current YES 7 3 2 42 The control system is UPS unit, backup PLC YES FAT, SAT, OQ

overload, tension damaged strategy, alarms for 230
surges VDC and 24 VDC circuits,
power failure testing
during commissioning
and OQ.
5.2. PS GENERATION
8. PS generator Failure of PS production YES 10 3 2 60 The produced PS doesn’t Pipe‐in pipe condenser Alarm
meet the specified quality. with in‐line conductivity List/P&ID/OQ
check on condensed PS
Fouling of the internal Conductivity
samples. Alarm for high
meter
surfaces of the equipment. conductivity.
YES
(20 AE‐001)
Periodical descaling
according to cleaning
SOPs.

#

G1 G2 G3
9. PS generator Feed rate is too low, NO 6 6 1 36 Low feed water level leads Thermal protection on Level gauge YES Technical

minimum level reached to low PS production and feed water pump. (20 LT‐001) documentation
in the column malfunction. /alarm list/OQ
Level sensor in the
column. Plant stop,
acoustic alarms.
10. PS generator Feed rate is too high or YES 6 6 1 36 The evaporation column Valves for water feed Level gauge YES Technical
maximum level reached can be overflowed. and heating steam feed (20 LT‐001) documentation
in the evaporation Contamination of PS with are regulated by level /alarm list/OQ

sensors in the column.
column feed water (especially
Plant stop, acoustic
microbiological).
alarm.

11. PS generator Contamination of PS YES 9 3 2 54 Fouling of the internal Lab. Analysis for By User By User Technical
generator surfaces of the equipment conductivity documentation

measurement behind PS /alarm list/OQ

generator.

If the quality of PS in
terms of conductivity is
insufficient, water has to
be drained directly after
the evaporation unit.
12. Heating steam Leakage in heating YES 3 1 3 9 Technical steam could Check of integrity by NA NA DQ, Technical

distribution steam system (heat come in contact with feed pressure test. documentation

exchanger) water. Contamination of OQ
DTS configuration of
the product is possible. The heat exchanger.
pure steam conductivity
SOP: ‘Preventive
overtakes the maximum maintenance’ to be
allowable value. established.

#

G1 G2 G3
13. Pressure Wrong measurement or YES 7 5 1 35 Inaccurate pressure Calibration to be Pressure YES DQ, Technical

measurement break down of the monitoring can lead to performed according to gauge documentation

instrument malfunction internal SOPs . (20 PT‐001) /alarm list/OQ
Exceeding pressure
inside the column
prompts an acoustic
alarm and stops the
plant.
Safety valve.
14. Pneumatic valves Breakage of drain valve YES 4 1 7 28 Water of insufficient SOP for preventive IQ

seal quality could enter the PS‐ maintenance to be
NA NA
circuit, if the valve seal established by the user,
according to user
collapses.
manual.
5.3. CONSTRUCTION/INSTALLATION
15. Self‐drainage of the Water stagnation in YES 7 2 2 28 Microbiological Application of dead‐ Technical
volume‐minimized Documentation
system deadlegs in PS side contamination of the NA NA
because of system. valves. Application of FAT/IQ
ASME BPE 3D rule. Pipes
construction faults.
to be installed with slope
towards drainage point
(minimum 1 %).
Discharges at the
deepest points of pipe
system.

#

G1 G2 G3

16. Cleanliness of System is YES 7 2 2 28 Negative influence on Pipes are delivered and Technical
NA NA Documentation
system contaminated during water quality is possible. stored under closed
installation or conditions. All gaps and FAT/IQ
outlets are closed during
assembling
all installation phases.
Sanitary Pipelines are
cleaned and passivated.

17. Material Components in YES 7 2 2 28 Application of wrong Certificated Stainless Technical
NA NA Documentation
product contact are materials can influence steel 316 L components
manufactured in the water quality. in product contact FAT/IQ
Gaskets (non‐metal
unsuitable, non‐
parts) in PTFE or EPDM
sanitary material.

18. Material Surface roughness of YES 7 2 2 28 Wrong surface roughness GMP surface roughness Technical
NA NA Documentation
components in can influence the for product contact
surfaces.
product or media product quality, because FAT/IQ
Exception for welds:
contact is not of biofilm generation.
Roughness as minimal as
suitable for sanitary
possible.
use Certificate for roughness
included in the technical
dossier.

#

G1 G2 G3
Weld defaults such as:
19. Weld seams Corrosion YES 7 3 2 42 For weld seams in TECHNICAL
‐ Incomplete penetration NA NA DOCUMENTATIO
contact with PS the
‐ Lack of fusion of the weld N/FAT/IQ
following requirements
ripples
are applied:
‐ Cracks
‐ Endoscopic test of all
‐ Undercut
hand welded seams
‐ Burn‐through
‐ Sampling endoscopic
‐ Porosity
test of orbital welded
‐ Arc strikes
seams (Test points must
‐ Excessive discoloration
be defined; 10 % to 20%
‐ Metallic or non‐metallic
of all welds made by
inclusions
orbital welding)
‐ Misalignment in excess of
Standard welding
15% of the nominal wall
technique: Orbital
thickness.
welding.

20. Identification of Inadequate or missing YES 7 3 2 42 Traceability to the relevant Labeling of quality PARTLIST/
NA NA P&ID/TECHNICAL
components labeling documentation is not possible. critical components
according by engraved DOCUMENTATIO
N
metal plates. Each
component is tagged.
21. System installation Installation failure YES 9 3 1 27 Malfunction caused by faulty Installation is performed NA NA IQ

installation can lead to poor according to the P&ID
product quality, rouging, and to BRAM‐COR
contamination. sanitary piping
procedures. Inspection
of installation is
performed during
commissioning activities.

#

G1 G2 G3
5.4. HARDWARE & ELECTRICAL COMPONENTS
NA NA
22. Control board Electrical hazard for YES 8 3 1 24 Unsafe operating conditions‐ IP 54 protection grade of DQ/ELECTRICAL
missing protection or. Control board of water the control board, safety SCHEME/IQ
(CB‐2010)
treatment systems shall be lock, GMP wiring, proper
designed and constructed wiring identification,
according to International emergency circuit
Safety standards. according to European
Safety Standards.
PLC (+visual NO
23. Hardware Hardware failure YES 8 2 2 32 Unsuitable or insufficient The specified HW is ALARM LIST/OQ
check of
testing factory‐tested (FAT) and
( PLC, PC, DCS, ... ) HMI)
re‐tested in the final
equipment location
(SAT/OQ). INTERNAL PLC
ERROR ALARM. Visual
Check.
Safety Device
24. Emergency circuit The emergency YES 9 5 1 45 Connection problem Plant stop and activation ALARM LIST/OQ
YES
pushbutton is on with of acoustic signal.
failure of restoring Troubleshooting
attempts. indications reported in
the user manual.

#

G1 G2 G3
Thermal
25. Feed water pump Failure of the pump YES 9 4 2 72 P‐2001 is not working. Installation of an ALARM LIST/OQ
electronic YES
(P‐2010) alarmed thermal
breaker
protection to the pump.
Plant stop and activation
of acoustic signal.
Troubleshooting
indications reported in
user manual.
Protection
26. Circuit 230 VAC Short‐circuit of a device YES 9 4 2 72 Short circuits of embedded Alarm, plant stop and ALARM LIST/OQ
automatic YES
supplied by 230 V AC. devices may lead to system activation of acoustic
switch
stop. signal. Troubleshooting
user manual.
Protection
27. Circuit 24 VDC Short‐circuit of a device YES 9 4 2 72 Short circuits of embedded Alarm, plant stop and ALARM LIST/OQ
automatic YES
supplied by 24 V DC. devices may lead to system activation of acoustic
switch
stop. signal. Troubleshooting
user manual.

#

G1 G2 G3
5.5. SOFTWARE

28. Software Software failure YES 9 3 1 27 Unsuitable or insufficient The SW is configured
NA NO FAT/OQ
software testing according to GMP
( PLC, PC, DCS, ... )
compliant internal
procedures. SW correct
running is verified during
FAT and OQ testing
steps. Procedures for SW
maintenance to be
established.
Access policy by 3 USER
29. Access policy Unauthorized access for YES 7 2 2 28 System violation for GROUPS :
software deficiency. unprotected login credentials Group 1 ‐ OPERATOR:
can modify only some
operating parameters
Group 2 – SUPERVISOR:
; can modify all operating
parameters
Group 3 ‐ MAINTENANCE
can modify all operating
parameters; users
management; critical data
FAT/Operating
management. NA NA
manual/OQ
BRAM‐COR access
configuration provides
following standard settings:
User shall log‐in by digiting
user ID + password, the
combination of which is
unique and may be changed
by the Customer in runtime.
No password aging.
Unlimited number of access
attempts.
Log‐out time: 5 minutes.

#

G1 G2 G3

30. Data storage Failure of data storage YES 6 3 1 18 Loss of historical data The operator panel Operating
NA NA
system does not perform manual/OQ
any data storage as
clearly explained in
DQ.
SW change Incorrect SW change Malfunction of the control

31. YES 3 4 2 24 system due to software SW changes shall be
management NA NA
recorded in a SW change SOP for SW
modification
control form. The SW change
shall be re‐tested after management
modification.
SOP for SW change
management to be
established by the
Customer.
5.6. SAFETY
Hot parts Burning risk for the Injuries due to high
32. YES 9 1 1 9 Rockwool Insulation of ‐
operator temperature of metallic NA NA
vessels and pipes (clad
elements with AISI 304 stainless
steel).
Warning labels stuck to
hot parts .
SOP for use of protective
gloves and devices to be
established by the user.

#

G1 G2 G3
Overpressure Overpressure risk Injuries due to, steam
33. YES 9 2 1 18 Pressure Equipment ‐
leakages and damages to NA NA
design/material choice
the equipment and construction. Safety
valve.
Pressure test.
Hearting Unsuitable electrical
34. YES 9 2 1 18 Electrical installation of ‐
hearting of the equipment NA NA
the CPSG to be
Electrical hazard performed by expert
electricians only.
Hearting of the control
board.
5.7. DOCUMENTATION
Documentation GMP technical Basic requirement for
35. YES 2 5 5 50 A careful description of
documentation is not qualification. Problems in
the documentation
available equipment qualification. NA NA DQ/IQ
provided with the
equipment is given in DQ
and submitted to
Customer’s approval.
The documentation
check‐list included in IQ
protocol provides a
traceability matrix for
each document.
Material in product
contact and instruments
certifications are
included in the technical
documentation.

#

G1 G2 G3
5.8. CLEANING AND MAINTENANCE
Cleaning Scaling caused by Decrease of productivity
36. NO 2 1 4 8 If feedwater quality
unsuitable feedwater
compliance to the
specification is constant
in time, no scaling is
normally detected in
CPSG generators.
Instructions for cleaning See point 9 See point 9 See point 9
and sanitization included
in the use and
maintenance manual.
SOPs for periodical
cleaning to be
established by the
Customer.
Maintenance Failure or breaking of a Plant stop with economical
37. YES 9 3 1 27 loss A spare part list is
critical component
provided with the
Technical
Documentation.
Spare parts to be Spare parts list,
purchased and stored by Various (see Various (see
User and
the Customer in order to the relevant the relevant
Maintenance
prevent plant stop. point) point) manual.
SOPs for preventive
maintenance to be
established by the
Customer according to
User manual.

#

G1 G2 G3
Maintenance Unsuitable working space Difficulties for maintenance
38. NO 5 2 1 10 operation and spare parts Instructions for
around the equipment NA NA
equipment positioning
replacement
are provided in the user Use and
and maintenance maintenance
manual. A clearance of 1 manual
meter to be kept around
the equipment for
maintenance purposes.

SECTION 1.3.
P&ID reading key
▹▹▷

Feature
Item Description Capacity Flow-rate Pressure Power Temp.
EMISSIONE - REVISIONI / ISSUE-REVISIONS
N.A.
VIA G.MERCALLI, 12/A
QUARTIERE S.P.I.P.
43122 PARMA - ITALY
TEL. +39 0521 538711
N.A. N.A.
FAX. +39 0521 538770
SIMBOLOGIA P&ID
P&ID SYMBOLOGY Spoldi GO 19.05.04
...
- N.A. 01070

SECTION 1.4.
P&ID
▹▹▷


SECTION 1.5.
Tie‐in drawing
▹▹▷

SECTION 1.6.
Conformity declaration of equipment
▹▹▷
UT_MOD_DCM_038
DICHIARAZIONE DI CONFORMITÀ
CONFORMITY DECLARATION
No. P_3108_DCM_0
MACCHINA TIPO/ EQUIPMENT PURE STEAM GENERATOR
MODELLO/ MODEL CPSG ST 1000
MATRICOLA/SERIAL NUMBER 3108
COMMESSA/JOB 11880
ANNO DI COSTRUZIONE/
2018
YEAR OF CONSTRUCTION
IL COSTRUTTORE DICHIARA, SOTTO LA SUA ESCLUSIVA RESPONSABILITA’, CHE LA MACCHINA IN
OGGETTO E’ CONFORME A QUANTO PRESCRITTO DALLA DIRETTIVA MACCHINE 2006/42/CE.
I MATERIALI IMPIEGATI SONO CONFORMI ALLE PRESCRIZIONI CGMP.
LE VERIFICHE DI PRESSIONE INTERNA ED ESTERNA HANNO DATO RISULTATI POSITIVI.
THE MANUFACTURER DECLARES UNDER HIS OWN RESPONSIBILITY THAT THE ABOVE
DESCRIBED EQUIPMENT COMPLIES WITH 2006/42/CE EUROPEAN DIRECTIVE FOR MACHINERY.
ALL MATERIALS AND WELDINGS COMPLY WITH CGMP PRESCRIPTIONS.
THE INTERNAL AND EXTERNAL PRESSURE TESTS HAVE BEEN PERFORMED WITH POSITIVE RESULTS.
DATA: 13/08/2018 ..................................................

DATE The Manufacturer
SECTION 1.7.
Quality declarations
▹▹▷
UT_MOD_DCM_038
DICHIARAZIONE DI QUALITA’ IMPIANTI
EQUIPMENT QUALITY DECLARATION
No. P_3108_EQD_0
BRAM‐COR S.p.A.
DICHIARA CHE L’IMPIANTO TIPO: PURE STEAM GENERATOR
Declares that the equipment type: CPSG ST 1000
NOSTRA COMMESSA N.: 11880
Our job number:
NOSTRA MATRICOLA N.: 3108
Serial number:
E’ stato progettato, costruito, collaudato, approvato in accordo alle procedure scritte interne di
progettazione, esecuzione e controllo interno del Sistema di Gestione Qualità aziendale, certificato
ISO 9001:2015, al fine di garantirne la conformità ai requisiti del Cliente, alla normativa vigente ed
alle Good Manufacturing Practices.
Has been designed, manufactured, tested, approved in accordance with internal written
design, execution and internal check procedures of the company ISO 9001:2015 certified
Quality System, in order to ensure its compliance with the Customer’s requirements, current
regulations and Good Manufacturing Practices.
DATA 13/08/2018
Date
UT_MOD_DCM_038
DICHIARAZIONE DI QUALITA’ DEL PROCESSO
PROCESS QUALITY DECLARATION
BRAM‐COR S.p.A.
DICHIARA
Declares
Che ogni fase di processo quali: vendita, progettazione, fabbricazione, installazione, validazione
ed assistenza tecnica di impianti per il trattamento delle acque a fine farmaceutico è tenuto
sotto controllo mediante: impiego di personale addestrato, apposite istruzioni di lavoro che
definiscono le modalità operative delle fasi più critiche del processo di produzione,
manutenzione delle attrezzature utilizzate, taratura degli strumenti utilizzati per prova,
misurazione e collaudo, ordine e pulizia dei locali nei quali avviene il processo, rispetto delle
normative applicabili, identificazione e rintracciabilità dei materiali e componenti utilizzati,
registrazione ed analisi dei risultati dei collaudi effettuati sia in sede che presso la sede del
cliente.
That each phase of the process such as: sale, design, manufacturing, installation, validation
and technical assistance of the plant for the pharmaceutical water treatment is kept under
control by trained personnel, proper working instructions defining the most critical phases of
production, maintenance of tools, calibration of the instruments that are used for inspection,
measuring and tests, cleaning of the rooms where the process takes place, compliance with
the applicable rules, identification and availability of materials and components, registration
and analysis of the results of the tests that are performed in our workshop and onsite.
DATA 13/08/2018
Date
UT_MOD_DCM_038
DICHIARAZIONE DI QUALITA’ STRUMENTI
QUALITY DECLARATION OF INSTRUMENTS
BRAM‐COR S.p.A.
DICHIARA
declares
Che gli strumenti utilizzati per la misurazione, la taratura, il controllo, la calibrazione e la prova,
sono controllati, tarati e calibrati in base alla procedura interna di gestione delle apparecchiature
di misura.
That the instruments that are used for measuring, calibration, checking and testing are
checked and calibrated following our internal procedure of measuring devices management.
DATA 13/08/2018
Date
UT_MOD_DCM_038
DICHIARAZIONE DI QUALIFICA SALDATORI
WELDERS QUALIFICATION DECLARATION
No. P_3108_WOQD_0
BRAM‐COR S.p.A.
DICHIARA CHE L’IMPIANTO TIPO: PS GENERATION AND DISTRIBUTIO
Our job number:
E’ costituito da componenti assemblati tra loro per mezzo di saldature eseguite a
regola d’arte da personale specializzato.
Con la presente si dichiara che i nostri saldatori qualificati sono stati istruiti sulle
modalità d’esecuzione delle saldature in ottemperanza delle normative vigenti ed
alle procedure interne di piping sanitario.
Is constituted by components that are assembled by means of duly executed welds performed by
trained staff.
Hereby we declare that our qualified welders have been instructed to operate according to the
cGMP and to written internal sanitary piping procedures.
DATA 13/08/2018 …………………………………………….

Date
UT_MOD_DCM_038
DICHIARAZIONE DI QUALITA’ SALDATURE
WELDS QUALITY DECLARATION
No. P_3108_WQD_0
BRAM‐COR S.P.A.
DICHIARA CHE L’IMPIANTO TIPO: PS GENERATION AND DISTRIBUTIO
Our job number:
E’ costituito da componenti assemblati tra loro per mezzo di saldature eseguite a
regola d’arte in accordo a procedure scritte interne di saldatura stilate in
ottemperanza delle normative vigenti ed allegate alla presente dichiarazione con il
nome “WPS” – Welding Procedure Specification, al fine di garantirne la conformità
ai requisiti del cliente.
Is constituted by components that are assembled by means of welds that are duly carried out
according to written welding procedures, which have been drawn up according to cGMP and
that are enclosed to this declaration as WPS ‐ Welding Procedure Specification, in order to
ensure their compliance with the customer’ s requirements.
DATA 13/08/2018
Date

Section 2
Components documentation

2.1. Part List
2.2. Technical Dossiers
2.3. Components certification
2.3.1. Calibration report of manometer
2.3.2. Roughness gauge calibration report


SECTION 2.1.
Part List
▹▹▷

LOCATION COLOMBIA
DOCUMENT NAME PART LIST
DOCUMENT CODE M_3108_PL_1
P&ID 23749
JOB No. 11880
SERIAL No. 3108
REVISIONS HISTORY
0 Issued for DQ approval 07/06/2018 A. Negri C. Opl G. Opl
1 As built 14/08/2018 A. Negri C. Opl G. Opl
BRAM‐COR S.p.A
Via Mercalli 12/A ‐ 43122 Parma ‐ Italy
Tel. +39 0521 538711
Fax: +39 0521 538770
Page 1 of 3
PART LIST
Customer: FARMALOGICA S.A. Job no.: 11880 Document code: M_3108_PL_1 Rev.: 1
System: PURE STEAM GENERATOR Serial no.: 3108 Equipment type: CPSG ST 1000
Certificates Item
Unit TAG Description Supplier Model Position Certification1
filed in 2 Rev.
SECTION 2.2.
‐ C‐2001 Column Ø457.2 BRAM‐COR Dwg. No. 23777 installed on frame A 0
ATTACH. 1
‐ CB‐2010 Electrical Control Board ELEMEK N.A. On frame / N.A. 0
SECTION 2.3.
20 DM‐001 Demister Ø455 h=150 Costacurta Filtro Mono 415 inside C‐2001 A 0
ATTACH. 4
DTS H 44410 SECTION 2.2.
‐ E‐2001 Heat Exchanger BRAM‐COR on C‐2001 A 0
Dwg. No. 23779 ATTACH. 2
SECTION 2.3.
20 FO‐001 Flow orifice ¾'' pipe BRAM‐COR N.A. C‐2001 drain A 0
ATTACH. 3
SECTION 2.3.
20 HV‐001 Manual membrane valve ‐ Conn. ½" T.C. ‐ AISI 316L Gemu 601 15 D80 40 5A 00 TS 1536 P‐2001 drain A 0
ATTACH. 8
SECTION 2.3.
20 HV‐002 Manual membrane valve ‐ Conn. ¾" T.C. ‐ AISI 316L Gemu 612 20 D80 40 52 01 TS 1536 C‐2001 drain A 0
ATTACH. 8
Capacitive level transmitter ‐ Conn. 1½" T.C. SECTION 2.3.
20 LT‐001 Endress+Hauser FMI51‐A1ATJJB1A1D on C‐2001 A + B 0
L=450mm ‐ AISI 316L ATTACH. 6
Multistage pump ‐ Q= 1,6 m3/h ‐ H=50 m ‐ 0,75 kW SECTION 2.3.
‐ P‐2001 Grundfos CRN1‐7 E‐CX‐GI‐E‐HQQE feed water inlet B 0
60 Hz ‐ Conn. 1½'' T.C. ‐ AISI 316 (440 V, 60Hz) ATTACH. 5
SECTION 2.3.
20 PSV‐001 Safety valve ‐ in 1½" T.C. ‐ out 2" T.C. ‐ Set 4.9 bar Universal S25C on C‐2001 A + B 0
ATTACH. 10
Pressure transducer ‐ Conn. 1½" T.C. dTrans p31 SECTION 2.3.
20 PT‐001 Jumo on C‐2001 A + B 0
Range: ‐1/+5 bar 402050 ATTACH. 7
FR 100 1/4 20 08 RMSA
Filter air reducer ‐ Conn. ¼'' with manometer
20 PCV‐001 Metal Work (reducer) Compressed air inlet on control board / N.A. 0
Range: 0‐8 bar + ACC. M 40 1/8 12 (manometer)
20 PS‐001 Pressure switch SMC ISE10‐M5‐B‐GR Compressed air inlet on control board / N.A. 0
Page 2 of 3
PART LIST
Customer: FARMALOGICA S.A. Job no.: 11880 Document code: M_3108_PL_1 Rev.: 1
Certificates Item
Unit TAG Description Supplier Model Position Certification1
filed in 2 Rev.
Pressure switch ‐ ⅜" bspg m. ‐ range 1‐10
20 PS‐002 Danfoss RT116 Industrial steam inlet / N.A. 0
diff. 0,3 ‐ 1,3
Modulating valve dn50 pn16 f.c./ actuator M805033C (valve)
20 PV‐001 Hofmann / SMC E‐2001: industrial steam / N.A. 0
6‐30 psi / serv Ø360 + ITV1030 (actuator)
Steam trap DN40 PN16 flanged connection ‐
20 ST‐001 Spirax Sarco FT43‐10 E‐2001: condense outlet / N.A. 0
CAST IRON
SECTION 2.3.
20 XV‐001 Pneumatic membrane valve ¾" T.C. ‐ AISI 316L Gemu 625 20 D 80 40 52 1 1/N 1536 P‐2001 Outlet A 0
ATTACH. 9
Pneumatic membrane valve ¾" T.C. (with closing stroke SECTION 2.3.
20 XV‐002 Gemu 625 20 D 80 40 52 1 1/N 1536 P‐2001 Outlet A 0
limiter) ‐ AISI 316L ATTACH. 9
SECTION 2.3.
20 XV‐003 Pneumatic membrane valve ¾" T.C. ‐ AISI 316L Gemu 625 20 D 80 40 52 1 1/N 1536 C‐2001 drain A 0
ATTACH. 9
‐ N.A. Ringlet pipe ⅜" bspg m. Roffia N.A. Industrial steam inlet / N.A. 0
NOTE 1:
A= with material certificate
B= with manufacturer or calibration certificate
NOTE 2:
Components certification is available in 'Technical Documentation' while technical datasheets and/or manuals are consultable in 'Components Datasheets and Manuals' folder.
Page 3 of 3

SECTION 2.2.
Technical Dossiers
▹▹▷

TECHNICAL DOSSIERS
SUMMARY
ATTACHMENT No. COMPONENT NAME DOSSIER CODE
1 COLUMN VESSEL M_3108‐1_FT_0
2 HEAT EXCHANGER M_3108‐2_FT_0
TECHNICAL DOCUMENTATION – M_3108_TD SECTION 2.2.
ATTACHMENT 1.
BRAM‐COR Column Vessel
 NOTE:
The main components are described in separate books called “Technical
Dossiers”, identified in following table and attached below.
The above‐mentioned files will be supplied in electronic version only.
BRAM‐COR TAG Technical Dossier Name Code
C‐2001 M_3108‐1_FT_0
TECHNICAL DOSSIER
COLUMN VESSEL
C‐2001
REVISION HISTORY
00 First emission 20/08/2018 P. Morlacchini V. Cucci A. Nagril
BRAM‐COR S.p.A.
Tel. +39 0521 538711
Fax: +39 0521 538770
COLUMN VESSEL
SUMMARY
INTRODUCTION
SECTION 1 – GENERAL INFORMATIONS
1.1. Product general description
SECTION 2 – DRAWING AND MATERIAL CERTIFICATES
2.1. Drawing
2.2. Material certificates
2.3. Insulation material
SECTION 3 –WELDING DOCUMENTATION
SECTION 4 –PASSIVATION REPORT AND TESTING CERTIFICATES
4.1. Pickling and passivation report
4.2. Non destructive test certificates
4.3. Hydraulic test certificates
TECHNICAL DOSSIER ‐ M_3108‐1_FT_0
COLUMN VESSEL

INTRODUCTION

HOW TO USE THIS TECHNICAL DOSSIER

This Technical Dossier provides complete information and instructions of use for the involved
component.
To ensure traceability, the material certificates refer to the related position in the element table
of the constructive drawing, as shown below.

COLUMN VESSEL

Each element is labelled with relative peening. The relative number is reported in the “position”
column on the left of the table, the second column describes the Item, the third indicates the
quantity, the fourth column indicates the material and the fifth indicates the dimensions.
An example in the following picture.

Each material certificate is consequently identified by the preceeding title page with the position
on the table.

COLUMN VESSEL

CONSIDERATIONS ABOUT SIGNATURES ON THE CERTIFICATES

Some certificates are issued by the manufacturer without the inspector’s signature.
According to the European Norm EN 10204 “Metallic products ‐ types of inspection documents”,
section 5 , ”The inspection document shall be validated by the responsible person(s) (name and
position). No signature is required for material certificates.
All the included certificates are therefore considered as validated even without signature.
The applicable certificates in this document conform to the original, are included “as received”,
either in paper copy or in PDF electronic format and cannot be overwritten by BRAM‐COR.
Consequently BRAM‐COR will not and cannot stamp or overwrite the manufacturers’ certificates
on customer’s request. No further conformity declarations by BRAM‐COR are therefore due to
justify the absence of signatures on the manufacturer’s certificates.

STAINLESS STEEL CODING

Stainless steel may be identified on the 3.1. certificate either by its AISI code (SAE grade) or by the
corresponding Euronorm code (EN steel number), according to its chemical composition, as
follows:

U.S.A. GERMANY GERMANY FRANCE JAPAN ITALY SWEDEN U.K. E.U. SPAIN RUSSIA

W.N.
AISI DIN 17006 AFNOR JIS UNI SIS BSI EURONORM UNE GOST
17007

X 5 CrNi 18 10 1.4301 304S15 08KH18N10
304 Z 6 CN 18‐09 SUS 304 X 5 CrNi 1810 23 32 X 6 CrNi 18 10 X 6 CrNi 19‐10
X 5 CrNi 18 12 1.4303 304S16 06KH18N11

304 L X 2 CrNi 1911
X 2 CrNi 18 11 1.4306 Z 2 CN 18‐10 SUS 304L 23 52 X 2 CrNi 19‐10
X 2 CrNiN 1811 304S11 X 3 CrNi 18 10 03KH18N11
X 2 CrNiN 18 10 1.4311 Z 2 CN 18‐10‐Az SUS 304LN 23 71

316 X 5 CrNiMo 17 12 2 1.4401 Z 6 CND 17‐11 SUS 316 X 5 CrNiMo 1712 23 47 316S31 X 6 CrNiMo 17 12 2 X 6 CrNiMo 17‐12‐03

X 2 CrNiMo 17 13 2 1.4404 Z 2 CND 17‐12 X 2 CrNiMo 1712 23 48 316S11 X 3 CrNiMo 17 12 2 03KH17N14M2
316 L SUS 316L
X 2 CrNiMo 18 14 3 1.4435 Z 2 CND 17‐13 X 2 CrNiMo 1713 23 53 316S13 X 3 CrNiMo 17 13 3 X 2 CrNiMo 17‐12‐03 03KH16N15M3
COLUMN VESSEL

SECTION 1
GENERAL INFORMATION


COLUMN VESSEL
SECTION 1.1.
Product general description
▹▹▷
VESSEL GENERAL DESCRIPTION
The equipment is made of one column pressure vessel to be connected to one double tube
sheet heat exchanger. In fact, it has the task to feed that exchanger with water and to receive
from it the steam produced.
The shape of the tank is in order to allow, during the going up of the steam towards the exit
connection, the separation of the water drops contained in it because of the diminution of the
entrainment speed. A stainless steel demister in the upper part of the column further increase
the title of the pure steam produced.
The tank is equipped with many connections: two connections with the exchanger, one
connection for water entry from feeding piping, one for pure steam produced exit (placed in
the highest point of the tank), one for draining (placed in the lowest point), one for a pressure
transducer and one connection for a safety valve, calibrated at maximum running pressure of
the equipment. Other two connections are in comunication with a level probe.
The frames and the components in contact with the product are made of stainless steel EN
1.4404 (AISI 316L), otherwise the secondary components are generally made of stainless steel
EN 1.4301 (AISI 304).
The equipment is designed according to the indications of Italian ISPESL collection VSR Rev. 95
Ed. 99 + Errata Corrige 2003.
MAIN FEATURES
 Capacity (shell side): 385.0 L
 Capacity (pipes side): N.A.
 Max. / Min. design pressure (shell side): 5.0 bar / F.V.
 Max. / Min. design pressure (pipes side): N.A.
 Max. / Min. design temperature (shell side): 180 °C / 0 °C
 Max./ Min. design temperature (pipes side): N.A.
 Fluid class: 2
APPLICATION FIELD
 Pharmaceutical industry
TECHNICAL DOSSIER ‐ M_3108‐1_FT_0 SECTION 1.1.
COLUMN VESSEL

SECTION 2
DRAWING AND MATERIAL CERTIFICATES

2.1. Drawing
2.3. Insulation Material

COLUMN VESSEL

SECTION 2.1.
Drawing
▹▹▷

COLUMN VESSEL

SECTION 2.2.
Material certificates
▹▹▷


Position 1
Drawing 23777
▹▹▷

TECHNICAL DOSSIER ‐ M_3108‐1_FT_0 SECTION 2.2

N. Bolla 10809 del 11/07/2018 - Materiale AAG44460 - 316LTTE 457,20X 4,00
Quantità 6 m - Colata 515095 - N. Ord. 832432 - 10 - Rif. Cliente 1440
Ilta Inox S.p.A.

Strada Statale 45 bis
26010 Robecco d'Oglio (CR) - Italia
Tel + 39 0372 9801

Fax + 39 0372 921538
e-mail:sales@ilta.arvedi.it
quality@ilta.arvedi.it
www.arvedi.it
TEST CERTIFICATE ACCORDING TO EN 10204(2005) 3.1 N°0000529020

ABNAHMEPRÜFZEUGNIS - CERTIFICAT D'ESSAIS - CERTIFICATO DI COLLAUDO Pag. 1di 1
Longitudinally laser welded tubes/Laser längsnahtgeschweisste rohre/Tubes soudes longitudinalement laser/Tubi saldati longitudinalmente laser
Customer: PROFILINOX S.P.A Q.re Ind.le S.P.I.P.
Besteller/Client/Cliente Via Nobel, 3/a 43100 PARMA PR
Customer Order N°: 800284 - Mill's Ilta Inox N°: 0411070109 - 006010 # 0421075528 - 000030
Bestellung/Commande Client/Ordine Cliente WerksN°/N° référence Interne/Conferma ordine
Specifications: EN 10296-2: 2005 / V=0,7 Tolerances: EN 10296-2 : OK
Anforderungen/Specifications/Specifiche Toleranzen/Tolérances/Tolleranze
Manufacturer's mark: Herstellerzeichen/Marque du fabricant/ Marchio del produttore Marking: EN 10296-2
Inspector's Stamp: A.C. Stempel des Sachverständigen/Poinçon de l'inspecteur/Punzone dell'ispettore Kenzeichnung/Marquage/Marcatura
Item DIMENSIONS PIECES N° METERS WEIGHT(kg) GRADE STANDARD CODE EXECUTION

Pos. Abmessungen Stückzahl Meter Gewicht/Poids Werkstoff/Nuance Normbezeichnung Ausführung
N° Dimensions/Dimensioni Piéces/Pezzi Métres/Metri Peso Materiale Designation/Designazione Execution/Esecuzione
6010 457.20 X 4.00 X 6000 4 24.00 1,099.000 TP.316L X2 CrNiMo 17-12-2 W1
1.4404
Z3 CND 17-12-02
UNS S31603
Chemical analysis acc.to: ASTM A240/ EN 10088-2/EN 10028-7 Last Edition Schmelzanalyse/Chimique analyse/Analisi chimica
Steel making process :E/AOD Erschmelzungsart/Procéde d'elaboration/Procedimento di elaborazione acciaio
Item Manufacturer HEAT N° %C % Si %S %P % Mn % Cr % Ni % Mo % Ti % Co % Cu %N

N° Hersteller/Fabricant/Produttore Schmelze/Couléé/Colata
6010 . . . . . . . . . . . . . . . . . . 515095 0.024 0.390 0.0010 0.031 1.270 16.510 10.000 2.030 0.100 0.048
Mechanical test acc. to tab.: 4 EN 10296-2 Mechanische Prüfungen/Essais mécaniques/Caratteristiche meccaniche
Item HEAT N° HOMOLOG. TEST SPECIMEN SIZE YIELD STRENGTH TENSILE ELONGAT. HARDNESS
Pos. Schmelze Zulassung Probe Abmessung Probestab Streck-Dehngrenze STRENGTH Bruchdehnung Haerte
N° Coulée Omologation Eprouvette Dime. Eprouvette Limite d'élasticitè Zugfestigkeit Allongament Dureté
Colata Omologazione Provino Dimensione provetta Limite di snervamento Résistance à traction Allungamento Durezza
n° mm. 0,2% N/mm² 1% Limite di rottura A5% HB
N/mm²
REQUIREMENT Anforderungen/Exigences/Requisiti >=190 >=225 490 - 800 >= 40.0
6010 515095 01 L 20 X 4.00 355 394 632 53.0
Test Results Ergebnisse der Prufungen/Résultat des essais/Risultati delle prove
Heat treatment: Wärmebehandlung/Traitement termique/Trattamento termico
Tecnological test: ====== / ====== / EN ISO 8492: OK - Prova piega sa / ====== Technologische Prüfung/Examen technologique/Prove tecnologiche
Residual Corrosion Test acc.to : =============== Korrosionsfòrdernde Rùckstàden/Essai residues corrosif/Prova residui corrosivi
Intergranular Corrosion Test acc.to: IK Beständigkeit/Essai corr.intergr./Prova di corrosione intergranulare
Non Destructive Test acc. to: EN ISO 10893-2/E1H: OK Zerstörungsfreie Prüfung/Contrôle non destructif/Controllo non distruttivo
Leak Test/Hydrostatic test to: EN ISO 10893-1: OK Dichtheitsprüfung/Essai d'étanchèité/Prova di tenuta
Uncorrect Material Test: al 100%: Favorevole Verwechlungsprüfung/Essai P.M.I./Prova antimiscuglio
Visual and gauging control: Favorevole Besichtigung und Ausmessung/Contrôle visuel et dimensionel/Controllo visivo e dimensionale
Notes:
Materiale conforme al tipo: 1.4401/316
We certify that the delivered products comply with the specification of the order / Wir bestaetigen, dass die gelieferte Ware den Bestellvorschriften entspricht / Nous
attestons que les produits livres sont conformes aux réferences de la commande / Noi attestiamo che il materiale spedito è conforme ai requisiti dell'ordine
Ing. Alessandro Canevari
Robecco d'Oglio, 14/02/2018 Mill's Inspector / Der Werksachverständige
D Inspecteur de l'usine / Firma Ispettore
PROFILINOX SPA - CONFORME ALL'ORIGINALE

Positions 2 ‐ 5 ‐ 11
Drawing 23777
▹▹▷


CERTIFICAT DE RECEPTION 3.1 / EN 10204:2004 Numéro de document Rev 00 Page 001 21193
Inspection Certificate 3.1 / EN 10204:2004 Document number Sheet /
Prüfbescheinigung 3.1 / EN 10204:2004 Bescheinigungnummer Seite 011
2017-108570
Client - Purchaser - Besteller Centro Servizi Metalli S.P.A.
Référence client - Purchase order - Kaufauftrag OF1011700142/
Projet - Project - Projekt Repère poste - - 44
Industeel Belgium ISO 9001 (Cert.95587-2011, Valid 02/06/2017) + MAQ REV 12 du 02/05/2012
Site : Rue de Châtelet 266 6030 Marchienne-au-Pont ISO 9001 (Cert.95587-2011, Valid 02/06/2017) + QAM REV 12 of 02/05/2012
Produit - Product - Erzeugnis Plate(s)

Commande / Poste - Internal order - Werksbestellung 1070111 / 000440
Bordereau de livraison - Delivery note - Lieferungsdokument 80307899
#010 - PRODUITS LIVRES - DELIVERED PRODUCTS - GELIEFERTEN GEGENSTÄNDE

Nuance - Grade - Werkstoff X5CrNiMo17-12-2 (1.4401) Selon norme - According to - Entsprechend EN 10088-2:2014
X2CrNiMo17-12-2 (1.4404) EN 10088-2:2014
UNS S31600 (316) ASTM A 240/M ED.2016
UNS S31603 (316L) ASTM A 240/M ED.2016
UNS S31600 (316) ASME IIA ED.2015 SA 240/M
UNS S31603 (316L) ASME IIA ED.2015 SA 240/M
X5CrNiMo17-12-2 (1.4401) EN 10028-7:2016+AD2000W2+ADW10
X2CrNiMo17-12-2 (1.4404) EN 10028-7:2016+AD2000W2+ADW10
X5CrNiMo17-12-2 (1.4401) EN 10088-4:2009
X2CrNiMo17-12-2 (1.4404) EN 10088-4:2009
Epaisseur - Thickness - Dicke 22.00 mm Largeur - Width - Breite 3,000 mm Longueur - Length - Länge 6,000 mm
Spécification - Specification - Spezifikation
- Acc to A/SA 480

- This supply complies with the main requirements of PED 2014/68/UE
relating to the basis materials regardless of the specific terms
of service.
- Nace MR 0175 / ISO 15156-3
- Nace MR 0103 / ISO17945
- Plate are free from radioactivity.
- Hot rolled, annealed and pickled.
Etat thermique de livraison - Heat treatment state of delivery - Wärmebehandlung Lieferzustand

Hypertrempe à l'air ( 1050 °C - 1 min/mm ) - Solution annealed and air quenched - Luft vergütet
Procédé d'élaboration - Melting process - Erschmelzungsart
17-04202
Electric-arc furnace - VOD - Finish n°1 - 1D - HRAP
Nbre N° produit N° de coulée N° de lot de contrôle Nbre N° produit N° de coulée N° de lot de contrôle
Nbr Product Ladle nr. Inspection lot nr. Nbr Product Ladle nr. Inspection lot nr.
Stz Erzeugnis Schmelze nr. Prüflos nr. Stz Erzeugnis Schmelze nr. Prüflos nr.
01 811921001 13241 811921.4001 / 811921.5001
Total - Total - Gesamtzahl 001
1148
06
20060925
EN 10088-4:2009
Produit laminé à chaud en acier de construction
Usages prévus: Construction de bâtiments et Génie civil
X5CrNiMo17-12-2 (1.4401)
X2CrNiMo17-12-2 (1.4404)
Nous certifions que les produits ci-dessus sont conformes aux prescriptions de la commande.
We hereby certify that the above mentioned products are complying with the order requirements.
Wir bestätigen hiermit, dass die obengenannten Erzeugnisse den Bestellungvorschriften entsprechen.
ALPHONSE MERENDA
27/03/2017
Gestionnaire Commande
Mill inspector
Werksbeauftragte
CERTIFICAT DE RECEPTION 3.1 / EN 10204:2004 Numéro de document Rev 00 Page 002
2017-108570

#020 - ANALYSE CHIMIQUE DE COULEE - LADLE CHEMICAL COMPOSITION - SCHMELZE CHEMISCHE ZUSAMMENSETZUNG
C Mn P S Si Cu Ni Cr Mo
% % % % % % % % %
Min. 10.000 16.500 2.000
13241 0.022 1.846 0.0351 0.0011 0.289 0.336 10.058 16.655 2.003
Max. 0.030 2.000 0.0450 0.0150 0.750 0.750 13.000 18.000 2.500
Nb Ti N Co
% % % %
Min.
13241 0.011 0.002 0.0321 0.084
Max. 0.100 0.100 0.1000
#041 - PMI - POSITIVE MATERIAL IDENTIFICATION - VERWECHSLUNGSPRÜFUNG
Non confusion de matière - Positive material identification - PMI Conform
Résultat du contrôle - Examination result - Prüfergebnis
Conforme aux spécifications précitées - Conforming to above specifications - Entspricht der vorgenannten vorschriften
ALPHONSE MERENDA
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2017-108570

#072 ESSAIS MECANIQUES - MECHANICAL TESTS - MECHANISCHE PRÜFUNGEN
DURETE SUR COUPON - HARDNESS ON SAMPLE - HÄRTE AUF COUPON

Brinell HB HB10 Ind HB10 Ind HB10 Ind HB10 Aver
Brinell HB - Brinell HB
N° lot QM Etat Loc Epr. T° Uni Mac Uni Brinell Brinell Brinell Brinell
Min
Max 217 217 217 217
811921.5001 000 T3/4 PSS 20 °C 171 171 171 171

DURETE NACE MR0103 HRC < 22
NACE MR0103 - NACE MR0103
N° lot QM Etat Loc Epr. T° Uni Mac
811921.5001 000 T3/4 PSS 20 °C

Test result HRC < 22

NACE MR0175 / ISO 15156-3
NACE MR0175 / ISO 15156-3 - NACE MR0175 / ISO 15156-3
811921.5001 000 T3/4 PSS 20 °C

Test result HRC < 22
TRACTION A L' AMBIANTE - ROOM TEMPERATURE TENSILE TEST - ZUGVERSUCH BEI RT

Traction Rp 0,2% Rp1% Rm A Lo=50 A
Tensile test - Zugversuch Lo=5,65V
So
N° lot QM Etat Loc Epr. T° Uni Mac Uni MPa MPa MPa % %
Min 220 260 520 40 45
Max 670
811921.5001 000 T3/4 PST 20 °C 256 299 569 66 57
RESILIENCE - TOUGHNESS - KERBSCHLAGZÄHIGKEIT

KCV EN 10X10mm Energ Ind Energ Ind Energ Ind Energ Ave
KCV EN 10X10mm - KCV EN 10X10mm
N° lot QM Etat Loc Epr. T° Uni Mac Uni J J J J
Min 42 42 42 60
Max
811921.5001 000 T3/4 PST 20 °C 286 270 242 266
Loc 3/4 Trois-Quart - 3/4 Width - 3/4 Breite
Loc T Tête - Top - Kopf
Epr. Epaisseur P Peau - Rolled Surface - Walzfläche
Epr. Face S Supérieure - Upper face - obere
Epr. Sens S Standard - Standard - Standard
Epr. Sens T Travers - Transverse - Quer
ALPHONSE MERENDA
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2017-108570

Etat 000 Etat thermique de livraison - Heat treatment state of delivery - Wärmebehandlung Lieferustand
Epr.Ep./Face/Sens PSS Peau - Rolled Surface - Walzfläche / Supérieure - Upper face - obere / Standard - Standard - Standard
Epr.Ep./Face/Sens PST Peau - Rolled Surface - Walzfläche / Supérieure - Upper face - obere / Travers - Transverse - Quer
#082 ESSAIS TECHNOLOGIQUES - TECHNOLOGICAL TESTS - TECHNOLOGISCHE PRÜFUNGEN
FERRITE SUR COUPON - FERRITE ON SAMPLE - FERRIT AUF COUPON

ASTM E562
ASTM E562 - ASTM E562
811921.4001 000 T3/4 SSS 20 °C

Standard ASTM E562/E1245
Number of Fields 5
Etchant N°96 (ASTM E407)
Magnification 500X
Test result Compliant with Standards
N° Location - Localisation - Lage Picture - Image - Bild
01 Top Surface AN_0001070111_000440_811921001_001(1)
02 1/4 thickness AN_0001070111_000440_811921001_001(2)
03 1/2 thickness AN_0001070111_000440_811921001_001(3)
04 3/4 thickness AN_0001070111_000440_811921001_001(4)
05 Bottom Surface AN_0001070111_000440_811921001_001(5)
Results - Résultats - Ergebnisse
Ferrite (%)
N° Location Measurements Requirement
Localisation - Stelle Mesures - Messungen Requis - Bedarf
Min Max
01 Up 0.670 0.000 0.000
02 1/4 thickness up 0.690 0.000 0.000
03 1/2 thickness 0.720 0.000 0.000
04 1/4 thickness bottom 0.450 0.000 0.000
05 Bottom 0.520 0.000 0.000
Average- Moyenne - Mittel 0.610 0.000 8.000
Std Deviation 0.118
95% CI 0.146
% RA 23.934
CORROSION - CORROSION - KORROSION Sensibilisé - Sensitized -Sensibilisiert

EN ISO 3651-2 A
Test description - Prüfbeschreibung
811921.5001 001 T3/4 SSS 20 °C

Test result Satisfactory as per specification
ALPHONSE MERENDA
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Mill inspector
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2017-108570

CORROSION - CORROSION - KORROSION Sensibilisé - Sensitized -Sensibilisiert

ASTM A262 E
ASTM A262 E - ASTM A262 E
811921.5001 002 T3/4 SSS 20 °C

Test result Satisfactory as per specification
Loc 3/4 Trois-Quart - 3/4 Width - 3/4 Breite
Loc T Tête - Top - Kopf
Epr. Epaisseur S Standard - Standard - Standard
Epr. Face S Supérieure - Upper face - obere
Epr. Sens S Standard - Standard - Standard
Etat 000 Etat thermique de livraison - Heat treatment state of delivery - Wärmebehandlung Lieferustand
Etat 001 SENSI - Sensitization (From 350 °C at 220 °C/h to 700 °C (-10/+10) (min: 30 min) - Down to 350 °C at 220 °C/h - 1 Cycle) - SENSI
Etat 002 SENSI - Sensitization (From 350 °C at 220 °C/h to 675 °C (-25/+0) (min: 60 min) - Down to 350 °C at 220 °C/h - 1 Cycle) - SENSI
Epr.Ep./Face/Sens SSS Standard - Standard - Standard / Supérieure - Upper face - obere / Standard - Standard - Standard
ALPHONSE MERENDA
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Mill inspector
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2017-108570

#101 - DIMENSIONNEL - DIMENSIONAL CHECK - MASSKONTROLLE

Cahier des charges Longueur - Specification Length - EN 10029:1991
Cahier des charges Largeur - Specification Width - EN 10029:1991
Cahier des charges Epaisseur - Specification Thickness - EN 10029 : 1991 CLASSE B
ALPHONSE MERENDA
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#111 - VISUEL-ETAT DE SURFACE - VISUAL EXAMINATION-SURFACE CONDITION - SICHTPRÜFUNG-OBERFLÄCHENZUSTAND

Norme applicable 1 - Applicable standard 1 - EN 10163 CL.B S-CL.3
ALPHONSE MERENDA
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2017-108570

#171 - PLANEITE - FLATNESS - EBENHEIT

Cahier des Charges Planéité - Flatness standard - Ebenheit norm EN 10029 TBL 4 CL N =<460Mpa
ALPHONSE MERENDA
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Mill inspector
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Inspection Number : 2017-108570
ANNEXES - APPENDIX - ANLAGEN 811921001 AN_0001070111_000440_811921001_001
ALPHONSE MERENDA
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Mill inspector
Werksbeauftragte
ALPHONSE MERENDA
27/03/2017
Mill inspector
Werksbeauftragte
ALPHONSE MERENDA
27/03/2017
Mill inspector
Werksbeauftragte
Position 3
Drawing 23777
▹▹▷
Quantità 6 m - Colata 04/77204 - N. Ord. 814853 - 10 - Rif. Cliente 602
TIPO DOCUMENTO − TYPE DOCUMENT (EN10204) Data − Date Pag. 1 / 1

Certificato di Controllo 3.1 05/03/2018
Via Portamurata, 8/A
42016 GUASTALLA (RE) − ITALIA Inspection Certificate 3.1
Tel. + + 39 522 83.65.55 (r.a.) AZIENDA CON SISTEMA DI GESTIONE
Fax + + 39 522 83.65.72 − 83.65.73 QUALITA’ CERTIFICATO SECONDO Nr. : 18020583
Cod. Fis. e P. IVA IT00323370353 UNI EN ISO 9001
PROFILINOX SPA ( 2238 ) Consegna: PROFILINOX SPA ( 13133 ) D.D.T. − DELIVERY NOTE
VIA NOBEL, NR. 3/A Q.RE IND.LE S.P.I.P. Delivery: VIA NOBEL N. 3/A Q.RE IND.LE S.P.I.P.
43122 PARMA PR 43100 PARMA PR
Italia Italia 18015288 − 05/03/2018
Riferimenti Normativi Tubi − Hollow Sections Standard: EN10217−7 / TC1−ISO1127 D3/T3 DELIVERY CONDITIONS = W0 WELDING FACTOR V=1 * D = Direction : L/T ** P = Position : W/M
Tubi Saldati Longitudinalmente Composizione Chimica CAPABLE TO MEET Proprietà Meccaniche e Tecnologiche
Longitudinal Welded Tubes Chemical Composition INTERGRANULAR CORROSION TEST Mechanical and Technical Properties
Dim. Sp. L Acciaio Fin. Lotto MT Peso Colata ( LADLE ) ( ACCORDING TO EN ISO 3651−2 ) ( EN ISO 6892−1 ) ( T = 23° )
Trazione / Tensile Test Durezza
Th. Steel Tot. WGT Heat
%C %Si %Mn %P %S %Nb %V %Al %Ti %Cr %Ni %Mo %Cu %N D* P** Rp0,2 Rp1,0 Rm A A80 Hardness
(mm) (mm) (mm) (m) (kg)
MPa % HRB
ORDINE CLIENTE − CUSTOMER ORDER ORDINE PADANA TUBI − P.T. ORDER FATTURA − INVOICE
800442 27/02/2018 SI − 18010455 − −
D.139,7 3,00 6000 1.4404−AISI 316L SP TN04156224 60,00 578 04/77204 0,022 0,450 0,930 0,035 0,001 16,700 10,100 2,040 0,045 L M 309 374 608 59,4
D.101,6 4,00 6000 1.4301/1.4307 SP TN04170544 114,00 1.078 02/742087 0,024 0,390 1,470 0,030 0,001 18,150 8,050 0,070 L M 433 458 666 56,7
800443 27/02/2018 SI − 18010530 − −
D.139,7 3,00 6000 1.4404−AISI 316L SP TN04156401 90,00 866 04/77204 0,022 0,450 0,930 0,035 0,001 16,700 10,100 2,040 0,045 L M 309 374 608 59,4
(EN ISO 8492 / 8493) (EN ISO 10893−1) Certifichiamo che il prodotto fornito
Controllo visivo e dimensionale: esito positivo Prova di schiacciamento o prova di espansione :esito positivo Prova di tenuta: esito positivo è conforme ai requisiti dell’ordine
Visual and dimensional control: OK Flattening test or drift expanding test: OK Leak tightness test: OK
(EN ISO 10893−2)
We certify that material supplied complies
with the requirements agreed on order
Verifica antimescolamento: esito positivo P.N.D.: correnti indotte sulla saldatura: esito positivo
Anti−mixing test : OK NDT: Eddy Current test on the weld: OK
Certificazioni / Certifications : Qualifiche / Qualifications: Padana Tubi & Profilati Acciaio S.p.A.
UNI EN 9001:2008 WPQR : EN ISO 15614−11 Marking: P.T.−Ø−th.−steel type−en standard−heat n° Ing. Stefano Passera
Dir. PED 2014/68/UE Annex1, Paragraph 4.3 Steel making process :AOD
Num. Cert. TUV: PED−0948−QS4.3−435−15 Rev.01 WLD : EN ISO 14732 operator qualified
NDT : Operator qualified according to ISO 9712 level 2
Controllo Qualità / Quality Department
M 7.5.19 − rev. 00 I3.1

Position 4
Drawing 23777
▹▹▷
TOPLINE STAINLESS
NO.62 LIMING INDUSTRIAL PARK, WENZHOU CITY, ZHEJIANG PROVINCE, CHINA
MILL TEST CERTIFICATE
ACCORDING TO EN10204 3.1B
Purchaser: BRAM-COR S.P.A. PI No.: TPL17TL014 PO No.: 428 Date:2017-03-30

HARDNESS
No. DESCRIPTION QTY(PCS) HEAT NO. SURFACE FINISH DIMENSION
HB
1 Short Welding Ferrule 14WMP 316L 1/2”-2.1/2” 5150 17175 ID Ra≦0.5µ GOOD GOOD
2 Long Welding Ferrule 14AMP 316L 1”-2” 2450 17175 ID Ra≦0.5µ GOOD GOOD
3 Short Welding Ferrule 14WMP 316L 3”-4” 450 17653 ID Ra≦0.5µ GOOD GOOD
5 End Cap 16AMP 316L 2”-4” 300 17886 ID Ra≦0.5µ GOOD GOOD
CHEMICAL COMPOSITION (%) PHYSICAL TENSILE PROPERTY
Yield Strength Tensile Strength Elongation
No. Material C Si Mn P S Ni Cr Mo
σ.2(Mpa) ≥ σb(Mpa) ≥ δ5 %
1 316L 0.017 0.58 1.74 0.021 0.025 10.10 16.53 2.04 218 525 47
2 316L 0.017 0.58 1.74 0.021 0.025 10.10 16.53 2.04 218 525 47
3 316L 0.019 0.57 1.76 0.022 0.023 10.09 16.51 2.03 216 522 48
4 316L 0.019 0.57 1.76 0.022 0.023 10.09 16.51 2.03 216 522 48
5 316L 0.021 0.62 1.56 0.031 0.018 10.05 16.55 2.09 214 520 42
Remarks: We hereby certify that the above specification and also with the requirements called for by the above order and is that which has been tested to the
satisfaction of the inspector.
STAMP:
Abnahmeprüfzeugnis 3.1 nach EN 10204
Inspection Certificate 3.1 acc. to EN 10204 A02
Bescheinigungsnummer - Document No.: 10001205805 / 00 A03
A04
Dockweiler AG - An der Autobahn 10/20 - 19306 Neustadt-Glewe - Germany A01
Certified as per
BPE-105 expiring on 2020-11-17,
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
Quartiere S.P.I.P. ISO 14001:2015 Cert. No. 07 104 980183
Directive 97/23/EG Annex I, Section 3.1
Via G. Mercalli 12/A Cert. No. 50164/4
AD 2000-Merkblatt HP0 &
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
ITALY www.dockweiler.com
Kundenbestellnr. - Customer P.O. no. A09 Auftrags-Nr. - Our order no. A13 Geliefert am - Delivered on A10
1237 1030121532 June 14, 2018

Lieferschein-Nr./Pos. - Our delivery no./item A14/A15 Chargen-Nr. des Artikels - Batch-no. A08
1080232439 / 900001 1700275416

Qualität - Quality B04 Stückzahl - Quantity B08 Länge - Length B10 NPS B15 Schedule B16
ASME BPE-2016 SF1 - 61,00 M - -

Zeichnungsnr. - Drawing no. B06 Schweißverfahren - Welding process A11 Stahlherstellungsverfahren - Steelmaking process C70
- - AOD, EAF
Produkt - Product B01/B09
TUBE 50,80 mm (2,000 ") x 1,65 mm (0,065 ") - WELDED - S31603 (316L)
Kennzeichnung - Marking B06
DOCKWEILER KA7964 50,80 MM X 1,65 MM AVG S31603 ASTM A269M/A270M/S2 WNDE ASME SA249M/S6/S7 HT# 850089 TMH
02/07/17 RATHGIBSON 043820/1C309832/2 ASME BPE SF1
Kundenspezifikation - Purchasers specification Kundenmaterialnr. - Purchasers material no.
- -
Vormaterialhersteller - Manufacturer of pre-material A12 Schmelze - Heat B07 Vormaterialchargennr. - Batch-no. of pre-material A16
RathGibson Janesville LLC 850089 1700275416
Schmelze - Heat B07 Anforderungen - Requirements B03
850089 ASTM A269-15a, ASTM A270M-15, ASME-SA249M-E17, BPE-16
Chemische Zusammensetzung Schmelze [Gew.-%] - Chemical Analysis Heat [WT-%]

Übertragen aus Vormaterialzeugnis - Results acc.to pre-material inspection certificate
Schmelze B07 Werkstoff B02 Herstellercode B14 C C71 Si C72 Mn C73 P C74 S C75 Cr C76 Ni C77 N C88
Heat Steel Grade Manufacturer's code
1 850089 S31603 (316L) - 0,013 0,420 1,470 0,034 0,012 16,60 10,10 0,0500
Ti C79 Mo C80 Al C81 Fe C82 Cu C83 Nb C84 Se C85 Ca C86 Ta C87 W C88 V C89 Cr(äq) - 0,91 x Ni(äq) - Cr(eq) - 0,91 x Ni(eq) C90
1 0,004 2,040 - - 0,400 - - - - - 0,0700 -
Materialkontrollen - Material inspection

Wärmebehandlung - Heat treatment: 850089 1040 °C, bright annealed, Inert Gas Atmosphere, B05
solution annealed
Materialverwechselungsprüfung - P.M.I.: 850089 OK D04
Zerstörende Prüfungen - Results of destructive tests

Zugversuch - Tensile test(s)

Schmelze - Heat B07 Probenform C10 Rp0.2 Rp1.0 C11 Rm C12 Bruchdehnung A C13 Brucheinschnürung Z C14
Type of test piece Elongation Reduction of area
- - - MPa psi MPa psi MPa % %
1 850089 - 354 51300 - - 614 56 -
1
Bescheinigungsnummer - Document no.10001205805 / 00 A03
Kerbschlagbiegeversuch - Impact test - Härte - Hardness C30

Schmelze - Heat B07 Probenform C40 Probenbreite C41 Mittelwert C42 Prüftemperatur C43 HV HR BHN
Type of test piece Width of test piece Mean value Test temperature
- - -
1 850089 - - - - - 84 B -
Schmelze - Heat B07 Aufweitversuch C50 Bördelversuch C51 Ringzugversuch C52 Ringfaltversuch C53 Biegeversuch C58
Flaring test Flange test Ring tensile test Flattening test Bend test
- - - - - - -
1 850089 OK OK - OK -
Schmelze - Heat B07 Ringaufdornversuch C54 Wurzelseitiger Ringfaltversuch C55 Schweißnahtbiegeversuch C56
Ring expanding test Reverse flattening test Reverse bend test
- - - - -
1 850089 - OK OK
Schmelze - Heat B07 IK-Test C57 Körngröße C59

Intergranular corrosion test Grain size
- - ASTM A262 Pract. E -

1 850089 OK -
Zerstörungsfreie Prüfungen - Results of non-destructive tests

Dichtheitsprüfung - Leak test

Schmelze - Heat B07 Innendruckversuch mit Wasser D05 Druckprüfung D13 Wirbelstromprüfung D06
Hydrostatic test Pneumatic test Eddy current test
- - - - -
1 850089 - - OK
Schmelze - Heat B07 Ferritgehalt D02 Ultraschallprüfung D07 Durchstrahlprüfung D08 Ultraschallprüfung D09
Ferrite test Ultrasonic test Radiographic test Ultrasonic test
- - - - - -
1 850089 - - - -
Endkontrolle - Final Inspection
Kontrolle Materialkennzeichnung: OK D01 Maßkontrolle: OK D01

Control of material marking Dimensional control
Oberflächenkontrolle: OK außen - outside D03 Materialverwechslung: - D04
Surface inspection innen - inside P.M.I.
Rauheit innen/Naht D11 Rauheit außen D12 Härteprüfung HV10 C30 Durchstrahlungsprüfung D08 Eindringprüfung (ZfP) D14
Roughness inside/ weld Roughness outside Hardness Radiographic test Penetrant testing (NDT)
EN ISO 4287, ASME B46.1 EN ISO 4287, ASME B46.1 EN ISO 6507-1 EN 1435 EN ISO 3452-1
Ra(avg) Ra(max) Ra(avg) Ra(max) - - -
0,25 µm 0,31 µm 0,67 µm 0,70 µm - - -
Ferritgehalt ges. Teil D02 Ferritgehalt LN & GW D02 Dichtheitsprüfung D05 Druckprüfung D13 Magn. Permeabilität D15
Ferrite test Ferrite test (weld seam) Leak test Pressure test Magnetic permeability
max avg max avg - - -

- - - - - - -
Konformitätserklärung / Certificate of Conformity

Hiermit wird bestätigt, dass das gelieferte Produkt mit den Anforderungen der Spezifikation und den Vereinbarungen der
Bestellung übereinstimmt.
We herewith confirm that the product supplied is in conformity with the demands of the specification and agreements in the order.
2
Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 June 14, 2018
Abnahmebeauftragter - Inspection representative Datum - Date Z02
Certified Individual (CI) acc. to ASME BPE, Part CR
Dieses Dokument wurde maschinell erstellt und ist ohne Unterschrift gültig.
This document was created electronically and is valid without signature.
Alle Angaben zu Normen und Spezifikationen ohne Verweis auf eine spezifische Revision oder ein Datum beziehen sich auf die
jeweils letzte Ausgabe.
All standards and specifications listed without a specific edition or date refer to the most current edition.
Angaben zu Fertigungs- und Schweißverfahren:

Zertifiziert nach DIN EN ISO 3834-2, DIN EN ISO 15614-1, ASME BPVC Section IX, Modul A2 der Richtlinie 2014/68/EU sowie
AD 2000-MerkblattHP0
Statement on manufacturing and welding procedures:
Certified as per DIN EN ISO 3834-2, DIN EN ISO 15614-1, ASME BPVC Section IX, Module A2 of Directive 2014/68/EU and AD 2000
Merkblatt HP0
3
Positions 6 - 14 - 24
D Drawing 23777
▹▹▷
TOPLINE STAINLESS

HARDNESS
HB
1 316L 0.017 0.58 1.74 0.021 0.025 10.10 16.53 2.04 218 525 47
2 316L 0.017 0.58 1.74 0.021 0.025 10.10 16.53 2.04 218 525 47
3 316L 0.019 0.57 1.76 0.022 0.023 10.09 16.51 2.03 216 522 48
4 316L 0.019 0.57 1.76 0.022 0.023 10.09 16.51 2.03 216 522 48
5 316L 0.021 0.62 1.56 0.031 0.018 10.05 16.55 2.09 214 520 42
STAMP:
Position 8
Drawing 23777
▹▹▷
Position 9
Drawing 23777
▹▹▷
Position 10
Drawing 23777
▹▹▷
TOPLINE STAINLESS

HARDNESS
HB
1 Short Welding Ferrule 14WMP 316L 1/2”-3/4” 750 85074M ID Ra≦0.5µ GOOD GOOD
2 Long Welding Ferrule 14AMP 316L 3/4” 1250 85074M ID Ra≦0.5µ GOOD GOOD
3 Long Welding Ferrule 14AMP 316L 1” 1250 85050M ID Ra≦0.5µ GOOD GOOD
4 Long Welding Ferrule 14AMP 316L 4” 50 85120M ID Ra≦0.5µ GOOD GOOD
5 End Cap 16AMP 316L 1"-1.5" 100 85038M ID Ra≦0.5µ GOOD GOOD
1 316L 0.014 0.69 1.62 0.027 0.021 10.07 16.12 2.07 227 535 44
2 316L 0.014 0.69 1.62 0.027 0.021 10.07 16.12 2.07 227 535 44
3 316L 0.021 0.52 1.74 0.021 0.017 10.06 16.07 2.09 217 527 47
4 316L 0.018 0.71 1.51 0.033 0.012 10.12 16.13 2.05 220 520 41
5 316L 0.013 0.64 1.52 0.025 0.023 10.10 16.05 2.07 223 531 46
STAMP:
Position 12
Drawing 23777
▹▹▷
A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1237 1030121532 June 14, 2018

1080232439 / 900003 1700263847

ASME BPE-2016 SF1 - 292,80 M - -

- - AOD, EAF
DOCKWEILER KA3925 38,10 MM X 1,65 MM AVG S31603 ASTM A269M/A270M/S2 WNDE ASME SA249M/S6/S7 HT# 852220 LMM
- -
852220 ASTM A269M-15a, ASTM A270M-15s2, ASME SA-249M-E15, ASME BPE

1 852220 S31603 (316L) - 0,016 0,380 1,420 0,025 0,011 16,60 10,20 0,0500
1 0,002 2,050 - - 0,740 - - - - - 0,1000 -

solution annealed


1 852220 - 347 50300 - - 600 59 -
1

- - -
1 852220 - - - - - 82 B -
- - - - - - -
1 852220 OK OK - OK -
- - - - -
1 852220 - OK OK


1 852220 OK -


- - - - -
1 852220 - - OK
- - - - - -
1 852220 - - - -

0,30 µm 0,38 µm 0,28 µm 0,30 µm - - -

- - - - - - -

2

Merkblatt HP0
3
Position 13
Drawing 23777
▹▹▷
Ilta Inox S.p.A.

Strada Statale 45 bis
26010 Robecco d'Oglio (CR) - Italia
Tel + 39 0372 9801

Fax + 39 0372 921538
e-mail:sales@ilta.arvedi.it
quality@ilta.arvedi.it
www.arvedi.it
TEST CERTIFICATE ACCORDING TO EN 10204(2005) 3.1 N°0000529020

ABNAHMEPRÜFZEUGNIS - CERTIFICAT D'ESSAIS - CERTIFICATO DI COLLAUDO Pag. 1di 1
Longitudinally laser welded tubes/Laser längsnahtgeschweisste rohre/Tubes soudes longitudinalement laser/Tubi saldati longitudinalmente laser
Customer: PROFILINOX S.P.A Q.re Ind.le S.P.I.P.
Besteller/Client/Cliente Via Nobel, 3/a 43100 PARMA PR
Customer Order N°: 800284 - Mill's Ilta Inox N°: 0411070109 - 006010 # 0421075528 - 000030
Bestellung/Commande Client/Ordine Cliente WerksN°/N° référence Interne/Conferma ordine
Specifications: EN 10296-2: 2005 / V=0,7 Tolerances: EN 10296-2 : OK
Anforderungen/Specifications/Specifiche Toleranzen/Tolérances/Tolleranze
Manufacturer's mark: Herstellerzeichen/Marque du fabricant/ Marchio del produttore Marking: EN 10296-2
Inspector's Stamp: A.C. Stempel des Sachverständigen/Poinçon de l'inspecteur/Punzone dell'ispettore Kenzeichnung/Marquage/Marcatura
Item DIMENSIONS PIECES N° METERS WEIGHT(kg) GRADE STANDARD CODE EXECUTION

Pos. Abmessungen Stückzahl Meter Gewicht/Poids Werkstoff/Nuance Normbezeichnung Ausführung
N° Dimensions/Dimensioni Piéces/Pezzi Métres/Metri Peso Materiale Designation/Designazione Execution/Esecuzione
6010 457.20 X 4.00 X 6000 4 24.00 1,099.000 TP.316L X2 CrNiMo 17-12-2 W1
1.4404
Z3 CND 17-12-02
UNS S31603
Chemical analysis acc.to: ASTM A240/ EN 10088-2/EN 10028-7 Last Edition Schmelzanalyse/Chimique analyse/Analisi chimica
Steel making process :E/AOD Erschmelzungsart/Procéde d'elaboration/Procedimento di elaborazione acciaio
Item Manufacturer HEAT N° %C % Si %S %P % Mn % Cr % Ni % Mo % Ti % Co % Cu %N

N° Hersteller/Fabricant/Produttore Schmelze/Couléé/Colata
6010 . . . . . . . . . . . . . . . . . . 515095 0.024 0.390 0.0010 0.031 1.270 16.510 10.000 2.030 0.100 0.048
Mechanical test acc. to tab.: 4 EN 10296-2 Mechanische Prüfungen/Essais mécaniques/Caratteristiche meccaniche
Item HEAT N° HOMOLOG. TEST SPECIMEN SIZE YIELD STRENGTH TENSILE ELONGAT. HARDNESS
Pos. Schmelze Zulassung Probe Abmessung Probestab Streck-Dehngrenze STRENGTH Bruchdehnung Haerte
N° Coulée Omologation Eprouvette Dime. Eprouvette Limite d'élasticitè Zugfestigkeit Allongament Dureté
Colata Omologazione Provino Dimensione provetta Limite di snervamento Résistance à traction Allungamento Durezza
n° mm. 0,2% N/mm² 1% Limite di rottura A5% HB
N/mm²
REQUIREMENT Anforderungen/Exigences/Requisiti >=190 >=225 490 - 800 >= 40.0
6010 515095 01 L 20 X 4.00 355 394 632 53.0
Test Results Ergebnisse der Prufungen/Résultat des essais/Risultati delle prove
Heat treatment: Wärmebehandlung/Traitement termique/Trattamento termico
Tecnological test: ====== / ====== / EN ISO 8492: OK - Prova piega sa / ====== Technologische Prüfung/Examen technologique/Prove tecnologiche
Residual Corrosion Test acc.to : =============== Korrosionsfòrdernde Rùckstàden/Essai residues corrosif/Prova residui corrosivi
Intergranular Corrosion Test acc.to: IK Beständigkeit/Essai corr.intergr./Prova di corrosione intergranulare
Non Destructive Test acc. to: EN ISO 10893-2/E1H: OK Zerstörungsfreie Prüfung/Contrôle non destructif/Controllo non distruttivo
Leak Test/Hydrostatic test to: EN ISO 10893-1: OK Dichtheitsprüfung/Essai d'étanchèité/Prova di tenuta
Uncorrect Material Test: al 100%: Favorevole Verwechlungsprüfung/Essai P.M.I./Prova antimiscuglio
Visual and gauging control: Favorevole Besichtigung und Ausmessung/Contrôle visuel et dimensionel/Controllo visivo e dimensionale
Notes:
Materiale conforme al tipo: 1.4401/316
We certify that the delivered products comply with the specification of the order / Wir bestaetigen, dass die gelieferte Ware den Bestellvorschriften entspricht / Nous
attestons que les produits livres sont conformes aux réferences de la commande / Noi attestiamo che il materiale spedito è conforme ai requisiti dell'ordine
Ing. Alessandro Canevari
Robecco d'Oglio, 14/02/2018 Mill's Inspector / Der Werksachverständige
D Inspecteur de l'usine / Firma Ispettore

Position 15
Drawing 23777
▹▹▷
A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1237 1030121532 June 14, 2018

1080232439 / 900002 1800323884

ASME BPE-2016 SF1 - 24,00 M - -

- - AOD, EAF, VOD

TUBE 19,05 mm (0,750 ") x 1,65 mm (0,065 ") - SEAMLESS - S31603 (316L)
DOCKWEILER-LA4021-19,05 x 1,65mm-3/4" x 0,065"-UNS S31603-ASTMA269/A270S NDE-ASME SA213 avg.Wall-Heat J183-Q11-TPS

GERMANY ASME BPE SF1
- -
TPS Technitube Röhrenwerk GmbH J183 1800318785
J183 ASTM A269-15a, ASTM A270-17-S2, ASME SA213 2017 avg. wall

1 J183 S31603 (316L) - 0,014 0,300 1,140 0,033 0,008 16,88 12,28 0,0300
1 - 2,070 - - - - - - - - - -

Wärmebehandlung - Heat treatment: J183 1040 °C, quenched in gas, solution annealed B05
Materialverwechselungsprüfung - P.M.I.: J183 OK D04


1 J183 - 244 - - - 571 60 -
1

- - -
1 J183 - - - - 145 HV - -
- - - - - - -
1 J183 OK - - OK -
- - - - -
1 J183 - - -

- - ASTM A262 Pract. E, DIN EN ISO -

3651-2A
1 J183 OK 6,5


- - - - ASTM E 426, ASTM A 1016

1 J183 - - OK
- - - - - -
1 J183 - - - -

0,21 µm 0,42 µm 0,19 µm 0,21 µm - - -

- - - - - - -

2

Merkblatt HP0
3
Position 16
Drawing 23777
▹▹▷
A04
Certified as per
ASME BPE Certificate of Authorization No.
BRAM-COR S.p.A. A06
Quartiere S.P.I.P. ISO 9001:2008 Cert No. 07 100 980183,
Directive 2014/68/EU Annex I Section 3.1 and 4.3
Via G. Mercalli 12/A Cert. No. 50164/4,
and AD 2000-Merkblatt W0 Cert. No. 50164/2
43122 PARMA www.dockweiler.com
ITALY
265 1030101828 February 6, 2017

1080187555 / 900005 1500194436

ASME BPE SF1 - 544,00 M - -

- - AOD, EAF
DOCKWEILER GA7737 76,2 MM x 1,65 MM AVG S31603 ASTM A269/A270M/S2 W NDEASME SA249M/S6/S7 HT # V8F6 RWW
RATHGIBSON C290357/4 IDMP/ODMP20/30µ-inRa ASME BPE SF1
- -
RathGibson Janesville LLC V8F6 1500175976
V8F6 ASTM A269-14e1, ASTM A270M-15, ASME SA249-E15, ASME BPE-14

1 V8F6 S31603 (316L) - 0,018 0,290 1,550 0,031 0,014 16,70 10,00 0,0500
1 - 2,010 - - 0,450 - - - - - - -

Wärmebehandlung - Heat treatment: V8F6 1040 °C, bright annealed, Inert Gas Atmosphere, B05
solution annealed
Materialverwechselungsprüfung - P.M.I.: V8F6 OK D04


1 V8F6 - 326 47265 - - 616 59 -
1

- - -
1 V8F6 - - - - - 81 B -
- - - - - - -
1 V8F6 OK OK - OK -
- - - - -
1 V8F6 - OK OK


1 V8F6 OK -


- - - - -
1 V8F6 - - OK
- - - - - -
1 V8F6 - - - -

0,20 µm 0,27 µm 0,24 µm 0,28 µm - - -

- - - - - - -

2
Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 February 6, 2017


Merkblatt HP0
3
Position 17
Drawing 23777
▹▹▷
Position 22
Drawing 23777
▹▹▷
A04
Zertifiziert nach ISO 9001, Richtlinie 97/23/EG Anhang I
BRAM-COR S.p.A. A06 Kap. 3.1 und 4.3 sowie AD 2000 Merkblatt W0
Quartiere S.P.I.P. Certified as per ISO 9001, directive 97/23/EC Annex I
Section 3.1 and 4.3, and AD 2000 Merkblatt W0
Via G. Mercalli 12/A
I-43122 PARMA www.dockweiler.com
2242 1030071025 December 3, 2014

1080117975 / 900008 1400125162

ASME BPE SF1 100,00 St/Pcs

AOD, EAF
ELBOW 90° DT-4.1.1-1 (DT-7) - 76,20 mm (3,000 ") x 1,65 mm (0,065 ") - WELDED - S31603 (316L)
DOCKWEILER FA3084 76.20x1.65mm S31603 HT:K7K3 ASME BPE SF1

RathGibson Janesville LLC K7K3 1400125162
K7K3 DIN EN 10217-7 TC1, ASTM A269-13, ASTM A270-10, ASME SA 249-E13

1 K7K3 S31603 (316L) 0,021 0,250 1,370 0,035 0,013 16,50 10,10 0,0300
1 2,090 0,440

Wärmebehandlung - Heat treatment: K7K3 1040 °C, Inert Gas Atmosphere, solution annealed B05
Materialverwechselungsprüfung - P.M.I.: K7K3 OK D04


MPa psi MPa psi MPa % %
1 K7K3 322 46695 611 64
Kerbschlagbiegeversuch - Impact test Härte - Hardness C30

1 K7K3 82 B
1
1 K7K3 OK OK OK
1 K7K3 OK OK

1 K7K3


1 K7K3 OK
1 K7K3

Oberflächenkontrolle: OK außen - outside D03 Materialverwechslung: sample testing OK D04
EN ISO 4287, ASME B46.1 EN ISO 4287, ASME B46.1 EN ISO 6507-1 EN 1435 EN 571-1
Ra(avg) Ra(max) Ra(avg) Ra(max)
0,18 µm 0,41 µm 0,48 µm
max avg max avg

Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 December 3, 2014


Zertifiziert nach DIN EN ISO 3834-2, DIN EN ISO 15614-1, ASME BPVC Section IX, Modul A1 der Richtlinie 97/23/EG sowie
2
AD 2000-Merkblatt HP0
Certified as per DIN EN ISO 3834-2, DIN EN ISO 15614-1, ASME BPVC Section IX, Module A1 of Directive 97/23/EC and AD 2000 Merkblatt
HP0
3
Position 23
Drawing 23777
▹▹▷
A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1357 1030122115 June 28, 2018

1080233811 / 900008 1700278025

ASME BPE-2016 SF1 2,00 St/Pcs - - -

- - AOD, EAF
T-PIECE DT-4.1.2-6 (DT-10) 76,20 mm 3,000 " x 1,65 mm 0,065 " / 38,10 mm 1,500 " x 1,65 mm 0,065 " - WELDED - S31603 (316L)
DOCKWEILER KA9061 76.20x1.65 mm/38.10x1.65 mm S31603 HT:850089/850384 ASME BPE SF1

- -

850089 ASTM A269-15a, ASTM A270-15-S2, ASME SA249-E15


1 850089 S31603 (316L) - 0,013 0,420 1,470 0,034 0,012 16,60 10,10 0,0500
2 850384 S31603 (316L) - 0,013 0,410 1,410 0,028 0,015 16,60 10,10 0,0500
1 0,004 2,040 - - 0,400 - - - - - 0,0700 -

2 0,004 2,060 - - 0,380 - - - - - 0,0800 -

solution annealed
850384 1040 °C, bright annealed, Inert Gas Atmosphere,
solution annealed
850384 OK
1


1 850089 - 318 46138 - - 606 58 -
2 850384 - 368 53300 - - 614 58 -

- - -
1 850089 - - - - - 83 B -
2 850384 - - - - - 85 B -
- - - - - - -
1 850089 OK OK - OK -
2 850384 OK OK - OK -
- - - - -
1 850089 - OK OK
2 850384 - OK OK


1 850089 OK -
2 850384 - -


- - - - -
1 850089 - - OK
2 850384 - - OK
- - - - - -
1 850089 - - - -
2 850384 - - - -

2
- 0,33 µm 0,69 µm 0,74 µm - - -

- - - - - - -


Merkblatt HP0
3
COLUMN VESSEL
SECTION 2.3.
Insulation material
▹▹▷
FIBRANgeo R-560-ΚΟ
Stonewool wired mat with galvanised mesh and stitching wire
Product Description
FIBRANgeo R-560-KO Stonewool wired mat with galvanised mesh and stitching wire is
industrially produced from molten rock spun into fibres.
It is classified as thermal insulation mineral wool product for use in building equipment and industrial
installations, according to the European Standard EN 14303 (MW - Mineral Wool insulation products).
Stonewool is a natural inorganic fibrous material, widely recognised for its thermal and sound
insulating properties, as well as its excellent performance towards fire protection.
FIBRANgeo R-560-KO is produced from mineral rock, initially fused in an electric furnace at 1520°C
and then spun into fibres. The loose stonewool fibres, with the addition of adhesive resin, oil and
special silicon compounds that provide hydrophobicity, become cohesive, elastic, non-hygroscopic
and water-repellent. The product is then stitched on galvanized wired mesh with galvanized wire,
formed into rolls and finally shrink-wrapped in PE film in packages.
The non-use of fossil fuels (e.g. coke) as a main production fuel minimises polluting gas emissions in
the environment.
Advantages
• Excellent thermal insulation

• Excellent sound absorption and sound reduction
SHEET
• Non-combustible material with excellent fire resistance

DATASHEET
• Insulating properties remain unaffected at high temperatures

• Open hive structure material with very low water vapour diffusion resistance, similar to the
resistance of air
TECHNICALDATA
• Water repellent and non-hygroscopic

• Natural, inorganic, odourless, chemically inert, suitable for use over stainless steel
• Lightweight, easy to handle, cut and install
TECHNICAL
• Resistant to vibrations
• Does not allow the development of micro-organisms, insects or rodents
• Recyclable
• Friendly to the environment and to the end user
1/5
Applications
FIBRANgeo R-560-KO is suitable for use in building equipment and industrial installations.
Thermal-acoustic-fire insulation of :
• Pipe work
• Ductwork
• Smoke exhaust ducts and chimneys
• Machines
• Silencer equipment
• Boiler, vessels and tank walls
• Heat exchangers
• Furnaces
0
• Max. Service Temperature 650 C
Packaging
Thickness Width Length Quantity/ Roll

[mm] [mm] [mm] [m2/ Roll]
30 1000 8.000 8,00
40 1000 5.000 5,00
50 1000 5.000 5,00
60 1000 5.000 5,00
80 1000 3.000 3,00
100 1000 2.500 2,50
120 1000 2.500 2,50
Other dimensions are available upon request.

TECHNICAL DATA SHEET
Facings
FIBRANgeo R-560-KO is also available with the following variants

to meet particular application requirements:
• FIBRANgeo R-560-KO SS Stainless steel mesh and stainless steel stitching wire
• FIBRANgeo R-560-KO GS Galvanized steel mesh and stainless steel stitching wire
2/5
Designation code:
MW(Μineral Wool)- EN 14303- T2- ST(+/250) 650 - WS1 - MU1 - AW1 - AFr35 - CL10 - F10 - PH10.5
Symbol
Technical Characteristics
EN-13162 Unit Value EN standard
0 EN 12667
Declared thermal conductivity at 10 C λD W/(mK) 0,035
EN 13787
ο
Maximum Service Temperature ST(+/250) C 650 EN 14706
Nominal thickness dN mm 30 - 120 EN 823
Α1
Fire classification - Class ΕΝ 13501-1
(Non-combustible)
ο
Melting temperature - C >1000 DIN 4102-17
Specific heat capacity c kJ/kg*K 0,84 -
Τ2
Thickness tolerance Τ Class EN 14303
(-5%, +15 %)
2
Short Term Water Absorption for 24 h WS kg/m <1 EN 1609
Water vapour diffusion resistance factor µ MU - 1 EN 12086
< 10
AS-quality for use
Water leachable chloride, fluoride and PH-value CL, F, PH mg/kg over stainless steel. EN 13468
PH-value neutral to
slightly alkaline
2
Air flow resistivity, r AFr kPa s/m 35 EN 29053
Weighted Sound Absorption Coefficient αw EN ΙSO 11654

AW - 1 ( Class Α)
(Thickness 50 mm) EN ISO 354
3
Density, ρ - kg/m 65 EN 1602
Declared Thermal Conductivity λD
Mean ο
θΜ C 50 100 150 200 250 300 350 400 500 600 650 EN14303
Temperature
Declared EN 12667
Thermal λΝ,P W/mK 0,039 0,046 0,054 0,063 0,075 0,087 0,101 0,116 0,151 0,193 0,221
EN 13787
Conductivity
3/5
Certifications
All FIBRANgeo stonewool insulation products meet the QUALITY and SAFETY requirements of the
European Standards.
The quality of FIBRANgeo products is assured in accordance with EN 14303, EN 14162, EN ISO
13787 and EN 13172 standards.
These standards establish the type and frequency of measurements executed both by recognised
and independent institutions, as well as by FIBRAN laboratories.
CE Certification
All FIBRANgeo stonewool insulation products have been certified according to the European Directive
89/106/EEC since 2004, and today conform to the European Regulation 305/2011 as this replaced the
above mentioned Directive.
In compliance with the above Construction Products Regulation, all types of FIBRANgeo T stonewool
products hold the CE marking and are in conformity with the European Norms EN 14303 and EN 13162,
which refer to mineral wool insulation products for industrial installations, building equipment and building
applications.
In accordance with the aforementioned Standards, every insulation product acquires a designation code
which declares its technical characteristics.
Furthermore, FIRAN S.A. has issued the Declaration of Performance (DoP) for all product types, available
on the company website: http://www.fibran.gr/dop/.
The Initial Type Test (ITT) as well as the Factory Production Control (FPC) have been performed by the
following European Notified bodies for CE marking:
Notified Bodies: Forschungsinstitut für Wärmeschutz e.V. München (FIW): Identification Number 0751
Materialprüfanstalt für das Bauwesen Hannover (MPA BAU): Identification Number 0764
EUCEB Certification
All FIBRANgeo stonewool insulation products also carry the certification mark EUCEB (European
Certification Board for Mineral Wool Products). EUCEB is an independent organization whose procedures
ensure compliance of mineral wool insulation products with the Directive’s 97/69/EC, Note Q, regarding
their fibres biosolubility and their non-classification as ‘carcinogenic’ materials.

Moreover, according to EC Regulation 790/2009 (August 10, 2009) they are not classified as products
that cause skin irritation.
ISO 9001:2008 Certification
The quality management system of FIBRAN S.A. complies with EN ISO 9001:2008 for the design and
manufacture of Mineral Wool (MW), as certified by the independent body TÜV NORD CERT, with initial
Certificate Registration No. 04 100 960680.
4/5
Handling and Storage
FIBRANgeo products should be stored indoors. If stored outdoors, they must be

protected from impregnation. Pallets shrink-wrapped weather tightly in PE film may be
stored outside. Separate packages should be placed on a flat pallet, not in direct
contact with the ground.
If part of the product gets wet, it must be dried before installation. Stonewool dries
quickly and its insulating properties remain unchanged after drying.
FIBRANgeo products are chemically inert and do not allow the growth of micro-
organisms, insects or rodents.
Handling, loading and unloading of the products should be carried out with care, to
avoid damage both the packaging and the boards’ edges.
Application and Personal Protection
For the selection and application of FIBRANgeo products all design requirements
should be taken into consideration.
FIBRANgeo products should be protected from impregnation, prior to and during
application.
The packaging film should be removed with care just before installation.
Working areas should be kept clean. Unnecessary or extensive contact of the skin and
eyes with products off-cuts, fibres and dust should be avoided, and protective wear
should be used (gloves, goggles, hats).
Sufficient ventilation of the working areas should be ensured, whilst power cutting tools
should always be provided with a mechanical system of dust intake.
Stonewool products are not considered hazardous waste. Waste disposal should be
carried out according to State and Local regulations.
DATE: 01/01/2014
Issue 5
THESSALONIKI
FIBRAN S.A.
th
6 km Thessaloniki-Oreokastro Rd.
P.O. Box 40306, A.C. 560 10
Thessaloniki, Greece info@fibran.gr
Tel. +30 2310 682 425 , 692 700 www.fibran.gr
Fax. +30 2310 683 131
FIBRAN reserves the right to alter or amend product specifications without notice. The information included in this
publication is correct to the best of our knowledge at the time of printing. Whilst FIBRAN will endeavour to ensure
publications are up to date, it is the user’s responsibility to check with the company the validity of the information
prior to materials’ use.
5/5
COLUMN VESSEL

SECTION 3
WELDING DOCUMENTATION


COLUMN VESSEL
SECTION 3.1.
Welding documentation
▹▹▷
3.1.1. WPS: Welding procedure specification (for manual welding)
3.1.2. WPQR: Welding procedure qualification record (for manual welding)
3.1.3. WPQ: Welding performance qualification (for manual welding)
3.1.4. WPS: Welding procedure specification (for orbital welding)
3.1.5. WPQR: Welding procedure qualification record (for orbital welding)
3.1.6. WPQ: Welding performance qualification (for orbital welding)
3.1.7. Filler material
COLUMN VESSEL

SECTION 3.1.1.
WPS: Welding procedure specification (for manual welding)
▹▹▷

COLUMN VESSEL

SECTION 3.1.2.
WPQR: Welding procedure qualification record (for manual welding)
▹▹▷

COLUMN VESSEL

SECTION 3.1.3.
WPQ: Welding performance qualification (for manual welding)
▹▹▷

COLUMN VESSEL

SECTION 3.1.4.
WPS: Welding procedure specification (for orbital welding)
▹▹▷

COLUMN VESSEL

SECTION 3.1.5.
WPQR: Welding procedure qualification record (for orbital welding)
▹▹▷

COLUMN VESSEL

SECTION 3.1.6.
WPQ: Welding performance qualification (for orbital welding)
▹▹▷

COLUMN VESSEL
SECTION 3.1.7.
Filler material
▹▹▷
Via L. Borsari, 27/A
43126 PARMA / ITALY
TEL. 0521/993377 - FAX 0521/988690
E-mail: info@oxysald.com - web: www.oxysald.com
Partita IVA IT 00705540342
CERTIFICATO DI CONFORMITA' / CERTIFICATE OF CONFORMANCE

Pagina 1 di 1
Certificato N° / Certificate N° 207/2016 Data / Date Diametri / Diameters 2,4 mm
03/05/2016 1,2 mm 3,2 mm
Descrizione / Description 1,6 mm
2,0 mm
Prodotto / Item Colata N° / Batch N°
Bacchette SIDER 316L NU3552
Materiale conforme alle norme AWS A5.9 EN 14343-A
Material's classification in accordance with ER316L 19 12 3 L
Analisi chimica / Chemical analysis (%) - EN 10204 - 3.1
Elemento Valori di riferimento AWS A5.9 Valori di riferimento EN 14343-A 19

Valore / Value
Element Reference values ER316L Reference values 12 3 L
Cr Range/Range 18,0000 20,0000 Range/Range 18,0000 20,0000 18,5700

Mn Range/Range 1,0000 2,5000 Range/Range 1,0000 2,5000 1,6000
Mo Range/Range 2,0000 3,0000 Range/Range 2,5000 3,0000 2,6900
Ni Range/Range 11,0000 14,0000 Range/Range 11,0000 14,0000 11,5500
Si Range/Range 0,3000 0,6500 Minore/Less than 0,6500 0,3700
C Minore/Less than 0,0300 Minore/Less than 0,0300 0,0240
Cu Minore/Less than 0,7500 Minore/Less than 0,3000 0,2200
P Minore/Less than 0,0300 Minore/Less than 0,0300 0,0270
S Minore/Less than 0,0300 Minore/Less than 0,0200 0,0150
Caratteristiche meccaniche / Mechanical properties - EN10204 - 2.2
Resistenza alla trazione

510,0000(N/mm) 2 0,0000 (N/mm) 2
Tensile Strenght Rm
Limite di snervamento
320,0000(N/mm) 2 0,0000 (N/mm) 2
Yield Strenght
Allungamento
30,0000(%) 0,0000 (%)
Elongation A
Analisi chimica del flusso / Chemical analysis of the flux (%) - EN 10204 - 3.1
MnO TiO2 CaO CaF 2 Fe 2 O3 SiO2 Al 2 O3 MgO P2O5
I dati riportati sono ricavati dai documenti del fornitore in nostro possesso
The data are obtained from the manufacturer's documents in our possesion
Certificato generato da un sistema informatico, valido senza firma

The certificate was generated by a computer system, and is valid without signature
OXY-SALD DI CORRADO VIGNOLA
Mod. 029 Rev. 3 Articolo commercializzato

COLUMN VESSEL
SECTION 3.1.8.
Gas ARGON certificate
▹▹▷
COLUMN VESSEL

SECTION 4
PASSIVATION REPORT
AND TESTING CERTIFICATES

4.2. Non‐destructive test certificates

COLUMN VESSEL

SECTION 4.1.
Pickling and passivation report
▹▹▷

COLUMN VESSEL

SECTION 4.2.
Non‐destructive test certificates
▹▹▷

CERTIFICATO DI ESAME V. & D.
V. & D. TEST CERTIFICATE
Commessa n°: Certificato n°:

11880 M_3108-1_VVD_0
Job number: Certificate number:
Matricola n°: Apparecchio: Colonna di Evaporazione

Serial number:
3108-1 Vessel: Column Vessel
Documento di riferimento: disegno numero

Reference document: drawing number
23777
Procedura di prova visiva:
PD_SOP_001_0
Visual test procedure:
Procedura di prova dimen.:
PD_SOP_002_0 - PD_SOP_012_0
Dimensional test procedure:
Si certifica che l'apparecchio in oggetto è stato sottoposto alle prove sotto menzionate alla presenza di:
We hereby certify that the following mentioned tests have been carried out on the vessel in object at the presence of:
Ispettore interno: ditta

Internal inspector:
Telolli I. firm:
BRAM-COR S.p.A.
Ispettore esterno: ditta

External inspector:
/ firm:
/
Controllo visivo giunti saldati Eseguito Giudizio: A = Accettabile / Acceptable

Welded joint visual test Executed Evaluation: R = Riparare / Repair
Difetti riscontrati (EN ISO 6520)/ Noticed defeacts (EN ISO 6520)
n° / n° Posizione / Position n° / n° Posizione / Position
Dimensioni controllate / Checked dimensions

Controllo dimensionale Eseguito Diametri interni / Internal diameters
Dimensional test Executed Diametri esterni / External diameters
Altezza (lunghezza) / Height (length)
Giudizio: A = Accettabile / Acceptable Bocchelli / Connections
Evaluation: R = Riparare / Repair Supporti / Fittings
Altre quote principali / Other main dimensions
Spessori controllati / Checked thicknesses

Controllo spessimetrico Eseguito Fasciami / Shells
Thickness test Executed Fondi / Bottoms
Flange / Flanges
Altri elementi principali / Other main parts
Firma ispettore interno: Data:

Internal inspector signature:
27/07/2018
Date:
Firma ispettore esterno: Data:

External inspector signature: Date:
Module: PD_MOD_VVD_000_0 Page 1 of 1

CERTIFICATO CONTROLLO LIQUIDI PENETRANTI
PENETRANT LIQUID TEST CERTIFICATE

11880 M_3108-1_VLP_0

3108-1
Serial number: Vessel: Column Vessel

23777
Si certifica che l'apparecchio in oggetto è stato sottoposto al tipo di prova sopra menzionato alla presenza di:
We hereby certify that the above mentioned test has been carried out on the vessel in object at the presence of:
Ispettore interno: ditta:

Internal inspector:
Telolli I. BRAM-COR S.p.A.
firm:
Ispettore esterno: ditta:

/ /
External inspector: firm:
Stato delle superfici: Come saldato Molato / Lucidato

Surfaces conditions: As welded Grinded / Polished
Lavorato Altro
Machined Other
Designazione prodotti (EN 3452-2): Temperatura:

EN 571-1-IICd-1 20 °C
Products designation (EN 3452-2): Temperature:
Procedura di prova n°: Giunti ispezionati (secondo ISPESL Raccolta S):

PD_SOP_004_0
Test procedure n°: Tested joints (according to ISPESL S Regulation):
Pulizia superficiale: G.M. ICRI - G153

Surface cleaning: G.M. ICRI - G153 Longitudinali / Longitudinal 35%
Applicazione penetrante: G.M. ICRI - G151 Circolari / Circular 15%
Penetrant application: G.M. ICRI - G151 Incroci / Crosses 0%
Tempo di penetrazione: 5 min Bocchelli / Connections 40%
Penetration time: 5 min Boccaporto / Man-hole 0%
Rimozione eccessi: G.M. ICRI - G153 Sostegni / Fittings 10%
Excess removal: G.M. ICRI - G153 0%
Applicazione rivelatore: G.M. ICRI - G164 0%
Developer application: G.M. ICRI - G164 0%
Tempo di sviluppo: 10 min 0%
Developing time: 10 min
Tempo massimo di lettura: 10 min
Maximum checking time: 10 min Giudizio: A = Accettabile / Acceptable
Pulizia superficiale: G.M. ICRI - G153 Evaluation: R = Riparare / Repair
Surface cleaning: G.M. ICRI - G153

27/07/2018
Internal inspector signature: Date:

Module: PD_MOD_VLP_003_0 Page 1 of 1

CERTIFICATO DI PROVA DI RUGOSITA'
ROUGHNESS TEST CERTIFICATE

11880 M_3108-1_VRS_0

3108-1
Documento di riferimento / Reference document: Report:

Instrument printed report:
disegno numero:
drawing number:
23777 Test N° 1:
Si certifica che l'apparecchio in oggetto è stato

sottoposto al tipo di prova sopra menzionato alla 4p
presenza di:
We hereby certify that the above mentioned test has been carried out
on the vessel in object at the presence of:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
1 (low. int.)
Ra max. accettabile:
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Test procedure: N.A.
Esito della prova:
Test result:
Giudizio: A = Accettabile / Acceptable

Evaluation: R = Riparare / Repair Note:
Modello strumento: Matricola:

Equipment model:
TR-200 Serial number:
1206172
Firma ispettore: Data:

Inspector signature: Date:
04/08/2018

Module: PD_MOD_VRS_002_0 Page 1 of 6


11880 M_3108-1_VRS_0

3108-1

disegno numero:
drawing number:
23777 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
1 (up. int.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018



11880 M_3108-1_VRS_0

3108-1

disegno numero:
drawing number:
23777 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
3 (int.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018



11880 M_3108-1_VRS_0

3108-1

disegno numero:
drawing number:
23777 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
8 (ext.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018



11880 M_3108-1_VRS_0

3108-1

disegno numero:
drawing number:
23777 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
11 (low. int.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018



11880 M_3108-1_VRS_0

3108-1

disegno numero:
drawing number:
23777 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
13 (up. int.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018


COLUMN VESSEL
SECTION 4.3.
Hydraulic test certificates
▹▹▷
CERTIFICATO DI PROVA IDRAULICA
HYDRAULIC TEST CERTIFICATE
Job number:
11880 Certificate number:
M_3108‐1_VPI_0

Serial number:
3108‐1 Vessel: Column Vessel
23777
Jamal B. BRAM‐COR S.p.A.
Internal inspector: firm:
0 0
Procedura di prova:
PD_SOP_000_0
Test procedure:
Tipo di fluido: acqua
Type of fluid: water
Temperatura del fluido:
15 °C
Fluid temperature:
Temperatura di parete:
18 °C
Wall temperature:
Membratura: Lato mantello Pressione di prova:

9.6 bar
Side: Shell side Test pressure:
Durata prova: Manometro tipo
30 min 0÷16 bar
Test duration: Pressure gauge type
N. di serie
109731
Serial nuber
Esito della prova:
Test result: Positivo Negativo (ripetere)
Positive Negative (repeat)
31/07/2018
Module: PD_MOD_VPI_001_1 Page 1 of 1

ATTACHMENT 2.
BRAM‐COR Heat Exchanger
 NOTE:
The main components are described in separate books called “Technical
Dossiers”, identified in following table and attached below.
The above‐mentioned files will be supplied in electronic version only.
BRAM‐COR TAG Technical Dossier Name Code
E‐2001 M_3108‐2_FT_0
TECHNICAL DOSSIER
HEAT EXCHANGER
E-2001
REVISION HISTORY
00 First emission 20/08/2018 P. Morlacchini V. Cucci B. Jamal
BRAM‐COR S.p.A.
Tel. +39 0521 538711
Fax: +39 0521 538770
HEAT EXCHANGER
SUMMARY
INTRODUCTION
SECTION 1 – GENERAL INFORMATIONS
SECTION 2 – DRAWING AND MATERIAL CERTIFICATES
2.1. Drawing
2.3. Insulation material
SECTION 3 –WELDING DOCUMENTATION
3.2. Pipes drifting procedure
SECTION 4 –PASSIVATION REPORT AND TESTING CERTIFICATES
4.2. Non destructive test certificates
HEAT EXCHANGER

INTRODUCTION

HOW TO USE THIS TECHNICAL DOSSIER

This Technical Dossier provides complete information and instructions of use for the involved
component.
To ensure traceability, the material certificates refer to the related position in the element table
of the constructive drawing, as shown below.

HEAT EXCHANGER

Each element is labelled with relative peening. The relative number is reported in the “position”
column on the left of the table, the second column describes the Item, the third indicates the
quantity, the fourth column indicates the material and the fifth indicates the dimensions.
An example in the following picture.

Each material certificate is consequently identified by the preceeding title page with the position
on the table.

HEAT EXCHANGER

CONSIDERATIONS ABOUT SIGNATURES ON THE CERTIFICATES

Some certificates are issued by the manufacturer without the inspector’s signature.
According to the European Norm EN 10204 “Metallic products ‐ types of inspection documents”,
section 5 , ”The inspection document shall be validated by the responsible person(s) (name and
position). No signature is required for material certificates.
All the included certificates are therefore considered as validated even without signature.
The applicable certificates in this document conform to the original, are included “as received”,
either in paper copy or in PDF electronic format and cannot be overwritten by BRAM‐COR.
Consequently BRAM‐COR will not and cannot stamp or overwrite the manufacturers’ certificates
on customer’s request. No further conformity declarations by BRAM‐COR are therefore due to
justify the absence of signatures on the manufacturer’s certificates.

STAINLESS STEEL CODING

Stainless steel may be identified on the 3.1. certificate either by its AISI code (SAE grade) or by the
corresponding Euronorm code (EN steel number), according to its chemical composition, as
follows:

U.S.A. GERMANY GERMANY FRANCE JAPAN ITALY SWEDEN U.K. E.U. SPAIN RUSSIA

W.N.
AISI DIN 17006 AFNOR JIS UNI SIS BSI EURONORM UNE GOST
17007

X 5 CrNi 18 10 1.4301 304S15 08KH18N10
304 Z 6 CN 18‐09 SUS 304 X 5 CrNi 1810 23 32 X 6 CrNi 18 10 X 6 CrNi 19‐10
X 5 CrNi 18 12 1.4303 304S16 06KH18N11

304 L X 2 CrNi 1911
X 2 CrNi 18 11 1.4306 Z 2 CN 18‐10 SUS 304L 23 52 X 2 CrNi 19‐10
X 2 CrNiN 1811 304S11 X 3 CrNi 18 10 03KH18N11
X 2 CrNiN 18 10 1.4311 Z 2 CN 18‐10‐Az SUS 304LN 23 71

316 X 5 CrNiMo 17 12 2 1.4401 Z 6 CND 17‐11 SUS 316 X 5 CrNiMo 1712 23 47 316S31 X 6 CrNiMo 17 12 2 X 6 CrNiMo 17‐12‐03

X 2 CrNiMo 17 13 2 1.4404 Z 2 CND 17‐12 X 2 CrNiMo 1712 23 48 316S11 X 3 CrNiMo 17 12 2 03KH17N14M2
316 L SUS 316L
X 2 CrNiMo 18 14 3 1.4435 Z 2 CND 17‐13 X 2 CrNiMo 1713 23 53 316S13 X 3 CrNiMo 17 13 3 X 2 CrNiMo 17‐12‐03 03KH16N15M3
HEAT EXCHANGER

SECTION 1
GENERAL INFORMATION


HEAT EXCHANGER

SECTION 1.1.
Product general description
▹▹▷

VESSEL GENERAL DESCRIPTION
This equipment is made of one double tube sheet heat exchanger for heat exchanging between
two fluids: one of process, which goes through the pipes (tube side) and one of service, or
primary, in the external interspace (shell side).
The process fluid (feeding water) is Purified Water, which is pre‐heated. The service fluid is,
instead, industrial steam.
The frames and the components in contact with the product are made of stainless steel EN
1.4404 (AISI 316L), otherwise the secondary components are generally made of stainless steel
EN 1.4301 (AISI 304).
The equipment is designed according to the indications of Italian ISPESL collection VSR Rev. 95
Ed. 99 + Errata Corrige 2003.
MAIN FEATURES
 Capacity (shell side): 55.0 L
 Capacity (pipes side): 55.0 L
 Max. / Min. design pressure (shell side): 9.0 bar / F.V.
 Max. / Min. design pressure (pipes side): 5.0 bar / F.V.
 Max. / Min. design temperature (shell side): 180 °C / 0 °C
 Max./ Min. design temperature (pipes side): 180 °C / 0 °C
 Fluid class: 2
APPLICATION FIELD
 Pharmaceutical industry
TECHNICAL DOSSIER ‐ M_3108‐2_FT_0 SECTION 1.1.
HEAT EXCHANGER

SECTION 2
DRAWING AND MATERIAL CERTIFICATES

2.1. Drawing
2.3. Insulation Material

HEAT EXCHANGER

SECTION 2.1.
Drawing
▹▹▷

HEAT EXCHANGER

SECTION 2.2.
Material certificates
▹▹▷


Positions 1 ‐ 22 ‐ 23
Drawing 23779
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Positions 2 ‐ 8 ‐ 13 ‐ 16
Drawing 23779
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Position 3
Drawing 23779
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CERTIFICATO DI COLLAUDO EN 10204 3.1 N° 441935 del 09.09.2015 Pag 1 / 1
Cliente: PROFILINOX S.P.A.

DDT Ordine SIDERINOX Ordine Cliente
N 2433 del 09.09.2015 N 1177 del 04.09.2015 N 04/09 del 04.09.2015
Descrizione prodotto
Tubo tondo inox Ø 60,3 x 3 mm AISI 316L spazzolato EN 10217-7 saldato longitudinalmente
Dimensione Acciaio Quantità [metri] Peso [kg]
60,3 x 3 mm EN 1.4404 / AISI 316L 222 596
Norma di produzione Laminazione Tolleranze Fattore di saldatura
EN 10217-7 D3 \ T3 V=1
Marcatura SIGLA PRODUTTORE-DIMENSIONE-ACCIAIO-COLATA-NORMA DI PRODUZIONE-ESECUZIONE-SIGLA ISPETTORE II
LIV. CND-RESPONSABILE PROFILA
Procedimento di saldatura Finitura superficiale W0
COMPOSIZIONE CHIMICA DELLA COLATA

Colata %C %Mn %P %S %Si %Cr % Ni % Mo % Ti
0,000 - 0,030 0,000 - 2,000 0,000 - 0,040 0,000 - 0,010 0,000 - 1,000 16,500 - 18,50010,000 - 13,000 2,000 - 2,500 0,000 - 0,000
0443720 0,019 0,930 0,029 0,001 0,440 16,810 10,150 2,010
I valori chimici si riferiscono al certificato rilasciato dall'Acciaieria secondo le norme EN 10088 / 10028-7 / ASTM A240 e archiviati presso la nostra sede.
RISULTATI DELLE PROVE * (D) Direzione: (L) Longitudinale, (T) Trasversale - ** (P) Posizione: (S) Saldatura, (M) Materiale
Lotto Classe (D) (P) PROVA DI TRAZIONE in Nmm2=MPa DUREZZA
di prova * ** Snervamento Carico di rottura Allungamento
Rp 0,2% Rp 1% Rm A% HRB
190 - 225 - 490 - 760 40 -
T15070337 TC1 L M 243 331 637 49
Esame visivo Prova di svasatura Prova di tenuta

OK UNI EN ISO 8493 OK UNI EN ISO 10893-1 OK
Controllo dimensionale Prova di schiacciamento Controllo non distruttivo Eddy Current
OK UNI EN ISO 8492 OK UNI EN ISO 10893-2 OK
Prova antimiscuglio Prova di piega della saldatura Prova corrosione intercristallina
OK EN 910 OK N. P. N. P.
SI DICHIARA CHE IL MATERIALE FORNITO E' CONFORME AI REQUISITI DELL'ORDINE

Note:
Certificazioni:
UNI EN ISO 9001
Dir. PED 97/23/EC All. 1, Punto 4.3, Comma 3
Documento rilasciato dall'Ispettore Documento emesso dal Rappresentante
AQUAP da nr. 7293-06-TU a nr. 7298-06-TU
Aziendale Autorizzato Aziendale Autorizzato
Qualificazioni:
WPS/WPAR: UNI EN ISO 15609-4/UNI EN ISO 15614-11
Personale WLD: UNI EN ISO 14732
Personale NDT: UNI EN ISO 9712 D. Ricco W. Amodeo
Cert. Coll. - Rev. 3 - 03/14

Position 4
Drawing 23779
▹▹▷



Marcegaglia THIS DOCUMENT WAS PRODUCED AUTOMATICALLY
46040 via Bresciani 16-Gazoldo degli Ippoliti Mantova-Italy Type/Tipo 3.1 CERTIFICATO DI COLLAUDO EN10204 AND IS VALID WITHOUT SIGNATURE Number/Numero 10517707454 Creato il 23/11/2017
Tel. +39 - 0376 685 1 Fax. +39 - 0376 685 600
www.marcegaglia.com QUALIFICA DEI PROCESSI DI SALDATURA: TUTTI I PROCESSI DI SALDATURA LASER SONO QUALIFICATI IN CONFORMITA' ALLA DIRETTIVA EUROPEA PED 97/23/EC
DALL'ORGANISMO NOTIFICATO N.1233 EUROPED TRAMITE LE WELDING PROCEDURE QUALIFICATION WPQR N° PM0907A001 Registration no. 10M203 E WPQR N° PM907A002
Stabilimento di Forlì: Registration no. 11M017. LE QUALIFICHE SONO VALIDE ANCHE SECONDO LA DIRETTIVA EUROPEA PED 2014/68/UE SECONDO L'ARTICOLO 48 PARAGRAFO 3.
via E.Mattei,20 47034 Forlimpopoli, Forlì-Cesena
tel+39.0543470111 fax+39.0543470105
Customer/Cliente Code: 0000010076 Consignee/Destinatario Merci Delivery/N° Consegna 8205715964 Quality Control/Controllo Qualità Pages/Pagine
ND C/O PROFILINOX - MARCEGAGLI ND C/O PROFILINOX - MARCEGAGLI Of/Del 23/11/2017 Q.M.D./RESP. S.Toscano
VIA NOBEL 3A Q.RE IND.LE S.P. VIA NOBEL 3A Q.RE IND.LE S.P. 1/1
43122 PARMA IT 43122 PARMA IT Delivery note nr/N° doc. di trasp. 2505004455 Plant Of/Stab. Forlì
Material/Codice Materiale Order Nr/ordine Client Order/Ordine cliente
59002825 Norma di collaudo: EN 10217-7 TC1 Tipo saldatura 1571857761/20 E-MAIL DANIELA
Description/Descrizione Tipo di Acciaio: TP 316L 1.4404 X2CrNiMo17-12-2 LASER WELDING
Part Number Client Date/data cliente
TXT002 48,3X2.77X6000 TP316L LAS Thickness tolerance: ISO 1127 D3-T3 27/11/2017
Item Batch/N° Partita Heat/Colata Quantity/Q.tà MTL Quantity/Q.tà KG Quantity/Q.tà PZZ Stato Fornitura Lavorazioni aggiuntive
1 17J4010803 0449737 120 591 15
2 17J4010812 0449737 120 588 15
WE CERTIFY THAT THE ABOVE MENTIONED
PRODUCTS COMPLAY WITH THE TERMS OF
ORDER CONTRACT AND THE STANDARDS
RECALLED IN THE PRESENT TEST
CERTIFICATE
C Si Mn P S N Cr Mo Ni
Batch/N° Partita tipoChimica (%) (%) (%) (%) (%) (%) (%) (%) (%)
16.5 2 10
0.03 1 2 0.045 0.015 0.11 18.5 2.5 13
17J4010803 RAW MATERIAL .023 .320 1.070 .0250 .0010 .0460 16.660 2.0400 10.030
17J4010812 RAW MATERIAL .023 .320 1.070 .0250 .0010 .0460 16.660 2.0400 10.030
MARCEGAGLIA SPECIALTIES FORLIMPOPOLI CERTIFICAZIONI DI SISTEMA LO STABILIMENTO MARCEGAGLIA SPECIALTIES DI FORLIMPOPOLI E' DOTATO DI UN SISTEMA
Rp 0.2 Rp 1.0 Rm A5
DI GESTIONE PER LA QUALITA' CERTIFICATO IN CONFORMITA' ALLA EN 9001:2008 E ISO\TS 16949:2009 E ISO 3834-2:2005 ED UN SISTEMA DI GESTIONE PER LA
Batch/N° Partita Type of mechanical test [MPa] [MPa] [MPa] (%)
SICUREZZA CERTIFICATO IN CONFORMITA' ALLA OHASAS 18001:2007 ED UN SISTEMA DI GESTIONE AMBIENTALE CERTIFICATO IN CONFORMITA' ALLA ISO 14001:2004.
190 225 490 40
690 MARCEGAGLIA SPECIALTIES FORLIMPOPOLI CERTIFICAZIONI DI PRODOTTO LE CERTIFICAZIONI DI PRODOTTO DELLA MARCEGAGLIA SPECIALTIES FORLIMPOPOLI
SONO DVGW SECONDO LA REGOLA TECNICA GW541 LA CUI GAMMA E' TUBI SALDATI TIG O LASER GRADO INOSSIDABILE 1.4404 DIA DA 15.00 A 108.00MM E 1.4521 DA
17J4010803 TUBE 384 424 624 45.9 15.00 A 54.00MM.
17J4010812 TUBE 382 422 620 46.8 TUV AD2000 W2\W10 E PED ANNEX I, PARAGRAPH 4.3 TUBI SALDATI TIG O LASER CON GRADO INOSSIDABILE 1.4301, 1.4306, 1.4307, 1.4401, 1.4404, 1.4541, 1.4571, 1.4435,
1.4436 SPESSORI DA 0.80 A 4.00MM E DIAMETRI DA 8.00 A 283.00 MM.
EHEDG PER TUBI ALIMENTARI TXT015.; TIFQ - CONFORMITA' ALLA DIRETTIVA EUROPEA 1935:2004 ED AL DECRETO MINISTERIALE ITALIANO 174:2004 PER TUBI
ALIMENTARI TXT003, TXT014 E TXT015.
PROVE NON DISTRUTTIVE PROVE DISTRUTTIVE

EDDY CURRENT TEST PER IL CONTROLLO DELLE PERDITE IDRAULICHE IN ACCORDO ALLA EN ISO 10893-1:2011: CONFORME PROVA DI SVASATURA IN ACCORDO ALLA EN ISO 8493:2005: CONFORME
EDDY CURRENT TEST PER L'INTERCETTAZIONE DELLE IMPERFEZIONI IN ACCORDO ALLA EN ISO 10893-2:2011: CONFORME PROVA DI SCHIACCIAMENTO IN ACCORDO ALLA EN ISO 8492:2004: CONFORME
PROVA ANTIMISCUGLIO: CONFORME PROVA DI MANDRINATURA AD ANELLO IN ACCORDO ALLA EN ISO 8495:2004: CONFORME
CONTROLLI VISIVI E DIMENSIONALI:CONFORMI PROVA DI TRAZIONE ESEGUITA IN CONFORMITA' ALLA EN ISO 6892-1:2009
PROVA DI CORROSIONE INTERGRANULARE IN ACCORDO ALLA EN ISO 3651-2:1998: CONFORME
Marcatura
Remarks/Note:
CHEMICAL COMPOSITION ACCORDING TO EN 10028-7 TUBE TO EN 10217-7 TC1 AND DIRECTIVE 2014/68/EU (PED), WELDING
FACTOR V=1

Position 5
Drawing 23779
▹▹▷


Off.Mecc.FERRARI Cav.UMBERTO & C SNC
26029 SONCINO (CR) ITALY
Spett.le BRAM-COR spa PARMA
MATERIALE per Vs.Ord.N.990 del 11/05/18
N.20 30478040 Flange UNI 2278 Aisi 304L DN40

Position 6
Drawing 23779
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Position 7
Drawing 23779
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Quantità 25 kg - Colata 161019B10 - N. Ord. 726866 - 10 - Rif. Cliente 1301

N. Bolla 9906 del 15/06/2017 - Materiale BCA05040 - 304 BPN
Type/Tipo 3.1 CERTIFICATO DI COLLAUDO EN10204
Registered seat and Administration offices/Sede Legale e amministrativa:
via Bresciani 16
46040 Gazoldo degli Ippoliti Number/Numero 10517292265
Mantova-Italy
Tel. +39 - 0376 685 1 Creato il 16/05/2017
Fax. +39 - 0376 685 600
www.marcegaglia.com
Customer/Cliente Consignee/Destinatario Merci Delivery/N° Consegna 8205706886 Quality Control/Controllo Pages/Pagine

ND C/O PROFILINOX - MARCEGAGLI ND C/O PROFILINOX - MARCEGAGLI Of/Del 16/05/2017
Qualità
VIA NOBEL 3A Q.RE IND.LE S.P. VIA NOBEL 3A Q.RE IND.LE S.P. 1/1
Q.M.D./RESP. L.Solazzi
43122 PARMA IT 43122 PARMA IT Delivery note nr/N° doc. di 2505001805
trasp. Plant Of/Stab. Gazoldo
C Si Mn P S Cr Ni N Rm Rp 0.2 RP 1 A HRB
Batch/N° Partita Quantity/Q.tà Heat/Colata (%) (%) (%) (%) (%) (%) (%) (%) [N/mm² [N/mm² [N/mm² (%)
54000817 PXP 35x5x4000 304/304L 4301/4307X5CrNi18-10/X2CrNi18-9 WNR 1.4301/1.4307 A304/A304L EN10028-7.EN10088-2.EN10088-4. ASTM A240. ASME SA240.
ASTM A480. ASME SA480 1571853026/50 . Data 17/05/2017
17NW002491 506 KG 161019B10 .024 .524 1.529 .0291 .0063 18.3358.133 .0464 627 427 487 52.2 85
17NW002492 500 KG 161019B10 .024 .524 1.529 .0291 .0063 18.3358.133 .0464 627 427 487 52.2 85
17NW002549 504 KG 161019B11 .024 .479 1.445 .0209 .0072 18.2818.112 .0417 638 438 498 51.8 88
17NW002550 510 KG 161019B11 .024 .479 1.445 .0209 .0072 18.2818.112 .0417 638 438 498 51.8 88
35 X 5 L=4000
Remarks/Note:
- Certifichiamo che i prodotti sopra elencati sono conformi alle prescrizioni dell'ordine - Processo di fabbricazione: forno ad arco-VOD/AOD-colata continua
- Documento validato in conformità ad EN10204 par. 5 Trattamento di solubilizzazione a 1050°C - Coil finish 1D
- Durabilità: NPD material conforming to NACE MR0175/MR0103 - ISO15156-1/ISO15156-3
- Sostanze Pericolose: NPD
- Per impieghi strutturali, costruzioni e ingegneria civile
- DoP disponibili su http://www.marcegaglia.com/brochure/e/quality/dop.html

Positions 9 ‐ 10
Drawing 23779
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Position 11
Drawing 23779
▹▹▷


A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1019 1030120481 July 10, 2018

1080234639 / 900003 1800336181

ASME BPE-2016 SF1 188,00 St/Pcs - - -

- - AOD, EAF
DOCKWEILER KA2297 50.80x1.65 mm S31603 HT:850448 ASME BPE SF1

- -

1 850448 S31603 (316L) - 0,015 0,390 1,430 0,030 0,012 16,70 10,10 0,0500
1 0,006 2,040 - 4,60 0,350 - - - - - 0,0800 -

solution annealed


1 850448 - 373 54000 - - 635 55 -
1

- - -
1 850448 - - - - - 84 B -
- - - - - - -
1 850448 OK OK - OK -
- - - - -
1 850448 - OK OK

- - - -
1 850448 - -


- - - - -
1 850448 - - OK
- - - - - -
1 850448 - - - -

- 0,27 µm 0,54 µm 0,79 µm - - -

- - - - - - -

2
Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 July 10, 2018

Merkblatt HP0
3

Position 12
Drawing 23779
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Quantità 6 m - Colata 04/77204 - N. Ord. 814853 - 10 - Rif. Cliente 602
TIPO DOCUMENTO − TYPE DOCUMENT (EN10204) Data − Date Pag. 1 / 1

Certificato di Controllo 3.1 05/03/2018
Via Portamurata, 8/A
42016 GUASTALLA (RE) − ITALIA Inspection Certificate 3.1
Tel. + + 39 522 83.65.55 (r.a.) AZIENDA CON SISTEMA DI GESTIONE
Fax + + 39 522 83.65.72 − 83.65.73 QUALITA’ CERTIFICATO SECONDO Nr. : 18020583
Cod. Fis. e P. IVA IT00323370353 UNI EN ISO 9001
PROFILINOX SPA ( 2238 ) Consegna: PROFILINOX SPA ( 13133 ) D.D.T. − DELIVERY NOTE
VIA NOBEL, NR. 3/A Q.RE IND.LE S.P.I.P. Delivery: VIA NOBEL N. 3/A Q.RE IND.LE S.P.I.P.
43122 PARMA PR 43100 PARMA PR
Italia Italia 18015288 − 05/03/2018
Riferimenti Normativi Tubi − Hollow Sections Standard: EN10217−7 / TC1−ISO1127 D3/T3 DELIVERY CONDITIONS = W0 WELDING FACTOR V=1 * D = Direction : L/T ** P = Position : W/M
Tubi Saldati Longitudinalmente Composizione Chimica CAPABLE TO MEET Proprietà Meccaniche e Tecnologiche
Longitudinal Welded Tubes Chemical Composition INTERGRANULAR CORROSION TEST Mechanical and Technical Properties
Dim. Sp. L Acciaio Fin. Lotto MT Peso Colata ( LADLE ) ( ACCORDING TO EN ISO 3651−2 ) ( EN ISO 6892−1 ) ( T = 23° )
Trazione / Tensile Test Durezza
Th. Steel Tot. WGT Heat
%C %Si %Mn %P %S %Nb %V %Al %Ti %Cr %Ni %Mo %Cu %N D* P** Rp0,2 Rp1,0 Rm A A80 Hardness
(mm) (mm) (mm) (m) (kg)
MPa % HRB
800442 27/02/2018 SI − 18010455 − −
D.139,7 3,00 6000 1.4404−AISI 316L SP TN04156224 60,00 578 04/77204 0,022 0,450 0,930 0,035 0,001 16,700 10,100 2,040 0,045 L M 309 374 608 59,4
D.101,6 4,00 6000 1.4301/1.4307 SP TN04170544 114,00 1.078 02/742087 0,024 0,390 1,470 0,030 0,001 18,150 8,050 0,070 L M 433 458 666 56,7
800443 27/02/2018 SI − 18010530 − −
D.139,7 3,00 6000 1.4404−AISI 316L SP TN04156401 90,00 866 04/77204 0,022 0,450 0,930 0,035 0,001 16,700 10,100 2,040 0,045 L M 309 374 608 59,4
(EN ISO 8492 / 8493) (EN ISO 10893−1) Certifichiamo che il prodotto fornito
Controllo visivo e dimensionale: esito positivo Prova di schiacciamento o prova di espansione :esito positivo Prova di tenuta: esito positivo è conforme ai requisiti dell’ordine
Visual and dimensional control: OK Flattening test or drift expanding test: OK Leak tightness test: OK
(EN ISO 10893−2)
We certify that material supplied complies
with the requirements agreed on order
Verifica antimescolamento: esito positivo P.N.D.: correnti indotte sulla saldatura: esito positivo
Anti−mixing test : OK NDT: Eddy Current test on the weld: OK
Certificazioni / Certifications : Qualifiche / Qualifications: Padana Tubi & Profilati Acciaio S.p.A.
UNI EN 9001:2008 WPQR : EN ISO 15614−11 Marking: P.T.−Ø−th.−steel type−en standard−heat n° Ing. Stefano Passera
Dir. PED 2014/68/UE Annex1, Paragraph 4.3 Steel making process :AOD
Num. Cert. TUV: PED−0948−QS4.3−435−15 Rev.01 WLD : EN ISO 14732 operator qualified
NDT : Operator qualified according to ISO 9712 level 2
Controllo Qualità / Quality Department
M 7.5.19 − rev. 00 I3.1

Position 14
Drawing 23779
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TOPLINE STAINLESS

HARDNESS
HB
1 316L 0.017 0.58 1.74 0.021 0.025 10.10 16.53 2.04 218 525 47
2 316L 0.017 0.58 1.74 0.021 0.025 10.10 16.53 2.04 218 525 47
3 316L 0.019 0.57 1.76 0.022 0.023 10.09 16.51 2.03 216 522 48
4 316L 0.019 0.57 1.76 0.022 0.023 10.09 16.51 2.03 216 522 48
5 316L 0.021 0.62 1.56 0.031 0.018 10.05 16.55 2.09 214 520 42
STAMP:
Position 15
Drawing 23779
▹▹▷
INSPECTION CERTIFICATE EN 10204 - 3.1 SHEET OF
Certified ISO 9001
Z.I. 2, CH-1860 AIGLE LRQA n° 943175
CERTIFICAT DE RECEPTION PAGE 1 DE 1
Tel. ++41-(0)24-468 46 46 N° 181536 Quality System
SEITE VON
ABNAHMEPRÜFZEUGNIS Management
Fax ++41-(0)24-468 46 01
* DER TÜV SUDWEST HAT MIT SCHREIBEN VOM 3 NOVEMBER 1992 AUF CONFIRMATION N° CUSTOMER:
DIE GEGENZEICHNUNG VERZICHTET AUFTRAGS N° 47414 X CLIENT/ KUND BRAM-COR
CUSTOMER ORDER N° COMMANDE CLIENT / KUNDENBESTELLUNG SPECIFICATIONS: HEAT N. QUANTITY DIMENSIONS LENGTH STEEL GRADE
COULEE N. QUANTITE mm LONGUEUR NUANCE D'ACIER
551 ANFORDERUNGEN SCHMELZE N. STÜCKE ABMESSUNGEN LÄNGE mm MARKENBEZEICHNUNG
PRODUCT PRODUIT / PRÜFGEGENSTAND
A213/A269 170912AV06 3007.6 m 10.00 x 1 6000 TP 316L
REDRAWN TUBES - TUBES ETIRES -
NACHGEZOGENE ROHRE
HEAT N. HEAT ANALYSIS ANALYSE DE COULEE / SCHMELZANALYSE ( 10 BAR = 1M Pa )

COULEE N. FLATTENING HYDROSTATIC TEST FLARING
SCHMELZE N. %C % Si % Mn %P %S % Cr % Ni % Mo %N % Ti % Cu % Fe % Al % Co %B % Zr % %
APLATISSEMENT ESSAI HYDRAULIQ BAR EVASEMENT
RINGFALTVERSUCH WASSERDRUCKVERSUCH
170912AV06 0.018 0.36 1.13 0.037 0.002 16.40 10.02 2.006 AUFWEITUNG
S NE NE
HEAT N. PRODUCT ANALYSIS ANALYSE PRODUIT / STÜCKANALYSE
COULEE N.
SCHMELZE N. %C % Si % Mn %P %S % Cr % Ni % Mo %N % Ti % Cu % Fe % Al % Co %B % Zr % %
0.0005 0.465 1.16 0.0238 0.0005 16.20 10.30 2.080 FLANGING REVERSE BENDING GRAIN SIZE ASTM
PIECE COLLET RETOURNEMENT INVERSE GROSSEUR DE GRAIN
BÖRDELVERSUCH WURZELSEITIGER RINGFA KORNGRÖSSE
HEAT TRAITMENT : ANNEALED AT : AND RAPIDLY COOLING S S NE

TREATEMENT THERMIQUE HYPERTREMPE A 1050° C ET REFROIDI RAPIDEMENT
WÄRMEBEHANDLUNG LÖSUNGSGEGLÜHT BEI UND ABGESCHRECKT
OF THE MATERIAL HAVE BEEN PASSED WITH SATISFACTORY RESULT THE : TEST ACCORDING TO : CORROSION TEST P.M.I. VISUAL CONTROL
Eddy Current SEP 1914/1925
100 % DU MATERIEL SATISFAIT AU(X) CONTROLE(S) SUIVANT
ASTM A 1016
TEST CORROSION TEST DE NON MELANGE CONTROLE VISUEL
DES MATERIALS HAT DIE PRÜFUNG BESTANDEN ENTSPRECHEND IK TEST VERWECHSELLUNGSPR. BESICHTIGUNGSKONTR.
NE S S
MARKING : H=170912AV06 REMARKS :
MARQUAGE REMARQUE
KENNZEICHNUNG ANMERKUNG
SPECIFICATION SPECIFICATION SPECIFICATION
SPEZIFIKATION SPEZIFIKATION SPEZIFIKATION
TEST RESULTS RESULTATS DES ESSAIS / ERGEBNIS DER PRÜFUNGEN ( 1 N/mm2 = 1M Pa )
SAMPLE OU INT. WALL THIC. LENGTH ROUGHNESS ROUGHNESS ROUGHNESS TENSILE TRACTION / ZUGVERSUCH HARDNESS S = Satisfactory - Satisfaisant - Zufriedenstellend
ECHANTILLON Ø EXT Ø EPAISSEU LONGUEUR RUGOSITE RUGOSITE RUGOSITE Rp 0,2% Rp 1% Rm A% DURETE.
PROBE AUSS. INN. WANDSTÄR LÄNGE RAUHIGKEIT RAUHIGKEIT RAUHIGKEIT N/mm 2 N/mm 2 N/mm 2 Lo=5,65 So HÄRTE NE = Not executed - Pas effectué - Nicht durchgeführt
TOLERANCES 10.00 8.00 1 6000 Ext.Ra Int.Ra HV3 Emis et vérifié par : Issued and checked by :
TOLERANZEN ±0.04 ±0.05 +20/0 <0.60 µm <0.60 µm µm
1 10.00 8.06 0.97 6000 0.41 0.53 255 293 554 58 139.2
2 260 297 553 58
Z.M.
10.00 8.06 0.97 0.32 0.55
Q.C. R. MARTENA
3 10.00 8.04 0.98 6020 0.20 0.52 254 293 559 58
4 10.00 8.04 0.98 0.55 0.58 278 321 597 58
5 10.00 8.04 0.98 6020 0.19 0.54 257 298 571 58 139.2
Aigle, 16-juil-18

Positions 17 ‐ 24
Drawing 23779
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Position 25
Drawing 23779
▹▹▷
N. Bolla 4186 del 16/03/2018 - Materiale BRA01830 - 304 TR9 18 L=3000
Quantità 6 kg - Colata 107170 - N. Ord. 813323 - 30 - Rif. Cliente 422

HEAT EXCHANGER

SECTION 2.3.
Insulation material
▹▹▷

Stonewool wired mat with galvanised mesh and stitching wire
Product Description
FIBRANgeo R-560-KO Stonewool wired mat with galvanised mesh and stitching wire is
industrially produced from molten rock spun into fibres.
It is classified as thermal insulation mineral wool product for use in building equipment and industrial
installations, according to the European Standard EN 14303 (MW - Mineral Wool insulation products).
Stonewool is a natural inorganic fibrous material, widely recognised for its thermal and sound
insulating properties, as well as its excellent performance towards fire protection.
FIBRANgeo R-560-KO is produced from mineral rock, initially fused in an electric furnace at 1520°C
and then spun into fibres. The loose stonewool fibres, with the addition of adhesive resin, oil and
special silicon compounds that provide hydrophobicity, become cohesive, elastic, non-hygroscopic
and water-repellent. The product is then stitched on galvanized wired mesh with galvanized wire,
formed into rolls and finally shrink-wrapped in PE film in packages.
The non-use of fossil fuels (e.g. coke) as a main production fuel minimises polluting gas emissions in
the environment.
Advantages
• Excellent thermal insulation

• Excellent sound absorption and sound reduction
SHEET
• Non-combustible material with excellent fire resistance

DATASHEET
• Insulating properties remain unaffected at high temperatures

• Open hive structure material with very low water vapour diffusion resistance, similar to the
resistance of air
TECHNICALDATA
• Water repellent and non-hygroscopic

• Natural, inorganic, odourless, chemically inert, suitable for use over stainless steel
• Lightweight, easy to handle, cut and install
TECHNICAL
• Resistant to vibrations
• Does not allow the development of micro-organisms, insects or rodents
• Recyclable
• Friendly to the environment and to the end user
1/5
Applications
FIBRANgeo R-560-KO is suitable for use in building equipment and industrial installations.
Thermal-acoustic-fire insulation of :
• Pipe work
• Ductwork
• Smoke exhaust ducts and chimneys
• Machines
• Silencer equipment
• Boiler, vessels and tank walls
• Heat exchangers
• Furnaces
0
• Max. Service Temperature 650 C
Packaging
Thickness Width Length Quantity/ Roll

[mm] [mm] [mm] [m2/ Roll]
30 1000 8.000 8,00
40 1000 5.000 5,00
50 1000 5.000 5,00
60 1000 5.000 5,00
80 1000 3.000 3,00
100 1000 2.500 2,50
120 1000 2.500 2,50
Other dimensions are available upon request.

Facings
FIBRANgeo R-560-KO is also available with the following variants

to meet particular application requirements:
• FIBRANgeo R-560-KO SS Stainless steel mesh and stainless steel stitching wire
• FIBRANgeo R-560-KO GS Galvanized steel mesh and stainless steel stitching wire
2/5
Designation code:
MW(Μineral Wool)- EN 14303- T2- ST(+/250) 650 - WS1 - MU1 - AW1 - AFr35 - CL10 - F10 - PH10.5
Symbol
Technical Characteristics
EN-13162 Unit Value EN standard
0 EN 12667
Declared thermal conductivity at 10 C λD W/(mK) 0,035
EN 13787
ο
Maximum Service Temperature ST(+/250) C 650 EN 14706
Nominal thickness dN mm 30 - 120 EN 823
Α1
Fire classification - Class ΕΝ 13501-1
(Non-combustible)
ο
Melting temperature - C >1000 DIN 4102-17
Specific heat capacity c kJ/kg*K 0,84 -
Τ2
Thickness tolerance Τ Class EN 14303
(-5%, +15 %)
2
Short Term Water Absorption for 24 h WS kg/m <1 EN 1609
Water vapour diffusion resistance factor µ MU - 1 EN 12086
< 10
AS-quality for use
Water leachable chloride, fluoride and PH-value CL, F, PH mg/kg over stainless steel. EN 13468
PH-value neutral to
slightly alkaline
2
Air flow resistivity, r AFr kPa s/m 35 EN 29053
Weighted Sound Absorption Coefficient αw EN ΙSO 11654

AW - 1 ( Class Α)
(Thickness 50 mm) EN ISO 354
3
Density, ρ - kg/m 65 EN 1602
Declared Thermal Conductivity λD
Mean ο
θΜ C 50 100 150 200 250 300 350 400 500 600 650 EN14303
Temperature
Declared EN 12667
Thermal λΝ,P W/mK 0,039 0,046 0,054 0,063 0,075 0,087 0,101 0,116 0,151 0,193 0,221
EN 13787
Conductivity
3/5
Certifications
All FIBRANgeo stonewool insulation products meet the QUALITY and SAFETY requirements of the
European Standards.
The quality of FIBRANgeo products is assured in accordance with EN 14303, EN 14162, EN ISO
13787 and EN 13172 standards.
These standards establish the type and frequency of measurements executed both by recognised
and independent institutions, as well as by FIBRAN laboratories.
CE Certification
All FIBRANgeo stonewool insulation products have been certified according to the European Directive
89/106/EEC since 2004, and today conform to the European Regulation 305/2011 as this replaced the
above mentioned Directive.
In compliance with the above Construction Products Regulation, all types of FIBRANgeo T stonewool
products hold the CE marking and are in conformity with the European Norms EN 14303 and EN 13162,
which refer to mineral wool insulation products for industrial installations, building equipment and building
applications.
In accordance with the aforementioned Standards, every insulation product acquires a designation code
which declares its technical characteristics.
Furthermore, FIRAN S.A. has issued the Declaration of Performance (DoP) for all product types, available
on the company website: http://www.fibran.gr/dop/.
The Initial Type Test (ITT) as well as the Factory Production Control (FPC) have been performed by the
following European Notified bodies for CE marking:
Notified Bodies: Forschungsinstitut für Wärmeschutz e.V. München (FIW): Identification Number 0751
Materialprüfanstalt für das Bauwesen Hannover (MPA BAU): Identification Number 0764
EUCEB Certification
All FIBRANgeo stonewool insulation products also carry the certification mark EUCEB (European
Certification Board for Mineral Wool Products). EUCEB is an independent organization whose procedures
ensure compliance of mineral wool insulation products with the Directive’s 97/69/EC, Note Q, regarding
their fibres biosolubility and their non-classification as ‘carcinogenic’ materials.

Moreover, according to EC Regulation 790/2009 (August 10, 2009) they are not classified as products
that cause skin irritation.
ISO 9001:2008 Certification
The quality management system of FIBRAN S.A. complies with EN ISO 9001:2008 for the design and
manufacture of Mineral Wool (MW), as certified by the independent body TÜV NORD CERT, with initial
Certificate Registration No. 04 100 960680.
4/5
Handling and Storage
FIBRANgeo products should be stored indoors. If stored outdoors, they must be

protected from impregnation. Pallets shrink-wrapped weather tightly in PE film may be
stored outside. Separate packages should be placed on a flat pallet, not in direct
contact with the ground.
If part of the product gets wet, it must be dried before installation. Stonewool dries
quickly and its insulating properties remain unchanged after drying.
FIBRANgeo products are chemically inert and do not allow the growth of micro-
organisms, insects or rodents.
Handling, loading and unloading of the products should be carried out with care, to
avoid damage both the packaging and the boards’ edges.
Application and Personal Protection
For the selection and application of FIBRANgeo products all design requirements
should be taken into consideration.
FIBRANgeo products should be protected from impregnation, prior to and during
application.
The packaging film should be removed with care just before installation.
Working areas should be kept clean. Unnecessary or extensive contact of the skin and
eyes with products off-cuts, fibres and dust should be avoided, and protective wear
should be used (gloves, goggles, hats).
Sufficient ventilation of the working areas should be ensured, whilst power cutting tools
should always be provided with a mechanical system of dust intake.
Stonewool products are not considered hazardous waste. Waste disposal should be
carried out according to State and Local regulations.
DATE: 01/01/2014
Issue 5
THESSALONIKI
FIBRAN S.A.
th
6 km Thessaloniki-Oreokastro Rd.
P.O. Box 40306, A.C. 560 10
Thessaloniki, Greece info@fibran.gr
Tel. +30 2310 682 425 , 692 700 www.fibran.gr
Fax. +30 2310 683 131
FIBRAN reserves the right to alter or amend product specifications without notice. The information included in this
publication is correct to the best of our knowledge at the time of printing. Whilst FIBRAN will endeavour to ensure
publications are up to date, it is the user’s responsibility to check with the company the validity of the information
prior to materials’ use.
5/5
HEAT EXCHANGER

SECTION 3
WELDING DOCUMENTATION

3.2. Pipes drifting procedure

HEAT EXCHANGER

SECTION 3.1.
▹▹▷
3.1.1. WPS: Welding procedure specification (for manual welding)
3.1.2. WPQR: Welding procedure qualification record (for manual welding)
3.1.3. WPQ: Welding performance qualification (for manual welding)

3.1.4. WPS: Welding procedure specification (for orbital welding)
3.1.5. WPQR: Welding procedure qualification record (for orbital welding)
3.1.6. WPQ: Welding performance qualification (for orbital welding)

3.1.7. Filler material

HEAT EXCHANGER

SECTION 3.1.1.
WPS: Welding procedure specification (for manual welding)
▹▹▷

HEAT EXCHANGER

SECTION 3.1.2.
WPQR: Welding procedure qualification record (for manual welding)
▹▹▷

HEAT EXCHANGER

SECTION 3.1.3.
WPQ: Welding performance qualification (for manual welding)
▹▹▷

HEAT EXCHANGER

SECTION 3.1.4.
WPS: Welding procedure specification (for orbital welding)
▹▹▷

HEAT EXCHANGER

SECTION 3.1.5.
WPQR: Welding procedure qualification record (for orbital welding)
▹▹▷

HEAT EXCHANGER
SECTION 3.1.6.
WPQ: Welding performance qualification (for orbital welding)
▹▹▷
HEAT EXCHANGER
SECTION 3.1.7.
Filler material
▹▹▷
43126 PARMA / ITALY
TEL. 0521/993377 - FAX 0521/988690

Pagina 1 di 1
03/05/2016 1,2 mm 3,2 mm
2,0 mm

Valore / Value


510,0000(N/mm) 2 0,0000 (N/mm) 2
Tensile Strenght Rm
320,0000(N/mm) 2 0,0000 (N/mm) 2
Yield Strenght
Allungamento
30,0000(%) 0,0000 (%)
Elongation A


HEAT EXCHANGER
SECTION 3.1.8.
▹▹▷
HEAT EXCHANGER

SECTION 3.2.
Pipes drifting procedure
▹▹▷

PIPES DRIFTING PROCEDURE
BRAM‐COR SpA – Via G. Mercalli 12/A Quartiere S.P.I.P.
43122 – PARMA – Italy
6 DRIFTING MACHINE CALIBRATION AND REGULATION
6.1 The operator, after having chosen the suitable mandrels for the work (see the mandrel system's
instruction manual), will calibrate them based on the tube sheets and spacers thickness inserted
between the external and internal tube sheet.
6.2 After having configurated the drifting system according to the specifications the operator will
balance and calibrate it according to what is indicated in the drifting machine instruction manual.
7 DRIFTING ON DOUBLE TUBE SHEET HEAT EXCHANGER
7.1 After having inserted the pipes in the internal tube sheets (welded onto the heat exchanger's
shell) proceed with blocking the external tube sheets in the correct position,
inserting spacers of the appropriate thickness and locking the components as shown in Fig. 1.
EXTERNAL TUBE SHEETS
SPACERS
SPACERS
BLOCKING CLAMPS
fig.1
7.2 The distance between the pipes' ends and the external surface of the external tube sheets
must be uniform and of an adequate measurement (around 1 mm).
7.3 The internal surface of the pipes' ends must be greased.
7.4 In order to avoid the pipe rotation during the first drifting, the pipes' opposite extremity
which must then be drifted must be blocked by a second operator with an appropriate tool
(sharp and thin gripper) which prevents the pipe from moving and rotating.
7.5 The first drifting to be carried out is on the internal tube sheets. First are drifted the pipes in the
external edge of a tube plate, and gradually those towards the inside until a circumference of
radius equal to half of the external one is reached. Instead, the remaining pipes will be drifted
by proceeding from those at the centre of the tube sheet towards those the most externally.
The drifting will be achieved using a long mandrel which will only drift the pipes in proximity
of the internal plate tube, but not in the external one (fig. 2).
INTERNAL TUBE SHEET

EXTERNAL TUBE SHEET
fig.2
7.6 By proceding in the same way the pipes are drifted on the second internal tube sheet. For this
reason the presence of the second operator is unnecessary.
Page 2 of 4
7.7 Once the pipes on the internal tube sheets have been drifted proceed with the drifting on the
external ones. The procedure used is the same as the one described in point 7.5, with the
difference that a short mandrel will be used in the place of a long one in order to operate more
correctly (fig. 3). Also in this case the presence of a second operator in unnecessary.
EXTERNAL TUBE SHEET
fig.3
7.8 The drifting must be carried out so that the internal diameter of the pipe (Dim) after the drifting
is increased, in respect to the initial internal diameter (Di), of a quantity equal to
the clearance between the initial external diameter of the pipe (De) and the hole in the tube plate
(Df) in order to totally occupy the available space, which has undergone a further increment
due to a permanent deformation, equal to 5÷10% of the initial thickness of the pipe:
Dim = Di + (Df ‐ De) + [2 x (0,05 ÷ 0,1) x S ] ( see fig. 4)
Dim= drifted pipe diameter

S
Di= pipe internal diameter
Df= tube sheet hole diameter
De Di Dim Df
De= pipe external diameter
S= pipe thickness
fig. 4
7.9 During the drifting operations, the mandrels must be periodically:
a) cleaned with appropriate solvent (pure acetone);
b) checked whilst working (disassembling, inspection, operating test);
c) alternated, to avoid overheating them.
8 DRIFTING ON A SINGLE TUBE SHEET HEAT EXCHANGER
8.1 The pipes are inserted in the tube sheets (welded to the heat exchanger's shell)
8.2 The distance between the pipes extremity and the external surface of the tube sheet must be
uniform and in the adequate measurement (around 1 mm).
8.3 The internal surface of the pipes' extremity must be greased.
8.4 In order to avoid the pipe rotation during the first drifting, the pipes end opposite to that
which is drifted, must be blocked by a second operator with an appropriate utensil
(sharp and thin gripper) that prevents the pipe from moving and rotating.
8.5 First are drifted the pipes in the external edge of a tube sheet, and gradually those towards the
inside until a circumference of radius equal to half of the external one is reached. Instead, the
remaining pipes will be drifted by proceeding from those at the centre of the tube sheet toward
those the most externally. During this phase the short mandrel is used (fig. 5).
Page 3 of 4
SINGLE TUBE SHEET
fig.5
8.6 The drifting must be carried out in such a way that the internal diameter of the pipe (Dim) after
the drifting is increased, in respect to the initial internal diameter (Di), of a quantity equal to
the clearance between the initial external diameter of the pipe (De) and the hole in the tube plate
(Df) in order to totally occupy the available space, and which has undergone a further increment
due to a permanent deformation, equal to 5÷10% of the initial thickness of the pipe:
Dim = Di + (Df ‐ De) + [2 x (0,05 ÷ 0,1) x S ] ( see fig. 4)
9 CLEANING
9.1 After the drifting, the pipes and tube sheets must be carefully cleaned from the grease, using
appropriate solvents (pure acetone).
10 HYDRAULIC TEST
10.1 The hydraulic test, carried out at the pressure defined by the designer is conducted according
to the relative procedure; it must guarantee the absolute absence of leaks in the drifted pipes.
11 REPAIRS
11.1 If during the hydraulic test leaks are found in the drifted pipes, it will be necessary to carry out
repairs as follows:
a) pipes redrifting, increasing the torque by 5÷8%
b) pipes redrifting, using a mandrel of the adequate length but with a diameter increased by
10%
Page 4 of 4
HEAT EXCHANGER
SECTION 4
PASSIVATION REPORT
AND TESTING CERTIFICATES
4.2. Non‐destructive test certificates
HEAT EXCHANGER
SECTION 4.1.
Pickling and passivation report
▹▹▷
HEAT EXCHANGER

SECTION 4.2.
Non‐destructive test certificates
▹▹▷

CERTIFICATO DI ESAME V. & D.
V. & D. TEST CERTIFICATE

11880 M_3108-2_VVD_0
Job number: certificate number:
Matricola n°: Apparecchio: Scambiatore di Calore

Serial number:
3108-2 Vessel: Heat Exchanger

23779
Procedura di prova visiva:
PD_SOP_001_0
Visual test procedure:
Procedura di prova dimen.:
PD_SOP_002_0 - PD_SOP_012_0
Dimensional test procedure:
Si certifica che l'apparecchio in oggetto è stato sottoposto alle prove sotto menzionate alla presenza di:
We hereby certify that the following mentioned tests have been carried out on the vessel in object at the presence of:
Ispettore interno: ditta

Internal inspector:
Telolli I. firm:
BRAM-COR S.p.A.
Ispettore esterno: ditta

External inspector:
/ firm:
/
Controllo visivo giunti saldati Eseguito Giudizio: A = Accettabile / Acceptable

Welded joint visual test Executed Evaluation: R = Riparare / Repair
Difetti riscontrati (EN ISO 6520)/ Noticed defeacts (EN ISO 6520)
n° / n° Posizione / Position n° / n° Posizione / Position
Dimensioni controllate / Checked dimensions

Controllo dimensionale Eseguito Diametri interni / Internal diameters
Dimensional test Executed Diametri esterni / External diameters
Altezza (lunghezza) / Height (length)
Altre quote principali / Other main dimensions
Spessori controllati / Checked thicknesses

Controllo spessimetrico Eseguito Fasciami / Shells
Thickness test Executed Fondi / Bottoms
Flange / Flanges
Altri elementi principali / Other main parts

Internal inspector signature:
27/07/2018
Date:

Module: PD_MOD_VVD_000_0 Page 1 di 1

CERTIFICATO CONTROLLO LIQUIDI PENETRANTI
PENETRANT LIQUID TEST CERTIFICATE

11880 M_3108-2_VLP_0

3108-2
Serial number: Vessel: Heat Exchanger

23779

Internal inspector:
Telolli I. BRAM-COR S.p.A.
firm:

/ /
Stato delle superfici: Come saldato Molato / Lucidato

Surfaces conditions: As welded Grinded / Polished
Lavorato Altro
Machined Other
Designazione prodotti (EN 3452-2): Temperatura:

EN 571-1-IICd-1 20 °C
Products designation (EN 3452-2): Temperature:
Procedura di prova n°: Giunti ispezionati (secondo ISPESL Raccolta S):

PD_SOP_004_0
Test procedure n°: Tested joints (according to ISPESL S Regulation):
Pulizia superficiale: G.M. ICRI - G153

Surface cleaning: G.M. ICRI - G153 Longitudinali / Longitudinal 35%
Applicazione penetrante: G.M. ICRI - G151 Circolari / Circular 15%
Penetrant application: G.M. ICRI - G151 Incroci / Crosses 0%
Tempo di penetrazione: 5 min Bocchelli / Connections 40%
Penetration time: 5 min Boccaporto / Man-hole 0%
Rimozione eccessi: G.M. ICRI - G153 Sostegni / Fittings 10%
Excess removal: G.M. ICRI - G153 0%
Applicazione rivelatore: G.M. ICRI - G164 0%
Developer application: G.M. ICRI - G164 0%
Tempo di sviluppo: 10 min 0%
Developing time: 10 min
Tempo massimo di lettura: 10 min
Maximum checking time: 10 min Giudizio: A = Accettabile / Acceptable
Pulizia superficiale: G.M. ICRI - G153 Evaluation: R = Riparare / Repair
Surface cleaning: G.M. ICRI - G153

27/07/2018

Module: PD_MOD_VLP_003_0 Page 1 di 1


11880 M_3108-2_VRS_0

3108-2

disegno numero:
drawing number:
23779 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
9 (low. int.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018

Module: PD_MOD_VRS_002_0 Page 1 di 6


11880 M_3108-2_VRS_0

3108-2

disegno numero:
drawing number:
23779 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
10 (up. int.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018



11880 M_3108-2_VRS_0

3108-2

disegno numero:
drawing number:
23779 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
12 (int.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018



11880 M_3108-2_VRS_0

3108-2

disegno numero:
drawing number:
23779 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
15 (int.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018



11880 M_3108-2_VRS_0

3108-2

disegno numero:
drawing number:
23779 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
16 (low. ext.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018



11880 M_3108-2_VRS_0

3108-2

disegno numero:
drawing number:
23779 Test N° 1:

presenza di:
Test N° 2:
Ispettore interno:
Internal inspector:
Morlacchini P.
ditta: N.A.
firm:
BRAM-COR S.p.A.
Ispettore esterno:
External inspector:
/
Test N° 3:
ditta:
firm:
/
N.A.
Posiz. elemento:
Item position:
16 (up. ext.)
Ra max. acceptable:
0,5 µm
Test N° 4:
Procedura di prova:
IO 75_05_02
Esito della prova:
Test result:


Equipment model:
1206172

04/08/2018


HEAT EXCHANGER
SECTION 4.3.
Hydraulic test certificates
▹▹▷
Job number:
M_3108‐2_VPI_0

Serial number:
3108‐2 Vessel: Heat Exchanger
23779
Procedura di prova:
PD_SOP_000_0
Test procedure:
15 °C
Fluid temperature:
18 °C
Wall temperature:
Membratura: Lato mantello Pressione di prova:

17.3 bar
Side: Shell side Test pressure:
30 min 0÷25 bar
N. di serie
95755
Serial nuber
Esito della prova:
31/07/2018
Module: PD_MOD_VPI_001_1 Page 1 di 2

Job number:
M_3108‐2_VPI_0

Serial number:
3108‐2 Vessel: Heat Exchanger
23779
Procedura di prova:
PD_SOP_000_0
Test procedure:
15 °C
Fluid temperature:
18 °C
Wall temperature:
Membratura: Lato tubi Pressione di prova:

9.6 bar
Side: Pipes side Test pressure:
30 min 0÷16 bar
N. di serie
109731
Serial nuber
Esito della prova:
31/07/2018
Module: PD_MOD_VPI_001_1 Page 2 di 2

SECTION 2.3.
Components certification
▹▹▷

ATTACHMENT 3.
BRAM‐COR Flow Orifice
Type: For connections ¾" T.C.

 Material certificate
 Roughness certificate

TECHNICAL DOCUMENTATION – M_3108_TD SECTION: 2.3.

 Material certificate
N. Bolla 12619 del 26/07/2017 - Materiale BRG01830 - 316LTR9 18 L=3000
Quantità 12 kg - Colata 38529-11483 - N. Ord. 731094 - 40 - Rif. Cliente 1440

N. Bolla 12619 del 26/07/2017 - Materiale BRG01830 - 316LTR9 18 L=3000
Quantità 12 kg - Colata 38529-11483 - N. Ord. 731094 - 40 - Rif. Cliente 1440

Commessa n°: 11880 Certificato n°: M_3108_VRS_1 Foglio 1/1

Job number: 11880 certificate number: M_3108_VRS_1 Sheet 1/1
Matricola n°: N.A. Apparecchio: Valvola di sicurezza

Serial number: N.A. Vessel: Safety valve

disegno numero N.A.

drawing number N.A. Test N° 1:

sottoposto al tipo di prova sopra menzionato alla N.A.
presenza di:
We hereby certify that the above mentioned test has been

carried out on the vessel in object at the presence of:
Test N° 2:
Ispettore interno: Morlacchini P.
Internal inspector:
ditta: BRAM-COR S.p.A. N.A.

firm:
Ispettore esterno: /
External inspector:
Test N° 3:
ditta: /
firm:
N.A.
Posiz. elemento: N.A.
Item position: N.A.
Ra max. accettabile: 0,5 µm

Ra max. acceptable: 0,5 µm Test N° 4:
Procedura di prova: IO 75_05_02

Test procedure: IO 75_05_02 N.A.
Esito della prova:
Test result:

Modello strumento: TR-200 Matricola: 1206172

Equipment model: Serial number:
Firma ispettore: Data 24/07/2018

Inspector signature: Date
Firma ispettore: Data

Module: PD_MOD_VRS_002_0

ATTACHMENT 4.
COSTACURTA Demister
Type: Filter mono 415

 Test certificate


CERTIFICATO DI COLLAUDO
TEST CERTIFICATE
N° 0014102/18
Data/Date
Tipo/Type EN 10204 3.1 05.07.2018
OdV/Job/Progetto/Project (N)
11769 1
Cliente/Customer
1985900 BRAM-COR SPA
Ordine/Order Data/Date
1268 15.06.2018
Descrizione/Description
RETI SPECIALI VICO-Tex® Tipo MONO - Style 415
Materiale/Material
AISI 316L
Tipo/Type Dimensioni/Dimensions
316L FILO DIA. 0.16 mm
Colata/Heat
KDGX00457
Analisi Chimica/Chemical Requirements
C MN P S SI CR NI MO
MIN 16.00 10.00 2.00
MAX 0.03 2.00 0.045 0.03 1.00 18.00 14.00 3.00
Proprietà Meccaniche/Mechanical Properties
ALLEGATO CERTIFICATO DI ACCIAIERIA

THE MILL CERTIFICATE IS ATTACHED
RIEPILOGO / SUMMARY
Pos./Item Disegno/Drawing Marca/Item
10
CONTROLLO DIMENSIONALE E CONFORMITÁ ALL'ORDINE - DIMENSIONAL CHECK AND CONFORMITY TO THE OREDER REQUIREMENTS
THIS DOCUMENT IS REPRODUCED BY A COMPUTERIZED SYSTEM AND IS CONFORM TO THE ORIGINAL

All. 0014102/18 Pag.1
All. 0014102/18 Pag.2

ATTACHMENT 5.
GRUNDFOS Multistage Pump
Type: CRN




ATTACHMENT 6.
ENDRESS+HAUSER Capacitive level transmitter
Type: FMI51

 Inspection certificate


Abnahmeprüfzeugnis nach EN 10204 - 3.1
Inspection certificate acc. to EN 10204 - 3.1
Zeugnis-Nr. / Certificate no. 3019210831/3032099849_50_1
Seite / page 1 / 2
Es wird bescheinigt, dass die gelieferten Erzeugnisse den Vereinbarungen bei der Bestellung
entsprechen. Darüber hinaus wird bescheinigt, dass bei der Herstellung der nachstehend aufgeführten
Erzeugnisse die vorgeschriebenen Prüfungen und / oder die zusätzlich aufgeführten Prüfungen nach den
bestehenden Prüfvorgaben durchgeführt und die erforderlichen Freigaben erteilt wurden. Die unten
aufgeführten Prüfungen wurden unter Aufsicht einer dazu autorisierten, unabhängigen Stelle
durchgeführt.
It is certified that the products supplied are in compliance with the requirements of the order.
Furthermore, it is confirmed that during the manufacturing of the subsequently listed products the
specified inspections and / or the additionaly ordered inspections have been performed according to the
valid procedures and the necessary releases have been given.
The subsequently listed inspections have been performed by especially authorized personnel.
Kunde / Customer: BRAM-COR S.P.A.

VIA G.MERCALLI, 12/A -Q.RE SPIP
IT-43100 PARMA
Kunden Bestell-Nr. / Customer order no.: 1255
E+H Auftrags-Nr. / E+H order no.: 3032099849
_____________________________________________________________________
Pos / item Menge / Qty Produktbezeichnung / Description
_____________________________________________________________________
0050 1 ST / PC FMI51-A1ATJJB1A1D
Liquicap M FMI51
S/N TAG
N70283010F0
Kennzeichnung / Marking 0RE2H

Teil / Part Adapter / adapter
Hersteller / Manufacturer OLARRA
Zeugnis-Nr. / Certificate No. 318431
Schmelze-Nr. / Heat No. 434423
Kennzeichnung / Marking 0PRN3

Teil / Part Konushülse / cone case
Hersteller / Manufacturer UGITECH
Zeugnis-Nr. / Certificate No. 82050865 000010
Kennzeichnung / Marking 0R5A8

Teil / Part Stab / rod
Hersteller / Manufacturer UGITECH
Zeugnis-Nr. / Certificate No. 82042263 000010
Abnahmeprüfzeugnis nach EN 10204 - 3.1
Inspection certificate acc. to EN 10204 - 3.1
Zeugnis-Nr. / Certificate no. 3019210831/3032099849_50_1
Seite / page 2 / 2
31.07.2018
Endress+Hauser SE+Co. KG Christian Doll

DE-79689 Maulburg - Abnahmebeauftragter -
- Inspector -
Dieses Zeugnis wurde elektronisch nach EN 10204 erstellt und ist ohne Unterschrift gültig.
Bei Rückfragen wenden Sie sich bitte an Ihre Endress+Hauser-Vertriebszentrale.
This document was generated electronically acc. to EN 10204 and is valid without signature.
If you have any queries, please contact your Endress+Hauser Sales Center.
Larrondo LOIU (VIZCAYA) España
P.O. Box 1.323/48080 Bilbao
Tel. 34-(4) 4 71 13 00
Fax.34-(4) 4 53 16 36
GUENTHER + SCHRAMM GMBH.

HELDENHEIMER STRASSE 65 Trade Mark - Zeichen des Lieferwerkes
Anagrama del suministrador
73447 OBERKOCHEN - ALEMANIA
Works Inspector Stamp - Werkssachverständiger
Sello del Inspector
Certificate type - APZ Nach Certificate nº - Prüf-Nr Date - Datum - Fecha

Certificado tipo EN 10204/3.1 Certificado nº 318431
26 - 06 - 2017
Our order Nº Heat Your order Nº
Werks - Nr 635615 Schmelze 434423 Bestell - Nr 4500319464-2000
Nº de Referencia Colada Pedido Nº
Steel Grade According to
Werkstoff X-2-CRNIMO-18-14-3 / 1.4435 Entsprechend EN 10.272-2007.
Calidad Corresponde
Shape and Size - Gegenstad Tolerance - Toleranz Bundles Bars Weight
Perfil y dimensión Tolerancia Bunde 2 Stäbe Gewitcht 2332 Kg
RUND 55 mm k 12 /ISO 286-1 /10060 Bultos Barras Peso
Requirements - Anforderungen - Exigencias

EN 10.088-3.2014. PED 2014/68/EU, Annex I, Parag.4.3/DGR 2014/68/EU
ASTM A 479 / A 479M-15. Anhang I Absatz 4.3 Certificate/Zertifikat Nr. 348/2008/MUC
AD-2000-W2/W10.
NACE MR-0175/ISO 15156-3 2015.
NACE MR-0103/ISO 17945-2015.
ASTM A 484 / A 484M-15.
Type 316 UNS S31600-Type 316L UNS S31603.
N°.410000144E.
Conformity letter/Zustimmungsschreiben TUV BADEN 28.01.1969
Waiving of Countersign/Gegenzeichnungsverzicht:01.03.1977
Melting process / Erschmelzungsart / Proceso de Fusión Heat treatment / Wärmebehandlung / Tratamiento térmico
1060C 4H/Std WATER/WASSER/AGUA
E.A.F. / A.O.D.
Solution annealed/Abgeschreckt/Hipertemple-Turned/Drehen/Torneado-
Test results - Ergebnis der Prüfungen - Resultados de los ensayos

Dimension of Specimen Rp0,2% Rp 1% Rm A A Z Hardness Impact test / Kersbschlag / Resiliencia
Abmessungen des Probestabes N/mm2 N/mm2 N/mm2 %L 5D %L 4D % Härte ISO V Jules
Medida de las probetas MPA MPA MPA HBw
RD. 10,00 mm. Min. 200 235 500 40 100

Max. 700 215
Temperature ºC Spec. Nº. 1 329 367 604 48 51 73 170 225/227/230
20 Probe Nr.
2 334 372 608 47 50 72 170 220/222/226
Pro Nº.
C Si Mn P S Cr Mo Ni N Co
Min. 0,010 17,00 2,50 12,50
Max. 0,030 1,00 2,00 0,045 0,020 19,00 3,00 15,00 0,1000
0,014 0,32 1,46 0,034 0,016 18,00 2,57 12,50 0,0320 0,16
Visual and dimensional inspection Radioactivity inspection Antimixing test Grain Size
Besichtingung und Ausmessung O.K. Radioaktivitätskontrolle O.K. Spektrosk Verwechslungspr O.K. Korngrösse 6-7
Control visual y dimensional Control de Radioactividad Antimezcla Tamaño de grano
Remarks - Bemerkungen - Observaciones
IC test acc./IK prüfung nach EN ISO 3651-2/98 Met.A. OK EDV / EDP
Ferrite % = 1,7 Acc. EN 10.204
IC test acc./IK prüfung nach ASTM A 262 E.15. OK Marian Tejedo
Quality Mng.
Works Inspector
Der Werkssachverständige
Inspector de fábrica
Impresa produttrice/Hersteller/Manufacturer ABNAHMEPRUEFZEUGNIS 3.1
UGITECH ITALIA S.r.l CERTIFICAT DE RECEPTION 3.1
Via G. Di Vittorio, 34/36 INSPECTION CERTIFICATE 3.1
20068 Peschiera Borromeo ----------------------------------------
Italien EN 10204 / 3.1
5 3 1
Numero / Nummer / Number Ordine produt. / Auftrag / Prod. Order N° colata / Schmelzen Nr / Heat N° n° lotto / Chargen / Batch
82042263 000010 4 I16401738000 11-1 641079 11-2 1640173800 11-3
Certificazione - Werkzeugnis - Certificate Marchio fabbrica
AD 2000-MERKBLATT W0 Herstellerzeichen
Pressure Equipment Directive Supplier's Mark 97
2014/68/EU Annex I Section 4.3 Marchio dell' esperto

ISO 9001 EN 9100 Prufstempe
ISO/TS 16949 EN 9120 lnpector's stamp 96
99 98 98-2
UGIMA 4435 STAB GESCHLIFFEN POLIERT ABGESCHRECKT KALTVERFORMT H9 RUND 8,000MM LONG
. 4,000M +100,000MM -0,000MM
Prodotto UGIMA 4435 BARRA RETTIFICATO LUCIDO SOLUBILIZZATA DÉF. A FREDDO H9 TONDO 8,000MM LONG. 4,000M +
Erzeugnisform UGIMA 4435 STAB GESCHLIFFEN POLIERT ABGESCHRECKT KALTVERFORMT H9 RUND 8,000MM LONG. 4,000M +100
Product UGIMA 4435 BAR GROUND POLISHED SOLUT° ANNEALED & COLD WORKED H9 ROUND 8,000MM LONG. 4,000M +100 6
Cliente - Besteller - Purchaser Ordine cliente - Kundebestellnummer - Purchase order number Ordine - Bestellung - Order
14112 Endress + Hauser GmbH + Co. KG 9 4500310328 10 769665 10 20

Norma di riferimento / Besugsnorm / Standard for reference
AD 2000 W2 ED 02.2009 1.4435 AD 2000 W10 ED 05.2016 1.4435
EN 10272 ED08 1.4435 BASLER NORME ED97, BN2 1.4435
NACE MR0175/ISO 15156-3:2015. 316/316L NACE MR0103/ISO 17945:2015. 316/316L
ASTM A479/A479M-16a TYPE 316L/316 ASTM A484/A484M-15
12-2
Specifica cliente / Kundenspezifikation / Customer's specification
410000143-E X2CRNIMO18-14-3 E 30.06.14 12-3
Numero Profilo Dimensione Lunghezza Peso
Stueckzahl Profile Ausmessung Laenge Gewicht
Pieces Nbr Shape Dimension Length Weight
4 18 RO 19 8,000 MM 21-1 4,000 21-2 2062 KG 22
Richiesta / Vorschrift / Required 42 43 44 45 46 47 48 49
Modo di Prova numero %C % SI % MN % NI % CR % MO %S %P
elaborazione Probenummer Min 12,5000 17,0000 2,5000
Erschmelzungsart Test number Max 0,0300 1,0000 2,0000 15,0000 19,0000 3,0000 0,0300 0,0450
Melting process
EAF +AOD CUU1 colata/ Schmelzen / Heat 0,0170 0,4790 1,5590 12,5770 17,0690 2,5370 0,0210 0,0290
+CC 38 39A Prodotto/ Erzeugnisform/Product
Richiesta / Vorschrift / Required 50 51 52 53 54 55 70 71 72 73 74 75

%N % TI
Min
Max 0,1000
colata/ Schmelzen / Heat 0,0340 0,0020

Prodotto/ Erzeugnisform/ Product
Richiesta / Vorschrift / Required 76 77 78 79 80 81 82 83 84 85 86 87
Min
Max
colata/ Schmelzen / Heat

Prodotto/ Erzeugnisform/ Product
Hiermit erklären wir, dass das zitierte Produkt mit den Anforderungen des Vertrags konform ist und den Anforderungen Peschiera Borromeo il 14.02.2017
sowie den geltenden Normen und Vorschriften nach den durchgeführten Kontrollen und Prüfungen in jeder Hinsicht entspricht,
Firma dell'ispettore
vorbehaltlich gelistete Ausnahmen oder Bedenken von dieser Konformitätserklärung; Dieses Dokument ist durch eine digitale
Unterschrift gültig. Produkt hergestellt gemäß REACH-Verordnung. 66-1 Der Werksachverständige
We declare that the mentioned product is in compliance with the requirements of the contract and that, after checks The work inspector
and tests, it meets in all respects the specified requirements and applicable standards and regulations, except reservations or
exceptions as listed in this declaration of conformity ; Document validated by electronic signature. Material manufactured in
the REACH regulation respect. 66-2 040001058695 Page 1/2 63
Impresa produttrice/Hersteller/Manufacturer ABNAHMEPRUEFZEUGNIS 3.1
UGITECH ITALIA S.r.l CERTIFICAT DE RECEPTION 3.1
Via G. Di Vittorio, 34/36 INSPECTION CERTIFICATE 3.1
20068 Peschiera Borromeo ----------------------------------------
Italien EN 10204 / 3.1
5 3 1
Numero / Nummer / Number Ordine produt. / Auftrag / Prod. Order N° colata / Schmelzen Nr / Heat N° n° lotto / Chargen / Batch
82042263 000010 4 I16401738000 11-1 641079 11-2 1640173800 11-3
Lim. Di snervamento Resistenza
traz.
Allungamento Strizione Durezza-Haerte-Hardness
Streckgrenze Zugfestigkeit Bruchdehnung Einschnurung
T°C Yield Strength Tensile Elongation Red area HB HV HRB HRC
24 90 Rp 0,2% Rp 1% Rm A5D A4D Z
°C Mpa Mpa Mpa % % %
Min 20 200 235 500 20
13 Max 20 900 235 22
Min
Max
Prova numero CUU1 1 L 20 480 611 665 26 28 70 203 18
Probenummer
Test number
39B
stato di riferimento / treatment on test
sample / Probestreifenbehandlung
14 25 26A 26B 27 28 89 29 30 88 100 37

Tasso di corrosione Resilienza-Kerbschlagzaehigkeit-Notch Toughness
Forging ratio Tipo Senso Valori individuali Media Espansione laterale
Verschmiedungsgrad Form T°C Richtung Min Einzelwerte Mittelwerte Seitliche Breitung
Type Direction Individual values Average Lateral Expansion
0
101 31 33 32 95 35 36 91
Stato di consegna / Lieferzustand / As °C J J
delivered
13
Abgeschreckt kaltverformt
stato di riferimento / treatment on test

sample / Probestreifenbehandlung
14
ZUSTIMMUNGSSCHREIBEN DER TÜV SÜD LIEGTVOR. AUF GEGENZEICHNUNG WIRD VERZICHTET. 56
KORNGRÖSSE >= 2 NACH ASTM E112/GRAIN SIZE>=2 ACCORDING TO ASTM E112
INTERKRISTALLINE KORROSION BESTÄNDIG NACH ASTM A262 METHOD E
VERWECHSLUNGSPRÜFUNG NACH SPEKTROSKOPISCHER PRÜFMETHODE : I.O.
SICHT- & MASSPRÜFUNG NACH NORM DIN EN 10272 2016-11 : I.O.
FREI VON RADIOAKTIVER STRAHLUNG & FREI VON TOXISCHEN WIRKSTOFFEN
ggggggggggggggg
DELTA-FERRIT = $$FERRIMAX$£ DELTA FERRITE = 0,5%
TÜV LETTER OF APPROVAL IN OUR POSSESSION. WE ABSTAIN OF A COUNTERSIGNATURE
INTERCRYSTALLINE CORROSION RESISTANT ACC.TO ISO 3651-2 PRACTICE A
INTERCRYSTALLINE CORROSION RESISTANT ACCORDING TO ASTM A262 PRACTICE E.
ANTIMIXING TEST PERFORMED TO SPECTROSCOPIC METHOD : CONFORM
SURFACE & DIMENSIONS ARE CONTROLLED TO EN 10272 2016-11
FREE OF RADIOACTIVITY STATEMENT & TOXIC PRODUCT
ISSUED IN AGREEMENT WITH TÜV SÜDDEUTSCHLAND - MANNHEIM OFFICE
AUSGESTELLT IM EINVERNEHMEN MIT DEM TÜV SÜDDEUTSCHLAND - MANNHEIM OFFICE
92 94
Hiermit erklären wir, dass das zitierte Produkt mit den Anforderungen des Vertrags konform ist und den Anforderungen
sowie den geltenden Normen und Vorschriften nach den durchgeführten Kontrollen und Prüfungen in jeder Hinsicht entspricht, Peschiera Borromeo il 14.02.2017
vorbehaltlich gelistete Ausnahmen oder Bedenken von dieser Konformitätserklärung; Dieses Dokument ist durch eine digitale
Unterschrift gültig. Produkt hergestellt gemäß REACH-Verordnung. 66-1 Firma dell'ispettore
We declare that the mentioned product is in compliance with the requirements of the contract and that, after checks Der Werksachverständige
and tests, it meets in all respects the specified requirements and applicable standards and regulations, except reservations or
exceptions as listed in this declaration of conformity ; Document validated by electronic signature. Material manufactured in The work inspector
the REACH regulation respect. 66-2
040001058695 Page 2/2 63

Endress+Hauser GmbH+Co. KG
Postfach/P.O. Box 1261
Final Inspection Report / Endprüfprotokoll
D-79690 Maulburg The manufacturer confirms that all measuring equipment used to assure the quality of the products
has been calibrated and is traceable (e.g. DKD/DAkkS, NIST, NABL...) to national or international
standards.
Der Hersteller bestätigt, dass die zu Qualitätsprüfungen des Erzeugnisses eingesetzten Messmittel
gültig kalibriert waren und auf nationale (z.B. DKD/DAkkS, NIST, NABL...) bzw. internationale
Normale rückführbar sind.
Liquicap M
TAG number Messstellen-Nummer
Order code Bestellcode FMI51-A1ATJJB1A1D

Serial number Seriennummer N70283010F0
Extended order code Erweiterter Bestellcode FMI51-A1ATJJB1A1D
Calibration 0% Kalibration 0% 35pF

Calibration 100% Kalibration 100% 230pF
Output type Ausgang FEI50H; 4-20mA HART
Software version Softwareversion
Probe length L1 Sondenlänge L1 L1 = 450 mm
Inactive probe length L3 Inaktive Sondenlänge L3
BRAM-COR S.P.A.
Customer order number Auftragsnummer des Kunden 1255
E+H sales order number E+H Auftragsnummer 3019210831 000050
Internal order number Interne Auftragsnummer 3032099849/0050
Ambient temperature Umgebungs- Temperatur 20°C ( ± 5 °C )
Ambient humidity Umgebungs-Luftfeuchte 65 % rel.F ( ± 20 % rel.F )
Ambient pressure Umgebungs-Luftdruck 1013 mbar ( ± 20 mbar )
Test step Testschritt Test result Testergebnisse
Probe: Sonde:
Probe Test Sondentest passed bestanden
Electronic Insert: Elektronik- Einsatz:

Functional Test Funktionstest passed bestanden
High Voltage Test Hochspannungstest passed bestanden
Complete Device: Komplettgerät:

Start-up Test Einschalttest passed bestanden
We confirm that all tests, according to the Quality Plan (QP), Wir bestätigen, dass alle Tests aus dem Qualitätsplan (QP),
have been performed successfully. erfolgreich durchgeführt wurden.
At the time of verification, the measuring points of the device Das Gerät entsprach zum Zeitpunkt der Prüfung an den aufgeführten
indicated above were in compliance to the published valid Messpunkten den gültigen technischen Spezifikationen (TI).
technical specification (TI).
TI00401F
This document was generated electronically and is valid Dieses Dokument wurde elektronisch erzeugt und ist ohne Unterschrift
without signature. gültig.
Date of inspection / Prüfdatum 31. Jul 2018

– End of document –
71111808 / 250002944 – Ende des Dokumentes –

ATTACHMENT 7.
JUMO Pressure transducer
Type: dTrans p31 ‐ 402050

 Calibration certificates



 Calibration certificate

ATTACHMENT 8.
GEMU Manual Membrane Valve
Type: 601
Type: 612

 Material and conformity certificates for 601
 Material and conformity certificates for 612


 Material and conformity certificates
for 601

for 612

ATTACHMENT 9.
GEMU Pneumatic Membrane Valve
Type: 625




ATTACHMENT 10.
UNIVERSAL Safety valve
Type: S25C

 Material certificates
 Conformity declaration


 Material certificates

 Conformity declaration
DICHIARAZIONE DI CONFORMITA' UE
VALVOLE DI SICUREZZA IVᵃ CATEGORIA
UE CONFORMITY DECLARATION
SAFETY VALVES CLASS IVᵃ
NUMERO OMOLOGAZIONE
UNIVERSAL srl
NUMBER APPROVAL
Via Molino Franzini 13 - Loc. Trevozzo 29031 Alta Valtidone - Piacenza Italy TEL. 0523997677 FAX 0523997354
0496
DIRETTIVA EUROPEA PED 2014/68/EU (PED) VALUTAZIONE DELLA CONFORMITA' EFFETTUATA DA DNV-GL MODULO B+D CERTIFICATO N°2666-
2013 E N°133872-2013-CE-ITA-ACCREDIA PROGETTAZIONE SECONDO EN ISO 4126-1 / I.S.P.E.S.L. RACCOLTA E FASCICOLO E.1.D.2
PED 2014/68/EU NOTIFY BODY: DNV-GL MODULE B+D CERTIFICATE NUMBER 2666-2013 E N°133872-2013-CE-ITA-ACCREDIA
DESIGNED AS PER EN ISO 4126-1 / I.S.P.E.S.L. RACCOLTA E FASCICOLO E.1.D.2
TIPO
TYPE S25C N° 3032
PRESSIONE DI TARATURA AL BANCO A TEMPERATURA AMBIENTE

SET PRESSURE ON BENCH AT AMBIENT TEMPERATURE
4,90 bar
FLUIDO VAPORE SATURO

FLUID STEAM
PORTATA MASSIMA :
1141,84 Kg/h
MASS FLOW RATE:
MATERIALI - MATERIALS
- LOTTO CORPO - LOTTO ATT. ENTRATA
- BODY LOT
4/16 - INELT CONN. LOT
- MARCHIO DI FABBRICA
- TRADE MARK
- CORPO VALVOLA ACCIAIO INOX 316 L
- BODY 316 L STAINLESS STEEL
- SEDE VALVOLA e ATT. ENTRATA ACCIAIO INOX 316 L
- INLET CONNECTION AND SEAT 316 L STAINLESS STEEL
- OTTURATORE ACCIAIO INOX 316 L
- DISC 316 L STAINLESS STEEL
- STELO ACCIAIO INOX 316 L
- SPINDLE 316 L STAINLESS STEEL
- VITE REGOLAZIONE ACCIAIO INOX 316 L
- ADJUSTING SCREW 316 L STAINLESS STEEL
- CHIUSURA ACCIAIO INOX 316 L
- LOCKING SCREW 316 L STAINLESS STEEL
- MOLLA ACCIAIO INOX 302
- SPRING 302 STAINLESS STEEL
DIMENSIONI / DIMENSIONS - GUARNIZIONE TENUTA METALLICA
d0 Ø 24,2 d1 Ø 32 - GASKET METAL TO METAL SEAT
DN 1"1/2 T.C. 0 B 60 - LEVA _
A Ø 64 C 60 - LEVA _
DN1 2" T.C. 0 D Ø 70
H 219 A1 Ø 64,0
ATTACCO ENTRATA DIAMETRO DI PASSAGGIO mm. SEZIONE DI PASSAGGIO (A) mm²
1"1/2 T.C. 24,2 459,727
INLET CONNECTION FLOW DIAMETER mm. FLOW AREA (A) mm²
ATTACCO USCITA DIAMETRO ORIFIZIO USCITA mm. AREA ORIFIZIO USCITA mm²
2" T.C. 32 803,84
OUTLET CONNECTION OUTLET DIAMETER mm. OUTLET FLOW AREA mm²
SCARTO DI CHIUSURA SOVRAPRESSIONE ALZATA
10% 10% 10,0 mm. Kdr 0,738 Kv -
BLOWDOWN OVERPRESSURE LIFT
CAMPO DI TARATURA P.N. TEMPERATURA DI ESERCIZIO
3,5 - 8,0 40 bar - 20°C ÷ +200°C
SET PRESSURE ADJUSTMENT RANGE N.P OPERATING TEMPERATURE
CALCOLO DELLA PORTATA DI SCARICO/DISCHARGE CAPACITY CALCULATION

VEDI FORMULE SUL RETRO/SEE EQUATIONS ON THE BACK
PRESSIONE DI SCARICO (P0) CONTROPRESSIONE ASSOLUTA (Pb)
RELIEVING PRESSURE (P 0 ) 6,39 bar ABSOLUTE BACK PRESSURE (Pb) bar 1
FUNZIONE ESPONENTE ISOENTROPICO (C) TEMPERATURA DI SCARICO (T0)

FUNCTION ISOENTROPIC EXPONENT (C) 0,635 2,5167 RELIEVING TEMPERATURE (T 0 ) 434 °K / 161 °C
MASSA MOLECOLARE (M) FATTORE DI COMPRIMIBILITÀ (Z) VOLUME SPECIFICO (V)
MOLAR MASS (M) - kg/kmol COMPRESSIBILITY FACTOR (Z) 1 SPECIFIC VOLUME (V) 0,297000 m3/kg
PESO SPECIFICO A 20° C (γ) kg/m³ per GAS/for GASES CALORE DI VAPORIZZAZIONE (r)
0,00 kCal/h
SPECIFIC WEIGHT 20° C ( γ ) kg/dm³ per LIQUIDI/for LIQUIDS VAPORISATION HEAT (r)
I materiali impiegati sono idonei per il funzionamento alle condizioni di esercizio sopra riportate e per il fluido a contatto. VERIFICA PERIODICA DI FUNZIONAMENTO
La valvola ha subito con buon esito il controllo finale compresa la prova idraulica a 60 bar. ATTENERSI AL
The employed materials are suitable to be used on the operating conditions metioned in this certificate and for the fluid in touch. D.Leg. N°329 DEL 01/12/2004
The safety valve has passed a last check including hydraulic test at 60 bar with a good result.
FIRMA AUTORIZZATA PER L'UNIVERSAL NELLA COMUNITA' EUROPEA/UNIVERSAL AUTHORIZED RAPRESENTATIVE WITHIN THE EUROPEAN COMMUNITY
TITOLO/TITLE DATA EMISSIONE CERTIFICATO ANNO DI FABBRICAZIONE
NOME/NAME
RESPONSABILE TECNICO DATE OF CERTIFICATE YEAR OF MANUFACTURE
TECHNICAL DIRECTOR MARIO MACCIO'
19/07/2018 2018
MANUALE USO E MANUTENZIONE SCARICABILE ALLA PAGINA DOWNLOAD DEL SITO www.universalvalves.it
OPERATING AND MAINTENANCE TO BE DOWNLOADED FROM OUR WEB SITE www.universalvalves.it


Commessa n°: 11880 Certificato n°: M_3108_VRS_1 Foglio 1/1

Job number: 11880 certificate number: M_3108_VRS_1 Sheet 1/1
Matricola n°: N.A. Apparecchio: Valvola di sicurezza

Serial number: N.A. Vessel: Safety valve

disegno numero N.A.

drawing number N.A. Test N° 1:

sottoposto al tipo di prova sopra menzionato alla N.A.
presenza di:
We hereby certify that the above mentioned test has been

carried out on the vessel in object at the presence of:
Test N° 2:
Ispettore interno: Morlacchini P.
Internal inspector:
ditta: BRAM-COR S.p.A. N.A.

firm:
Ispettore esterno: /
External inspector:
Test N° 3:
ditta: /
firm:
N.A.
Posiz. elemento: N.A.
Item position: N.A.
Ra max. accettabile: 0,5 µm

Ra max. acceptable: 0,5 µm Test N° 4:
Procedura di prova: IO 75_05_02

Test procedure: IO 75_05_02 N.A.
Esito della prova:
Test result:

Modello strumento: TR-200 Matricola: 1206172

Equipment model: Serial number:
Firma ispettore: Data 24/07/2018

Firma ispettore: Data

Module: PD_MOD_VRS_002_0

SECTION 2.4.
Instruments used for internal test
▹▹▷

2.4.1. Calibration report of manometer
2.4.2. Roughness gauge calibration report


SECTION 2.4.1.
Calibration report of manometer
▹▹▷

Centro di Taratura LAT N° 093
Calibration Centre
LAT N° 093
Laboratorio Accreditato di
Membro degli Accordi di Mutuo
Taratura Riconoscimento
EA, IAF e ILAC
Signatory of EA,IAF and ILAC

Mutual Recognition Agreements
FORZA
PRESSIONE
MOMENTO 41126 Cognento MODENA
TORCENTE Via Bottego, 33/A
Tel. +39 059 346441
FORCE
Fax +39 059 2922007
PRESSURE srl
TORQUE E-mail: lab@aep.it
Pagina 1 di 4
Page 1 of 4
CERTIFICATO DI TARATURA LAT 093 131716P
Certificate of Calibration
- data di emissione 2016/06/27

date of issue Il presente certificato di taratura è emesso in base
- cliente STRUMENTAZIONE INDUSTRIALE S.r.l. all'accreditamento LAT N° 093 rilasciato in accordo
customer ai decreti attuativi della legge n. 273/1991 che ha
Via Barro, 56/58 istituito il Sistema Nazionale di Taratura (SNT).
28045 INVORIO (NO) ACCREDIA attesta le capacità di misura e di
- destinatario - taratura, le competenze metrologiche del Centro e
receiver la riferibilità delle tarature eseguite ai campioni
nazionali e internazionali delle unità di misura del
Sistema Internazionale delle Unità (SI).
Questo certificato non può essere riprodotto in
- richiesta 20676 modo parziale, salvo espressa autorizzazione
application
scritta da parte del Centro.
- in data 2016/06/09
date
This certificate of calibration is issued in compliance with the
Si riferisce a accreditation LAT N° 093 granted according to decrees
Referring to connected with Italian law No. 273/1991 which has
established the National Calibration System. ACCREDIA
- oggetto Manometro digitale
attests the calibration and measurement capability, the
item (Digital pressure gauge)
metrological competence of the Centre and the traceability
- costruttore AEP transducers of calibration results to the national and international
manufacturer
standards of the International System of Units (SI).
- modello LAB DMM This certificate may not be partially reproduced, except with
model
the prior written permission of the issuing Centre.
- matricola 916801
serial number
- data di ricevimento oggetto -
date of receipt of item
- data delle misure 2016/06/27
date of measurements
- registo di laboratorio RL/131716P
laboratory reference
I risultati di misura riportati nel presente Certificato sono stati ottenuti applicando le procedure di taratura citate alla pagina seguente, dove sono
specificati anche i campioni o gli strumenti che garantiscono la catena di riferibilità del Centro e i rispettivi certificati di taratura in corso di validità.
Essi si riferiscono esclusivamente all’oggetto in taratura e sono validi nel momento e nelle condizioni di taratura, salvo diversamente specificato.
The measurement results reported in this Certificate were obtained following the calibration procedures given in the following page, where the reference standards or
instruments are indicated which guarantee the traceability chain of the laboratory, and the related calibration certificates in the course of validity are indicated as well.
They relate only to the calibrated item and they are valid for the time and conditions of calibration, unless otherwise specified.
Le incertezze di misura dichiarate in questo documento sono state determinate conformemente alla Guida ISO/IEC 98 e al documento EA-4/02.
Solitamente sono espresse come incertezza estesa ottenuta moltiplicando l’incertezza tipo per il fattore di copertura k corrispondente ad un
livello di fiducia di circa il 95 %. Normalmente tale fattore k vale 2.
The measurement uncertainties stated in this document have been determined according to the ISO/IEC Guide 98 and to EA-4/02. Usually, they have been estimated as
expanded uncertainty obtained multiplying the standard uncertainty by the coverage factor k corresponding to a confidence level of about 95%.
Normally, this factor k is 2.
Il Responsabile del Centro
Head of the Centre
p.i. Paolo Lioi
Firma Digitale - Digital Signature

Calibration Centre
41126 Cognento MODENA Laboratorio Accreditato di LAT N° 093
Via Bottego, 33/A Taratura Membro degli Accordi di Mutuo
Tel. +39 059 346441 Riconoscimento
Fax +39 059 2922007 EA, IAF e ILAC
E-mail: lab@aep.it Signatory of EA,IAF and ILAC

www.aep.it Mutual Recognition Agreements
CERTIFICATO DI TARATURA LAT 093 131716P Pagina 2 di 4

Certificate of Calibration Page 2 of 4
Di seguito vengono riportate le seguenti informazioni: In the following, information is reported about:
- la descrizione dell’oggetto in taratura (se necessaria); - description of the item to be calibrated (if necessary);
- l’identificazione delle procedure in base alle quali sono state eseguite le tarature; - technical procedures used for calibration performed;
- gli strumenti/campioni che garantiscono la catena della riferibilità del Centro; - instruments or measurement standards which guarantee the traceability chain of the Centre;
- gli estremi dei certificati di taratura di tali campioni e l’Ente che li ha emessi; - relevant calibration certificates of those standards with the issuing Body;
- il luogo di taratura (se effettuata fuori dal Laboratorio); - site of calibration (if different from the Laboratory);
- le condizioni ambientali e di taratura; - calibration and environmental conditions;
- i risultati delle tarature e la loro incertezza estesa. - calibration results and their expanded uncertainty.
I risultati di misura riportati nel presente Certificato sono stati ottenuti applicando le procedure N. PTQ021r10
The measurement results reported in this Certificate were obtained following procedures No.
La catena di riferibilità ha inizio dai campioni di prima linea N. V-1668 (cod. PMP07-07), 64242 (cod. AMM04-07)
Traceability is through first line standards No.
muniti di certificati validi di taratura rispettivamente N. 14-0738-02, 14-0738-03 (INRIM), LAT 044 M140423
validated by certificates of calibration No.
CONDIZIONI AMBIENTALI DI TARATURA (CALIBRATION CONDITIONS)
Temperatura ambiente (Room temperature): 23,2 °C ± 1,0 °C
Umidità relativa (Relative humidity): 58,1 % ± 5 %
Pressione atmosferica (Atmospheric pressure): 1012 mbar ± 3 mbar
SISTEMA CAMPIONE DI SECONDA LINEA (SECOND LINE SAMPLING SYSTEM)
Oggetto (Device): Bilancia di pressione numerica (Digital pressure balance)
Costruttore (Manufacturer): Desgranges et Huot
Tipo (Type): 21000
N° di Serie (Serial number): 4638
Testa di misura (Mounting block): 410
Campo di misura (Measurement range): (0 ÷ 60) bar
Modalità di taratura (Calibration procedure) : Pressione relativa alla pressione atmosferica
(Pressure relative to the atmospheric value)
Certificato di taratura N° (Certificates of calib. No): LAT 093 44316P
Incertezza estesa (Expanded uncertainty) : U = 158 + 3,9E-05 · p [Pa]
SISTEMA IN TARATURA (SYSTEM IN CALIBRATION)

Oggetto (Device): Manometro digitale (Digital pressure gauge)
Costruttore (Manufacturer): AEP transducers
Tipo (Type): LAB DMM
Posizione (Position) : Verticale (Vertical)
Fluido di misura (Measurement fluid) : Gas -Azoto (Nitrogen)
upp
Risoluzione (Resolution): 0,002 bar
NOTE (NOTES):
5
1 bar = 10 Pa
I valori della pressione di riferimento riportati nel certificato, sono calcolate al livello di riferimento dell’oggetto in taratura (∆h = -0,02 m).
(All quoted reference pressures are calculated at the level of the calibration system.)
Calibration Centre
Fax +39 059 2922007 EA, IAF e ILAC


VERIFICA INIZIALE (INITIAL CHECK)
Pressione di Pressione
Riferimento misurata
(Reference pressure) (measured pressure)
bar bar
0,0000 0,000
12,4995 12,512
24,9989 25,022
NOTA: lo strumento È stato aggiustato prima della taratura.

(NOTE: the instrument HAS BEEN adjusted before the calibration.)
LETTURE (READINGS)
1° Ciclo (1st Cycle) 2° Ciclo (2nd Cycle) 3° Ciclo (3rd Cycle)

Pressione di Pressione Pressione di Pressione Pressione di Pressione
Riferimento misurata Riferimento misurata Riferimento misurata
(Reference pressure) (Measured press.) (Reference pressure) (Measured press.) (Reference pressure) (Measured press.)
bar bar bar bar bar bar
0,0000 0,000 0,0000 0,000 0,0000 0,000
2,4999 2,500
7,4997 7,498
12,4994 12,496 12,4994 12,496 12,4994 12,496
19,9991 19,994
24,9989 24,996
24,9989 24,996
19,9991 19,990
12,4994 12,490
7,4997 7,490
2,4999 2,492
0,0000 -0,006
Calibration Centre
Fax +39 059 2922007 EA, IAF e ILAC


RISULTATI DI TARATURA (CALIBRATION RESULTS)

Elaborazione conforme alla guida EURAMET cg-17 (2011) e al documento tecnico SIT/Tec-009/05 (2005).
Calculation according to EURAMET cg-17 (2011) and SIT/Tec-009/05 (2005) guidelines.
Pressione Media pressione Media pressione Errore di

nominale di riferimento misurata indicazione
(Nominal pressure) (Mean reference pres.) (Mean measured pres.) (Error)
Pr, mean Pi, mean e
bar bar bar bar
0 0,0000 -0,0030 -0,0030
2,5 2,4999 2,4960 -0,0039
7,5 7,4997 7,4940 -0,0057
12,5 12,4994 12,4930 -0,0064
20 19,9991 19,9920 -0,0071
25 24,9989 24,9960 -0,0029
I risultati di taratura sono presentati come medie dei valori ottenuti a pressione crescente e decrescente.
The calibration results are shown as means of values at increasing and decreasing pressure.
Pressione Ripetibilità Isteresi Incertezza estesa Incertezza estesa

nominale di misura quando NON si
(Nominal pressure) (Repeatability) (Hysteresis) (Expanded uncertaity effettano correzioni
of measurement) (Error span)
b h U U'
bar bar bar bar bar
0 - 0,006 0,0037 0,0067
2,5 - 0,008 0,0050 0,0089
7,5 - 0,008 0,0051 0,011
12,5 0,000 0,006 0,0042 0,011
20 - 0,004 0,0035 0,011
25 - 0,000 0,0028 0,0057
Nel calcolo dell'incertezza estesa di misura U si è tenuto conto dell'incertezza del campione, della ripetibilità, dell'isteresi, della risoluzione,
e dell'incertezza dell'eventuale strumento di misura del segnale elettrico (tensione, corrente, frequenza, ecc.).
In the calculations of expanded uncertainty of meas. U, we have kept into consideration the uncertainty due to reference standard, repeatability,
resolution, hysteresis and due to the uncertainty of eventual measurement instrument of electric signal (voltage, current, frequency, etc.).
U è l'incertezza estesa da associare alla misura nel caso in cui si effettui la correzione sulla lettura: P corretta = P indicata - e.
U is the espanded uncertainty to be associated to the measurements when the correction on the reading is performed: P corrected = P showed - e.
U' e l'incertezza estesa nel caso in cui NON si effettuino correzioni sulle letture dello strumento.
U' is the expanded uncertainty when corrections on instrument readings is NOT performed.
Operatore Tecnico
Technical Operator
dr. Francesco Cavaliere
Calibration Center
Laboratorio Accreditato
di Taratura LAT N° 093
Pagina 1 di 4
Page 1 of 4
- data di emissione 2018/02/06

date of issue Il presente certificato di taratura è emesso in base
- cliente STRUMENTAZIONE INDUSTRIALE S.r.l. all'accreditamento LAT N° 093 rilasciato in accordo
customer ai decreti attuativi della legge n. 273/1991 che ha
Via Barro, 56/58 istituito il Sistema Nazionale di Taratura (SNT).
28045 INVORIO (NO) ACCREDIA attesta le capacità di misura e di
- destinatario - taratura, le competenze metrologiche del Centro e
receiver la riferibilità delle tarature eseguite ai campioni
nazionali e internazionali delle unità di misura del
Sistema Internazionale delle Unità (SI).
- richiesta 58/S18 modo parziale, salvo espressa autorizzazione
application
scritta da parte del Centro.
- in data 2018/01/18
date
This certificate of calibration is issued in compliance with
Si riferisce a the accreditation LAT N° 093 granted according to decrees
Referring to connected with Italian law No. 273/1991 which has
- oggetto Manometro digitale
attests the calibration and measurement capability, the
item (Digital pressure gauge)
metrological competence of the Centre and the traceability
- costruttore AEP transducers of calibration results to the national and international
manufacturer
standards of the International System of Units (SI).
- modello LAB DMM This certificate may not be partially reproduced, except with
model
the prior written permission of the issuing Centre.
- matricola 859585 (MANP20-100)
serial number
- data di ricevimento oggetto -
- data delle misure 2018/02/05
- registo di laboratorio RL/21218P
I risultati di misura riportati nel presente Certificato sono stati ottenuti applicando le procedure di taratura citate alla pagina seguente, dove sono
specificati anche i campioni o gli strumenti che garantiscono la catena di riferibilità del Centro e i rispettivi certificati di taratura in corso di validità.
Essi si riferiscono esclusivamente all’oggetto in taratura e sono validi nel momento e nelle condizioni di taratura, salvo diversamente specificato.
The measurement results reported in this Certificate were obtained following the calibration procedures given in the following page, where the reference standards or
instruments are indicated which guarantee the traceability chain of the laboratory, and the related calibration certificates in the course of validity are indicated as well.
They relate only to the calibrated item and they are valid for the time and conditions of calibration, unless otherwise specified.
Le incertezze di misura dichiarate in questo documento sono state determinate conformemente alla Guida ISO/IEC 98 e al documento EA-4/02.
Solitamente sono espresse come incertezza estesa ottenuta moltiplicando l’incertezza tipo per il fattore di copertura k corrispondente ad un
livello di fiducia di circa il 95 %. Normalmente tale fattore k vale 2.
The measurement uncertainties stated in this document have been determined according to the ISO/IEC Guide 98 and to EA-4/02. Usually, they have been estimated
as expanded uncertainty obtained multiplying the standard uncertainty by the coverage factor k corresponding to a confidence level of about 95%.
Normally, this factor k is 2.
Il Responsabile del Centro

Head of the Centre
p.i. Paolo Lioi
Firma Digitale - Digital Signature

Calibration Center
Pagina 2 di 4
Page 2 of 4
I risultati di misura riportati nel presente Certificato sono stati ottenuti applicando le procedure N. PTQ021r13
The measurement results reported in this Certificate were obtained following procedures No.
La catena di riferibilità ha inizio dal campione di misura di riferimento N. 6473 (cod. PMP01-94), 3516 (cod. AMM01-94)
Traceability is through reference mesurement standard N.
muniti di certificati validi di taratura rispettivamente N. 50694 (DH-COFRAC), LAT 044 M170730, LAT 044 M170731
validated by certificates of calibration No.
CONDIZIONI AMBIENTALI DI TARATURA (CALIBRATION CONDITIONS)

Temperatura ambiente (Room temperature): 19,9 °C ± 1,0 °C
Umidità relativa (Relative humidity): 37,3 % ± 5 %
CAMPIONE DI MISURA (MEASUREMENT STANDARD)

Oggetto (Device): Bilancia di pressione a pesi diretti (Dead weights pressure balance)
Costruttore (Manufacturer): DH Budenberg
Tipo (Type): 50000 II
Accoppiamento (Piston-Cylinder assembly) 5 bar/kg
Modalità di taratura (Calibration procedure) : Pressione relativa alla pressione atmosferica
(Pressure relative to the atmospheric value)
Certificato di taratura N° (Certificates of calib. No): 02517BP (LAT N. 093)
Incertezza estesa (Expanded uncertainty) : U = 378 + 5,0·10⁻⁵ · p [Pa]
SISTEMA IN TARATURA (SYSTEM IN CALIBRATION)

Oggetto (Device): Manometro digitale (Digital pressure gauge)
Costruttore (Manufacturer): AEP transducers
Tipo (Type): LAB DMM
N° di Serie (Serial number): 859585 (MANP20-100)
Posizione (Position) : Verticale (Vertical)
Fluido di misura (Measurement fluid) : Liquido (Liquid)(di-ethyl-hexyl-sebacate)
Risoluzione (Resolution): 0,01 bar
NOTE (NOTES):
1 bar = 105 Pa
I valori della pressione di riferimento riportati nel certificato, sono calcolate al livello di riferimento dell’oggetto in taratura (∆h = 0 m).
(All quoted reference pressures are calculated at the level of the calibration system.)
Calibration Center
Pagina 3 di 4
Page 3 of 4
VERIFICA INIZIALE (INITIAL CHECK)
Pressione di Pressione
Riferimento misurata
(Reference pressure) (measured pressure)
/bar /bar
0,0000 0,00
50,0197 50,04
100,0187 100,05
NOTA: lo strumento NON È stato regolato prima della taratura.

(NOTE: the instrument HAS NOT BEEN adjusted before the calibration.)
LETTURE (READINGS)
1° Ciclo (1st Cycle) 2° Ciclo (2nd Cycle) 3° Ciclo (3rd Cycle)

Pressione di Pressione Pressione di Pressione Pressione di Pressione
Riferimento misurata Riferimento misurata Riferimento misurata
(Reference pressure) (Measured press.) (Reference pressure) (Measured press.) (Reference pressure) (Measured press.)
/bar /bar /bar /bar /bar /bar
0,0000 0,00 0,0000 0,00 0,0000 0,00
10,0204 10,03
30,0204 30,03
50,0197 50,04 50,0197 50,04 50,0196 50,04
80,0190 80,04
100,0186 100,05
100,0186 100,05
80,0190 80,06
50,0197 50,05
30,0204 30,03
10,0204 10,02
0,0000 0,00
Calibration Center
Pagina 4 di 4
Page 4 of 4
RISULTATI DI TARATURA (CALIBRATION RESULTS)

Elaborazione conforme alla guida EURAMET cg-17: 2017.
Calculation according to EURAMET cg-17: 2017 .
Pressione Media pressione Media pressione Errore di

nominale di riferimento misurata indicazione
(Nominal pressure) (Mean reference pres.) (Mean measured pres.) (Error)
Pr, mean Pi, mean e
/bar /bar /bar /bar
0 0,0000 0,000 0,000
10 10,0204 10,025 0,005
30 30,0204 30,030 0,010
50 50,0197 50,045 0,025
80 80,0190 80,050 0,031
100 100,0186 100,050 0,031
I risultati di taratura sono presentati come medie dei valori ottenuti a pressione crescente e decrescente.
The calibration results are shown as means of values at increasing and decreasing pressure.
Pressione Ripetibilità Isteresi Incertezza estesa Incertezza estesa

nominale di misura quando NON si
(Nominal pressure) (Repeatability) (Hysteresis) (Expanded uncertaity effettano correzioni
of measurement) (Error span)
b h U U'
/bar /bar /bar /bar /bar
0 - 0,00 0,0058 0,0058
10 - 0,01 0,0092 0,014
30 - 0,00 0,0078 0,018
50 0,00 0,01 0,010 0,035
80 - 0,02 0,015 0,046
100 - 0,00 0,011 0,042
Nel calcolo dell'incertezza estesa di misura U si è tenuto conto dell'incertezza del campione, della ripetibilità, dell'isteresi, della risoluzione,
e dell'incertezza dell'eventuale strumento di misura del segnale elettrico (tensione, corrente, frequenza, ecc.).
In the calculations of expanded uncertainty of meas. U, we have kept into consideration the uncertainty due to reference standard, repeatability,
resolution, hysteresis and due to the uncertainty of eventual measurement instrument of electric signal (voltage, current, frequency, etc.).
U è l'incertezza estesa da associare alla misura nel caso in cui si effettui la correzione sulla lettura: P corretta = P indicata - e.
U is the espanded uncertainty to be associated to the measurements when the correction on the reading is performed: P corrected = P showed - e.
U' e l'incertezza estesa nel caso in cui NON si effettuino correzioni sulle letture dello strumento.
U' is the expanded uncertainty when corrections on instrument readings is NOT performed.
Operatore Tecnico (Technical Operator): Sig. Luca Castellazzi

SECTION 2.4.2.
Roughness gauge calibration report
▹▹▷

MO 76_01_12
rev 02
ROUGHNESS GAUGE CALIBRATION REPORT N. 100/2018
RAPPORTO DI TARATURA RUGOSIMETRO
BRAM‐COR Procedure No.
IO 76_01_09 Roughness gauge calibration
Procedura BRAM‐COR
Ref. Standard:
UNI EN ISO 5436‐1 /UNI EN ISO 12179
Norme di riferimento:
ROUGHNESS GAUGE DESCRIPTION/DESCRIZIONE DEL RUGOSIMETRO
Manufacturer: Serial number:
Costruttore:
INNOVATEST Numero di serie:
1206172
Model: Instrument Range:
TR‐200 Range dello strumento:
Ra, Rq : 0.005 ‐ 16 μm
Modello:
REFERENCE SPECIMEN DETAILS/DATI DEL CAMPIONE DI RUGOSITÀ
Description:
Reference roughness plate/Piastrina di riferimento a rugosità certificata
Descrizione:
Manufacturer:
INNOVATEST Serial number 140829
Costruttore:
Nominal roughness:
1,67 μm
Rugosità nominale:
Calib. Certificate No.: Attached
128/2015
Allegato 
Certificato di taratura N.:
ROUGHNESS GAUGE ACCURACY TEST RESULTS/RISULTATI DEL TEST DI ACCURATEZZA DEL RUGOSIMETRO
Accuracy verification of the Nominal Ra of
Max. acceptable range of reading (from ...
roughness gauge on the ref.specimen
to...) in μm (2% tolerance)
(in μm)
reference specimen. Ra (in μm) Pass/Fail
Verifica dell'accuratezza del Rugosità
rugosimetro sul campione di nominale del Range di accettabilità in μm
rugosità campione
1st reading/1a lettura 1,68 1,67 1,64 ‐ 1,70 Pass

Mean value/Ra media 1,68 1,67 1,64 ‐ 1,70 Pass
The roughness gauge was submitted to the accuracy verification with positive result before roughness test execution on the
surfaces under inspection.
Il rugosimetro è stato sottoposto a verifica dell'accuratezza con esito positivo prima di eseguire il test di rugosità sulle
superfici da controllare.
Test executed by: Signature: Date:
Paolo Morlacchini Firma: Data:
04/08/2018
Test eseguito da:
Verified by: Signature: Date:
Cristina Opl
Firma: Data:
04/08/2018
Verificato da:
. .& s
M
SMS.r.I.
Laboratorio Metrologlco
Calibration Centre
Laboratorio Accreditato di LAT N° 041

Via Brandizzo, 182 - 10088 VOLPIANO (TO) Taratura Riconoscimento
Tel.: 011 9953753 - Fax: 011 9953754 EA, IAF e ILAC
E-mail: laboratorlo@sm-instruments.com Slgnatory of EA, IAF and ILAC

Internet: www.sm-lnstruments.com Mutuai Recognltlon Agreements
Pagina 1di3
Page 1 af3
CERTIFICATO DI TARATURA LAT 041 128/2015

- data di emissione 2015-06-1 o Il presente certificato di taratura è emesso in base

date of issue all'accreditamento LAT N° 041 rilasciato in accordo
ai decreti attuativi della legge n. 273/1991 che ha
Spett. Ditta Rupac srl
- cliente istituito il Sistema Nazionale di Taratura (SNT).
Via Luigi Alamanni, 14
customer ACCREDIA attesta le capacità di misura e di
20141 Milano (Ml)
taratura, le competenze metrologiche del Centro e
la riferibilità delle tarature eseguite ai campioni
- destinatario nazionali e internazionali delle unità di misura del
receiver Sistema Internazionale delle Unità (SI).
- richiesta modo parziale, salvo espressa autorizzazione
Ordine n· 3264 - 53302
application scritta da parte del Centro.
- in data
2015-06-05
date
This certificate of calibration is issued in ccmpliance with
the accreditation LA T N' 041 granted according to decrees
Si riferisce a
connected with ltalian law No. 27311991 which has
Referring to
- oggetto
campione di rugosità attests the calibration and measurement capability, the
item
metrologica/ competence of the Centre and the traceability
- costruttore
of calibration results to the national and intemational
manufacturer
standards of the lntemational System of Units (SI).
-modello
una zona in cristallo This certificate may not be partial/y reproduced, except
model
with the prior written permission of the issuing Centre.
- matricola 140829
serial number
- data di ricevimento oggetto
2015-06-09
- data delle misure 2015-06-1 o
- registro di laboratorio
file 1 A/2015
I risultati di misura riportati nel presente Certificato sono stati ottenuti applicando le procedure di taratura citate alla pagina
seguente, dove sono specificati anche i campioni o gli strumenti che garantiscono la catena di riferibilità del Centro e i rispettivi
certificati di taratura in corso di validità. Essi si riferiscono esclusivamente all'oggetto in taratura e sono validi nel momento e
nelle condizioni di taratura, salvo diversamente specificato.
The measurement results reported in this Certificate were obtained fol/owing the calibration procedures given in the following page, where the
reference standards or instruments are indicated which guarantee the traceability chain of the laboratory, and the related calibration certificates in
the course of validity are indicated as well. They relate only to the calibrated item and they are valid tor the time and conditions of ca/ibration, unless
otherwise specified.
Le incertezze di misura dichiarate in questo documento sono state determinate conformemente alla Guida ISO/IEC 98 e al
documento EA-4/02. Solitamente sono espresse come incertezza estesa ottenuta moltiplicando l'incertezza tipo per il fattore di
copertura k corrispondente ad un livello di fiducia di circa il 95 %. Normalmente tale fattore k vale 2.
The measurement uncertainties stated in this document have been determined according to the ISOllEC Guide 98 and to EA-4/02. Usually, they
have been estimated as expanded uncertainty obtained multiplying the standard uncertainty by the coverage factor k corresponding to a confidence
leve/ af about 95%. Normally, this factor k is 2.
aprioglio Cristi
~ SMS.r.I. Centro di Taratura LAT N° 041
~ Laboratorio Metrologico Calibration Centre
LAT N° 041
Via Brandizzo, 182 - 10088 VOLPIANO (TO) Taratura Riconoscimento
E-mali: laboratorio@sm-1nstruments.com Signatory of EA, IAF and ILAC
I nternet: www.sm-lnstruments.com Mutuai Recognltlon Agreements
Pagina2di3
Page 2of3

Di seguito vengono riportate le seguenti informazioni:

In the following, information ls reported about:
I risultati di misura riportati nel presente Certificato PT01 - edizione 2 revisione O

sono stati ottenuti applicando le procedure N. PT02 - edizione 2 revisione O
The measurement results reported in this Certificate
W&re obtained fo/fowing procedures No.
PT03 - edizione 2 revisione 1
Elenco degli strumenti che garantiscono la riferibilità:

List of Too/s that ensure traceability:
Rugosimetro da laboratorio N.
S133
Roughness /aboratory tester No.
Campione di prima linea N.

First fine standards No.
16883
Muniti di certificati validi di taratura rispettivamente N.

emesso da. 10~839-01 del 2011~1-18
Validated by certificates ot ca/ibration No. 1.N.Ri.M.
issue by.
Condizioni ambientali, temperatura. (20,0 :1: o,s) •e

Ambient condiffon, temperature
Riferimenti nonmativl:
Standards references:
UNI CEI EN ISO/IEC17025:2005 "Requisiti generali per la competenza dei laboratori di prova e di taratura"
UNI EN ISO 4287:2009 "Specifiche geometriche dei prodotti (GPS) - Stato della superficie: Metodo del profilo - Tennini,
definizioni e parametri dello stato della superficie"
UNI EN ISO 4288:2000 "Specifiche geometriche dei prodotti (GPS) - Stato della superficie: Metodo del profilo - Regole e
procedure per il rilevamento dello stato della superficie"
UNI EN ISO 3274:1998 "Specifiche geometriche dei prodotti (GPS)- Stato della superficie: Metodo del profilo -
Caratteristiche nominali degli strumenti a contatto (tastatore)"
ISO 16610-21 :2011 "Geometrica! product specifications (GPS) - Filtration - Part 21: Linear profile filters: Gaussian
fllters"
UNI EN ISO 5436-1 :2001 "Specifiche geometriche dei prodotti (GPS)- Stato della superficie: Metodo del profilo; Campioni di
riferimento - Misure materializzate"
UNI EN ISO 9001 :2008 "Sistemi di gestione per la qualità - Requisiti"
UNI EN ISO 10012:2004 "Sistemi di gestione della misurazione - Requisiti per i processi e le apparecchiature di misurazione•
Accredia DT-05-0T revOO "Introduzione ai criteri di valutazione della Incertezza di mi-sura nelle tarature·
UNI CEI ENV 13005:2000 "Guida all'espressione dell'incertezza di misura•
Nella pagina seguente sono riportati i risultati delle tarature e la loro incertezza estesa.
In the next page are show the results of the calibration and their expanded uncertainty of measuremenl
~ SMS.r.I. Centro di Taratura LAT N° 041
~ Laboratorio Metrologico Calibration Centre
LAT N° 041
Mem bro degli Accord I di Mutuo
Via Brandizzo, 182 - 10088 VOLPIANO (TOJ Taratura Riconoscimento
E·mall: laboratorlo@lsm-lnstruments.com Slgnat ory of EA, IAF a nd ILAC
Internet: www.sm-lnstruments.com Mutuar Recog nltion Agreements
Pagina 3 di 3
Page3of3

Cerlificate of Calibration
TABELLA RISULTATI SPERIMENTALI RELATIVI A:
CAMPIONE DI RUGOSITÀ: matr. n°: 140829 Tipo: UNI EN ISO 5436-1 C3
AREA:A
Tipo di riferimento: LS Filtro: Gaussiano Banda passante: 1:300
VALORE VALORE SCARTO INCERTEZZA

PARAMETRO CUT-OFF
NOMINALE MISURATO [1J TIPO 121 ESTESA 131
Ra 1,67 µm 1,614 µm O,Bmm 0,004 µm 0,081 µm
111
Il valore misurato costituisce la media di 12 rilevamenti in tratti diversi del campione con uguale spaziatura sull'intera
121
superficie secondo la disposizione UNI EN ISO 5436-1 , a fianco è riportato il relativo scarto tipo sperimentale della media .
[3] L'incertezza estesa U indicataè espressa con il fattore di copertura K = 2, che per una distribuzione normale corrisponde ad
una probabilità di copertura del 95%. Nella valutazione dell'incertezza tipo non è stata considerata la stabilità dell'oggetto nel
lungo periodo.

Section 3
Electrical, Hardware and Software documentation

3.1. Electrical and pneumatic drawing
3.2. Electrical insulation test and control board conformity
declaration
3.5. PLC/HMI software identification form
3.7. PLC/HMI software recovery procedures


SECTION 3.1.
Electrical and pneumatic drawing
▹▹▷

SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
250A1 250A4
250A2 250A5
IM 151 CPU PM-E 2 AI 2 AI 2 AO PM-E 8 DI 8 DI 8 DO PM-E 8 DO
SF SF SF SF
BF
RUN-P
STOP
P1 P2 P3
MRES
PROFINET PROFINET PROFINET ON
LAN LAN LAN
FRCE
RUN
STOP
P1 P2 P3 PWR PWR PWR

LAN
X1
ET 200S
AUX1 AUX1 AUX1
DC24V 1 51 51 5 1 51 51 5 1 5
1L+ 1M A A A A A A
4 8 4 8 4 8
2 62 62 62 62 62 62 62 62 62 6
MMC 3 73 73 7 3 73 73 73 73 73 73 7
2L+ 2M
A A A A A A
4 84 84 84 84 84 84 84 84 84 8
A A A A A A A A A AA A A A
4 84 84 8 4 8 4 84 8 4 8
A AA AA A A AA AA A A A
3 73 73 7 3 73 73 7 3 7
SPAC
SPAC
PEW256 PEW258
SPAC
PEW260 PEW262
SPAC
PAW256 PAW258
SPAC
E0.0 E0.1 E0.2 E0.3 E0.4 E0.5 E0.6 E0.7
SPAC
E1.0 E1.1 E1.2 E1.3 E1.4 E1.5 E1.6 E1.7
SPAC
A0.0 A0.1 A0.2 A0.3 A0.4 A0.5 A0.6 A0.7
SPAC
A1.0 A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7
SPAC
SPAC
SPAC
PM-E 2 AI 2 AI 2 AI PM-E 8 DI 8 DI 8 DO PM-E 8 DO
SF SF SF
PWR PWR PWR
AUX1 AUX1 AUX1

1 51 51 5 1 51 51 5 1 5
A A A A A A
4 8 4 8 4 8
2 62 62 62 62 62 62 62 62 62 6
3 73 73 73 73 73 73 73 73 73 7
A A A A A A
4 84 84 84 84 84 84 84 84 84 8
4 84 84 8 4 84 84 8 4 8
3 73 73 7 3 73 73 7 3 7
60 x 60
60 x 60
60 x 60
60 x 60
60 x 60
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC
SPAC

SECTION 3.2.
Electrical insulation test and control board conformity declaration
▹▹▷

DICHIARAZIONE DI CONFORMITA’
Il committente:
Spett. le Ditta
BRAM-COR S.P.A.
Bram-Cor S.p.a.
Via
Via Mercalli G. Mercalli 12/A,
,12/A
43122 ParmaUgozzolo, PR 43122,
Costruttrice del quadro elettrico: ANGELLA

MODELLO: CPSG_ST_1000
SCHEMA ELETTRICO : M_3108_SE_0
Dichiara di aver realizzato il quadro elettrico citato in conformità alle

disposizioni legislative sono state applicate le direttive e le norme
armonizzate:
2014/35/EU Direttiva bassa tensione
2014/30/EU Compatibilità elettromagnetica
CEI EN 61439 Quadri Elettrici di bassa tensione
EN 60204/1 Sicurezza equipaggiamento elettrico
Prove eseguite sull’impianto:

Ispezione dell’apparecchiatura ivi compreso il controllo del cablaggio e
la prova di funzionamento elettrico.
Verifica dei mezzi di protezione e continuità elettrica dei circuiti di
protezione.
Verifica della tensione di isolamento.
Verifica di tensione applicata.
il Tecnico
Parma, 18/07/2018
Via Strasburgo,28
43123 Parma (Pr)
Telefax. : 0521-272893
E-MAIL : s.pasqua@elemek.it
Partita IVA 02510540343
Allegato :
(x) scheda di collaudo con esito delle prove ;
STRUMENTO MULTIFUNZIONE CHAUVIN ARNOUX C.A 6116
DECLINA
Ogni responsabilità per sinistri a persone o a cose derivanti da manomissioni
dell’impianto da parte di terzi ovvero da carenze di manutenzione o riparazione
Parma, 18/07/2018
il Tecnico
Via Strasburgo,28
43123 Parma (Pr)
Telefax. : 0521-272893
SCHEDA DI COLLAUDO / CALIBRATURA
QUADRO ELETTRICO DI COMANDO
CPSG_ST_1000
Prova di continuità del conduttore di protezione (norma CEI 64.8 612.2 e VDE 0413
parte 4)
Corrente applicata durante la prova: >/= 200mA
Tempo di durata della prova 10 secondi.
Sezione minima effettiva del

Valore medio della
Punto di prelievo della misura sul quadro conduttore di protezione
Resistenza Ravq < 5 Esito della prova
elettrico equipotenziale della parte in prova
OHM
(mm2)
Barra di terra - Portella 4mmq 0,08 Positivo
Barra di terra -Terra Trasformatore 2,5mmq 0,08 Positivo
Prova di resistenza dell’isolamento (norma CEI 64.8 612.3 e VDE 0413 Parte 1)
Tensione applicata durante la prova: >/= 500V c.c.
Conduttore/i di prelievo della misura Esito della prova

1° fase - Barra di Terra 2000 Mohm
Parma, 18/07/2018 il Tecnico
Via Strasburgo,28
43123 Parma (Pr)
Telefax. : 0521-272893

SECTION 3.3.
Hardware design specification
▹▹▷


LOCATION COLOMBIA
DOCUMENT NAME HARDWARE DESIGN SPECIFICATION
DOCUMENT CODE M_3108_HDS_0
JOB No. 11880
SERIAL No. 3108

REVISION HISTORY
0 First issue 06/08/2018 S. Magri V. Cucci B. Jamal

BRAM‐COR S.P.A.
Tel. 0039 0521 538711
Fax: 0039 0521 538770
GENERAL INDEX
1. GENERAL .................................................................................................................................................... 3
2. HARDWARE ARCHITECTURE ....................................................................................................................... 3
3. HARDWARE DESCRIPTION .......................................................................................................................... 4
3.1. HMI .............................................................................................................................................................. 4
3.2. PLC ............................................................................................................................................................... 4
3.2.1. PLC SCHEME ............................................................................................................................................ 5
3.2.2. CPU .......................................................................................................................................................... 5
3.2.3. I/O MODULES .......................................................................................................................................... 6
4. POWER SUPPLY .......................................................................................................................................... 7
5. HARDWARE CONNECTION .......................................................................................................................... 7

HARDWARE DESIGN SPECIFICATION ‐ M_3108_HDS_0 PAGE 2 OF 7
1. GENERAL
This document specifies in detail the hardware architecture of the PURE STEAM GENERATOR.
This document does not describe in detail the electrical specifications and functionality of the system.
These specifications are described in the TECHNICAL DOCUMENTATION (M_3108_TD).
The system is based on communication between commonly used components that control and monitor
the correct operation:
• Human machine interface (HMI);
• Unit of Industrial Automation (PLC);
• System analog and digital I/O, integrated into the PLC;
• Communication bus between PLC and HMI.

2. HARDWARE ARCHITECTURE
The control system (inside the control board) is summarized by the following figure.

CB‐2010

ETHERNET

HMI NETWORK PLC

Digital Digital
Output
Input

Analogic Analogic

Input Output

There is only one PLC which is in charge of the main program of the system.
The CPU has its own ETHERNET network which is used for communication with I/O modules interface
and to HMI panel.
All components (CPU, I/O Cards, Modem, HMI, etc.) are installed on system control board together with
all necessary electrical components for a correct functioning of the plant. More specifically in the control
cabinet there are the following functions:
• Power Input
• Control Equipment
• Monitoring/Recording Equipment
• Motor Brach Circuits
• Actuators and Sensors
3. HARDWARE DESCRIPTION
3.1. HMI
The HMI Touch Panel system (on the control board) is the user interface used to interact to the process
by the controller.
The main functions are:
• Alarms management
• Setting‐up limit values
• Sequences steps flow control
• Manual Control
• Sequences activation
• Measured variables trends
• Output of counters
Login to the HMI system is permitted to authorized users only. This means that each access can be
performed from authorized personnel. Changes made via the HMI panel are not automatically saved on
the storage device of the PLC (MMC), but saved to a separate DBs only.
The HMI configuration is also saved to a non‐volatile MMC memory upon completion of commissioning
and testing. When the system is started for the first time following installation of the memory, the
program is loaded from the MMC to the RAM of the HMI. This prevents program loss in the event of
power failure affecting the RAM.
Below the main hardware features of the HMI panel:

Reference Description Supplier Item
6AV21232GB030AX0 KTP700 BASIC PN Siemens 252P1
The HMI manual, is attached to this document (attachment 1).

3.2. PLC
The control system operates independently from the user interface (HMI), i.e. the system can continue
to operate although the user interface fails.
The listed below functions are performed by the PLC:
• Sequences (i.e. Startup, Sanitization, Normal Operation, etc.)
• Start and stop of actuators (valves, pumps, etc.)
• Control Functions (Frequency controlled pumps, control valves etc.)
• Input of measured values and setting of limit values
• Activation of HMI

The PLC is made from a CPU and a series of analogical/digital modules: these are described in the
following paragraphs.

3.2.1. PLC SCHEME

POWER SUPPLY FOR I/O MODULES

CPU

ANALOGIC
ANALOGIC DIGITAL DIGITAL
INPUT OUTPUT INPUT OUTPUT

3.2.2. CPU
The CPU has the ability to communicate with the HMI through the ETHERNET network cable.
The main characteristics for CPU and interface modules expansion, are below summarized:

6ES71518AB010AB0 SIMATIC DP IM151‐8 PN/DP CPU X ET200S Siemens 250D1
CPU Manual Operating Instructions, is attached to this document (attachment 2).

3.2.2.1. MMC STORAGE DEVICE
The PLC program is stored in a non‐volatile memory card (MMC) after completion of commissioning and
testing activities. In the first time plant startup, the program is loaded from the MMC to the RAM of the
PLC. This prevents the program data can be lost in the event of a power failure affecting RAM.
The memory card is insert on CPU module. Below the main feature of the storage device:

6ES79538LG200AA0 SIMATIC S7, MICRO MEMORY CARD 128KB Siemens 250D1

3.2.3. I/O MODULES
The I/O modules are the interfaces to the process. There is a modular I/O system required to the
process.
As far as their power supply concerns, Input – Output modules, analogic and digital, are powered (in
groups) by the following power supply cards:

6ES71384CA010AA0 ET200S, POWERMODUL. PM‐E, DC24V
Siemens 250G1÷250G3
6ES71934CD200AA0 TERMINAL MODULE ET200S with AUX1

Analogic and digital I/O interfaces are generally described here below. For further details, please consult
the TECHNICAL DOCUMENTATION:
 Electrical and Pneumatic Scheme
 Input/Output List

ANALOGIC INPUT

Reference Description Supplier Item I/O Address
SIMATIC DP, ELETTR. MODULE X ET200S 2AI
6ES71344GB010AB0
2 WIRES 250A1 PEW256÷258
6ES71934CA400AA0 TERM. BLOCK TM‐E15S26‐A1(ET200S)(5P)
Siemens
ET200S ANAL. INPUT MODULE 4DMU‐ 4
6ES71344GB110AB0
WIRES 250A2 PEW260÷262

ANALOGIC OUTPUT

6ES71354GB010AB0 SIMATIC DP, ET200S. ELETTR. MODULE 2AO
Siemens 250A3 PAW256÷258

DIGITAL INPUT

6ES71314BF000AA0 SIMATIC DP ET 200S 8DI DC24V
250A4 E0.0÷E0.7
Siemens
6ES71314BF000AA0 SIMATIC DP ET 200S 8DI DC24V
250A5 E1.0÷E1.7

DIGITAL OUTPUT

6ES71324BF000AA0 SIMATIC DP ET 200S 8DO DC24V/0,5A
250A6 A0.0÷0.7
Siemens
6ES71324BF000AA0 SIMATIC DP ET 200S 8DO DC24V/0,5A
250A7 A1.0÷A1.7

4. POWER SUPPLY
To power, at the voltage of 24VDC, all hardware cards on the control boards, there is a sized power
supply for the needs of the plant.
In the following table the main hardware characteristics of the power supply are summarized:

6EP13343BA10 POWER PACK SITOP 24V/10A Siemens 102G1

5. HARDWARE CONNECTION
The ETHERNET network is a Siemens‐specific interface used for communication between the PLC and
the HMI and/or other peripherals.
The ETHERNET works according to the Master‐Slave principle.
The following scheme represents the network architecture configuration for this system:


ATTACHMENT 1
HMI MANUAL
▹▹▷

HARDWARE DESIGN SPECIFICATION
Basic Panels 2nd Generation ___________________
Preface
1
___________________
Overview
___________________
Safety instructions 2
SIMATIC HMI
___________________
Mounting and connecting 3
HMI devices
Basic Panels 2nd Generation ___________________
Operating the device 4
___________________
Configuring the device 5
Operating Instructions
___________________
Commissioning a project 6
___________________
Maintenance and care 7
___________________
Technical specifications 8
___________________
Technical Support A
___________________
Abbreviations B
03/2014
A5E33293231-AA
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG A5E33293231-AA Copyright © Siemens AG 2014.

Industry Sector Ⓟ 03/2014 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Preface
Purpose of the operating instructions

These operating instructions provide information based on the requirements defined by
IEC 62079 for documentation. This information relates to the HMI device, its storage,
transportation, place of use, installation, use and maintenance.
These operating instructions are intended for a variety of target groups. The following table
shows the chapters of these operating instructions that are of particular importance for the
respective target group.
Target group Chapter

All "Safety instructions"
Operators "Overview"
The operator operates and monitors the system "Operating the device"
during the process control phase.
Commissioning engineers All chapters.
The commissioning engineer integrates the HMI Depending on the use of the HMI device,
device into the system and ensures the operating certain chapters may not be of relevance to the
capability of the HMI device for the process control commissioning engineer, e.g. the section
phase. "Maintenance and servicing."
Service technicians All chapters.
Service technicians rectify faults that occur during Depending on the use of the HMI device,
the process control phase. certain chapters may not be of relevance to the
service technicians, e.g. the section
"Maintenance and servicing."
Maintenance technicians Maintenance and care
Maintenance technicians carry out servicing and
maintenance work during the process control
phase.
The information system of WinCC contains additional information. The information system is
integrated as online help in WinCC and contains instructions, examples and reference
information in electronic form.
Basic Panels 2nd Generation

Operating Instructions, 03/2014, A5E33293231-AA 3
Preface
Scope
These operating instructions are valid for all versions of the SIMATIC HMI Basic Panels. The
following naming conventions apply:
Device designation Device type Interface type Can be configured with

SIMATIC HMI
KTP400 Basic Touch device with PROFINET WinCC (TIA Portal) as of V13
KTP700 Basic function keys PROFINET
KTP700 Basic DP PROFIBUS
KTP900 Basic PROFINET
KTP1200 Basic PROFINET
KTP1200 Basic DP PROFIBUS
Basic knowledge required

Knowledge of automation technology and process communication is necessary to
understand the operating instructions.
An understanding of the use of computers and operating systems is also required.

4 Operating Instructions, 03/2014, A5E33293231-AA
Preface
Illustrations and text highlighting

This manual contains figures of the described devices. The figures may deviate from the
supplied device in certain details.
The following graphical highlighting facilitates reading these operating instructions:
Graphical highlighting Description

If the instructions involve
several tasks, the individual
tasks are highlighted by a red
number circle.
A light blue highlight indicates

components and tools that are
required in the course of a
task.
KTP700 Basic is sometimes

shown in the figures as a
representation of all Basic
Panels.
The following text highlighting facilitates reading these operating instructions:
Text highlighting Scope

"Add screen" • Terms that appear in the user interface, for example, dialog
names, tabs, buttons, menu commands
• Input values, for example, limits, tag values
• Path information
"File > Edit" Operational sequences, for example, menu commands, shortcut
menu commands
<F1> Keyboard operation

Preface
Note information highlighted as follows:
Note
A note contains important information on described products and their handling or on a
section of this documentation.
Names of the software

Configuration and runtime software have different names as follows:
● "WinCC (TIA Portal) V13", for example, refers to the configuration software.
The term "WinCC" is used in a general context. The full name is always used when it is
necessary to differentiate between different versions of the configuration software.
● "WinCC Runtime" refers to the runtime software that can run on HMI devices.
Names of the hardware

These operating instructions describe the new "Basic Panels 2nd Generation" which
replaces the current Basic Panels. The term "Basic Panel" is used synonymously for a
"Basic Panel 2nd Generation" in these instructions.
Trademarks
Names labeled with a ® symbol are registered trademarks of the Siemens AG. Other names
used in this documentation may be trademarks, the use of which by third parties for their
own purposes could violate the rights of the owner.
● HMI®
● SIMATIC®
● SIMATIC HMI®
● WinCC®

Table of contents
Preface ................................................................................................................................................... 3
1 Overview............................................................................................................................................... 11
1.1 Product overview..........................................................................................................................11
1.2 Design of the PROFINET devices ...............................................................................................12
1.3 Design of the PROFIBUS devices ...............................................................................................13
1.4 Scope of delivery..........................................................................................................................14
1.5 Accessories ..................................................................................................................................15
2 Safety instructions ................................................................................................................................. 17
2.1 General safety instructions ..........................................................................................................17
2.2 Notes about usage .......................................................................................................................19
3 Mounting and connecting ...................................................................................................................... 21
3.1 Preparations .................................................................................................................................21
3.1.1 Checking the package contents ...................................................................................................21
3.1.2 Checking the operating conditions ...............................................................................................21
3.1.3 Selecting a mounting position ......................................................................................................21
3.1.4 Checking clearances ....................................................................................................................23
3.1.5 Making the mounting cutout .........................................................................................................24
3.2 Mounting the HMI device .............................................................................................................25
3.3 Connecting the HMI device ..........................................................................................................26
3.3.1 Connection sequence ..................................................................................................................27
3.3.2 Connecting the equipotential bonding circuit ...............................................................................27
3.3.3 Connecting the power supply.......................................................................................................29
3.3.4 Connecting a programming device ..............................................................................................31
3.3.5 Connecting the configuration PC .................................................................................................31
3.3.6 Connecting the controller .............................................................................................................33
3.3.7 Connecting a USB device ............................................................................................................35
3.4 Switching on and testing the HMI device .....................................................................................36
3.5 Securing the cables .....................................................................................................................37
4 Operating the device ............................................................................................................................. 39
4.1 Overview ......................................................................................................................................39
4.2 General functions of the screen keyboard ...................................................................................41
4.3 The screen keyboards .................................................................................................................42
4.4 Entering data ................................................................................................................................46

Table of contents
5 Configuring the device .......................................................................................................................... 47

5.1 Opening the settings ................................................................................................................... 47
5.2 Overview ..................................................................................................................................... 48
5.3 Configuring the time server ......................................................................................................... 49
5.4 Enter time and date ..................................................................................................................... 50
5.5 Activating the acoustic signal ...................................................................................................... 51
5.6 Configuring Autostart or wait time ............................................................................................... 52
5.7 Changing the password settings ................................................................................................. 52
5.8 Displaying licensing information for the HMI device ................................................................... 55
5.9 Displaying information about the HMI device.............................................................................. 56
5.10 Changing the network configuration ........................................................................................... 57
5.11 Changing the MPI/DP settings .................................................................................................... 58
5.12 Enabling a data channel.............................................................................................................. 59
5.13 Calibrating the touch screen ....................................................................................................... 60
5.14 Changing the monitor settings .................................................................................................... 61
5.15 Setting the screen saver ............................................................................................................. 62
6 Commissioning a project ....................................................................................................................... 63
6.1 Overview ..................................................................................................................................... 63
6.2 Operating modes ......................................................................................................................... 64
6.3 Data transmission options ........................................................................................................... 65
6.4 Transfer ....................................................................................................................................... 65
6.4.1 Overview ..................................................................................................................................... 65
6.4.2 Starting the manual transfer ........................................................................................................ 65
6.4.3 Starting the transfer automatically .............................................................................................. 66
6.4.4 Testing a project .......................................................................................................................... 68
6.5 Backup and restore ..................................................................................................................... 69
6.5.1 Overview ..................................................................................................................................... 69
6.5.2 Backup and restore using ProSave ............................................................................................ 70
6.5.3 Backup and restore using WinCC ............................................................................................... 71
6.6 Updating the operating system - Basic Panel DP ....................................................................... 72
6.6.1 Overview ..................................................................................................................................... 72
6.6.2 Resetting the factory settings ...................................................................................................... 73
6.6.3 Updating the operating system using ProSave ........................................................................... 73
6.7 Updating the operating system - Basic Panel with PROFINET interface ................................... 74
6.7.1 Overview ..................................................................................................................................... 75
6.7.2 Resetting the factory settings ...................................................................................................... 75
6.7.3 Updating the operating system using ProSave ........................................................................... 76
6.7.4 Updating the operating system using WinCC ............................................................................. 77
6.7.5 Resetting to factory settings with ProSave ................................................................................. 78
6.7.6 Resetting to factory settings with WinCC .................................................................................... 80

Table of contents
7 Maintenance and care........................................................................................................................... 81

7.1 Maintenance and care .................................................................................................................81
7.2 Recycling ......................................................................................................................................82
8 Technical specifications ........................................................................................................................ 83
8.1 Certificates and approvals ...........................................................................................................83
8.2 Electromagnetic compatibility ......................................................................................................84
8.2.1 Emitted interference .....................................................................................................................84
8.2.2 Immunity to interferences .............................................................................................................84
8.3 Mechanical ambient conditions ....................................................................................................84
8.3.1 Transport and storage conditions ................................................................................................84
8.3.2 Operating Conditions ...................................................................................................................84
8.4 Climatic ambient conditions .........................................................................................................85
8.4.1 Transport and storage conditions ................................................................................................85
8.4.2 Operating Conditions ...................................................................................................................85
8.4.3 Climate diagram ...........................................................................................................................86
8.5 Protection classes ........................................................................................................................86
8.5.1 Insulation test ...............................................................................................................................87
8.5.2 Protection against foreign objects and water ...............................................................................87
8.6 Dimension drawings .....................................................................................................................88
8.6.1 Dimensional drawing of KTP400 Basic ........................................................................................88
8.6.3 Dimensional drawing of KTP700 Basic DP ..................................................................................89
8.6.5 Dimension drawings of KTP1200 Basic .......................................................................................91
8.6.6 Dimensional drawing of KTP1200 Basic DP ................................................................................92
8.7 Technical specifications ...............................................................................................................93
8.7.1 Power supply................................................................................................................................94
8.7.2 KTP400 Basic, KTP700 Basic and KTP700 Basic DP ................................................................94
8.7.3 KTP900 Basic, KTP1200 Basic and KTP1200 Basic DP ............................................................95
8.8 Interface description .....................................................................................................................97
8.8.1 Power supply................................................................................................................................98
8.8.2 PROFIBUS (Sub-D RS422/485) ..................................................................................................98
8.8.3 PROFINET (Ethernet) ..................................................................................................................98
8.8.4 USB ..............................................................................................................................................99
8.9 Scope of functions with WinCC..................................................................................................100
A Technical Support ............................................................................................................................... 103
A.1 Service and support ...................................................................................................................103
A.2 System events............................................................................................................................103
B Abbreviations ...................................................................................................................................... 105
Glossary ............................................................................................................................................. 107
Index................................................................................................................................................... 113

Table of contents

Overview 1
1.1 Product overview
The beauty of simplicity
New, cost-efficient HMI generation meets the trend for high-quality visualization even in
small machines and plants
Siemens meets the requirements of users for high-quality visualization and operation even in
small and medium-size machines and plants with the second generation of SIMATIC HMI
Basic Panels. While the price of the new devices is based on the current panels, their scope
of performance has been expanded tremendously. The high resolution and a color depth of
up to 65,500 colors are major factors contributing to the increased performance.
Even the connectivity either by PROFINET or PROFIBUS interface plus USB port could be
significantly improved. Configuration and operation of the new panels has become easier in
connection with simplified programming by means of the new WinCC software version in the
TIA Portal.

Overview
1.2 Design of the PROFINET devices
1.2 Design of the PROFINET devices

The figure below shows the design of the PROFINET devices using KTP700 Basic as an
example.
① Power supply connection ⑥ Mounting seal

② USB port ⑦ Function keys
③ PROFINET interface ⑧ Rating plate
④ Recesses for a mounting clip ⑨ Connection for functional ground
⑤ Display/touch screen ⑩ Guide for labeling strips

Overview
1.3 Design of the PROFIBUS devices
1.3 Design of the PROFIBUS devices

The figure below shows the design of the PROFIBUS devices using KTP700 Basic DP as an
example.
① Power supply connection ⑥ Mounting seal

② RS 422/RS 485 port ⑦ Function keys
③ USB port ⑧ Rating plate
④ Recesses for a mounting clip ⑨ Functional earth connection
⑤ Display/touch screen ⑩ Guides for labeling strips

Overview
1.4 Scope of delivery
1.4 Scope of delivery

The scope of delivery of the HMI device includes the following components:
Name Figure Quantity

HMI device 1
Quick Installation Guide 1
Mounting clips with According to the quantity required

grub screw for mounting, in accessory kit
Power supply terminal 1, in accessory kit

Overview
1.5 Accessories
1.5 Accessories
Accessories are not included in the HMI device scope of delivery, but can be ordered on the
Internet under Industry Mall (http://mall.automation.siemens.com).
This section contains the number of accessories available at the time of publication of the
operating instructions.
Storage media and I/O devices
Name Article number

USB memory stick 8 GB 6ES7648-0DC50-0AA0
Industrial USB Hub 4 6AV6671-3AH00-0AX0
Converters, adapters and connectors
Name Purpose Article number

RS 422 to RS 232 Connection of third-party controllers to Basic 6AV6671-8XE00-0AX0
converter Panels DP
90 degree elbow For RS 422/RS 485 port, cable outlet to rear 6AV6671-8XD00-0AX0
adapter
PROFIBUS connector Recommended PROFIBUS connector with 6GK1500-0FC10
straight cable outlet
PROFINET RJ45 Required for connection of Basic Panels with 6GK1901-1BB10-2AA0
connector PROFINET interface to PROFINET
"IE FC RJ45 Plug 2x2"
Protective foil
Name Purpose Article number

Protective film 4" Protective film set for KTP400 Basic 6AV2124-6DJ00-0AX0
Protective film 7" Protective film set for KTP700 Basic and 6AV2124-6GJ00-0AX0
KTP700 Basic DP
Protective film 9" Protective film set for KTP900 Basic 6AV2181-3JJ20-0AX0
Protective film 12" Protective film set for KTP1200 Basic and 6AV2181-3MJ20-0AX0
KTP1200 Basic DP
Service packages
Name Article number

Set of 20 mounting clips 6AV6671-8KX00-0AX2
Set of 10 power supply terminals 6AV6671-8XA00-0AX0

Overview
1.5 Accessories

Safety instructions 2
2.1 General safety instructions
Working on the control cabinet
WARNING
Open equipment
The HMI device is an open equipment. This means the HMI device may only be installed in
cubicles or cabinets that provide front panel access for operating the device.
The cubicle or cabinet in which the HMI device is installed may only be accessed with a key
or tool and only by trained, authorized personnel.
Dangerous voltage
Opening the cabinet will expose high voltage parts. Contact with these parts could be fatal.
Always disconnect the cabinet from the mains before opening it.
High frequency radiation
Note
Unwanted operating states
High-frequency radiation, for example, from cellular phones, can trigger unwanted operating
states.
Installation as intended
WARNING
Installation only in machinery that conforms to the machinery directive
You are not permitted to commission the HMI device unless it has been verified that the
machine in which the HMI device is to be installed complies with directive 2006/42/EC.

Safety instructions
2.1 General safety instructions
ESD
A device equipped with electronic components is an electrostatic sensitive device. Due to
their design, electronic components are sensitive to overvoltage and thus to the discharge of
static electricity. Note the corresponding regulations when handling ESD.
Industrial Security
Siemens offers products and solutions with Industrial Security functions that support the safe
operation of equipment, solutions, machines, devices and/or networks. They are important
components in a comprehensive Industrial Security concept. As a result the products and
solutions from Siemens are constantly evolving. Siemens recommends obtaining regular
information regarding product updates.
For safe operation of Siemens products and solutions appropriate protective measures (e.g.,
cell protection concept) must be taken and each component must be integrated in a
comprehensive Industrial Security concept, which corresponds with the current state of
technology. The products of other manufacturers need to be taken into consideration if they
are also used. You can find addition information on Industrial Security under
(http://www.siemens.com/industrialsecurity).
Sign up for our product-specific newsletter to receive the latest information on product
updates. For more information, see under (http://www.siemens.de/automation/csi_en_WW).

Safety instructions
2.2 Notes about usage
NOTICE
The HMI device is approved for indoor use only.
The HMI device may be damaged if it is operated outdoors.
Operate the HMI device indoors only.
Industrial applications
The HMI device is designed for industrial applications. It conforms to the following standards:
● Requirements of the emission standard for industrial environments, EN 61000-6-4: 2007
+ A1:2011
● ESD immunity requirements to DIN EN 61000-6-2:2005
Use in residential areas
Note
The HMI device is not intended for use in residential areas. Operation of an HMI device in
residential areas can have a negative influence on radio/TV reception.
If the HMI device is used in a residential area, you must take measures to achieve Limit
Class B conforming to EN 55011 for RF interference.
Individual acceptance is required.
Use with additional measures

The HMI device should not be used at the following locations unless additional measures are
taken:
● In locations with a high degree of ionizing radiation
● In locations with severe operating conditions, for example, due to:
– Corrosive vapors, gases, oils or chemicals
– Electrical or magnetic fields of high intensity
● In systems that require special monitoring, for example, in:
– Elevators
– Systems in especially hazardous rooms

Safety instructions
Notes on communication
Note
Communication errors caused by address conflict
Communication errors can occur if several devices in a network share the same bus address
or IP address.
Make sure that your HMI device is assigned a unique address in the network.
Note
Updating tag values following a communication error
If communication between an HMI device and controller is interrupted, all tag values
displayed on the HMI device will be replaced by a hash mark ("#").
When the communication between the HMI device and controller is restored, all tag values
will be updated immediately. The cycle time for updating the tag values begins again at "0".
Ethernet communication with Basic Panels with PROFINET interface
Basic Panels with PROFINET interface support the following types of communication:
• PROFINET basic function for commissioning and diagnostics
• Standard Ethernet communication

3.1 Preparations
3.1.1 Checking the package contents

Check the package content for visible signs of transport damage and for completeness.
Note
Damaged parts
Do not install parts damaged during shipment. In the case of damaged parts, contact your
Siemens representative.
The package content is described in section Scope of delivery (Page 14).

Keep the provided documentation in a safe place. The documentation is part of the HMI
device and is required for subsequent commissioning.
3.1.2 Checking the operating conditions

Note the information in the following sections of these operating instructions before installing
the HMI device:
● Certificates and approvals (Page 83)
● Electromagnetic compatibility (Page 84)
● Mechanical ambient conditions (Page 84)
● Climatic ambient conditions (Page 85)
● Protection classes (Page 86)
● Technical specifications (Page 93)

Mounting and connecting
3.1 Preparations
3.1.3 Selecting a mounting position

The device is suitable for installation in:
● Mounting cabinets
● Control cabinets
● Switchboards
● Consoles
In the following, all of these mounting options are referred to by the general term "cabinet".
The device is self-ventilated and approved for inclined mounting at angles up to +/-35° from
the vertical in stationary cabinets.
NOTICE
Damage due to overheating
Inclined installation reduces the convection by the device and therefore the maximum
permitted ambient temperature for operation.
If there is sufficient forced ventilation, the device can also be operated in the inclined
mounting position up to the maximum permitted ambient temperature for vertical
installation. The device may otherwise be damaged and its certifications and warranty will
be rendered null and void.
The ambient temperature ranges listed in this section apply to the temperature inside the
cabinet.
Mounting position
Select one of the approved mounting positions for your device. The approved mounting
positions are described in the following sections.
Mounting in horizontal format

Ambient temperature in the cabinet with horizontal mounting:
● Vertical mounting (0° inclined): Maximum +50 °C
● Inclined mounting (inclined up to 35°): Maximum +40 °C

3.1 Preparations
Mounting in vertical format

Ambient temperature in the cabinet with vertical mounting:
● Vertical mounting (0° inclined): Maximum +40 °C
● Inclined mounting (inclined up to 35°): Maximum +35 °C
See also
Operating Conditions (Page 85)
3.1.4 Checking clearances

The following clearances are required around the HMI device to ensure sufficient self-
ventilation:
Required clearance around the HMI

devices.
All dimensions in mm

3.1 Preparations
3.1.5 Making the mounting cutout
Note
Stability of the mounting cutout
The material in the area of the mounting cutout must provide sufficient strength to guarantee
the lasting and safe mounting of the HMI device.
The force of the mounting clips or operation of the device may not lead to deformation of the
material in order to achieve the degrees of protection described below.
Degrees of protection
The degrees of protection of the HMI device can only be guaranteed if the following
requirements are met:
● Material thickness at the mounting cutout for a protection rating of IP65 or Front face only
Type 4X/Type 12 (indoor use only): 2 mm to 6 mm.
● Permitted deviation from plane at the mounting cutout: ≤ 0.5 mm
This condition must be met for the mounted HMI device.
● Permitted surface roughness in the area of the seal: ≤ 120 µm (Rz 120)
Mounting compatibility
The mounting cutouts of the Basic panels are compatible with the mounting cutouts of the
following SIMATIC HMI devices:
Mounting cutout Basic Panel Compatible with the mounting cutouts of the HMI device
KTP400 Basic KTP400 Basic color PN
KTP700 Basic, KTP700 Basic DP KTP600 Basic color PN; TP700 Comfort
KTP900 Basic TP900 Comfort
KTP1200 Basic, KTP1200 Basic DP TP1200 Comfort

3.2 Mounting the HMI device
Dimensions of the mounting cutout

Dimensions of the mounting cutout for the Basic
HMI devices in horizontal mounting position:
Dimensions of the mounting cutout for the Basic

HMI devices in vertical mounting position:
All dimensions in mm
See also
Accessories (Page 15)
Required tools and accessories

Slotted screwdriver, size 2
Mounting clips for HMI device Required quantity
KTP400 Basic 4
KTP700 Basic 7
KTP700 Basic DP 7
KTP900 Basic 10
KTP1200 Basic 12
KTP1200 Basic DP 12

Inserting the HMI device

1. Slide the labeling strip
into the device using
the guide, if available.
2. Insert the HMI device

into the mounting
cutout from the front.
Make sure that
protruding labeling
strips are not caught
between the mounting
cutout and HMI device.
Securing the HMI device with mounting clips

1. If mounting clips and grub screws are
available separately in the accessory
kit, insert a grub screw into the
mounting clip bore hole and turn it
several times.
2. Place the first mounting clip into the

corresponding cutout.
3. Fasten the mounting clip with a size 2

screwdriver. The maximum permitted
torque is 0.2 Nm.
4. Repeat steps 1 to 3 for all mounting

clips required to secure your HMI
device.

3.3 Connecting the HMI device
3.3.1 Connection sequence
Required tools and accessories

Before you start connecting the HMI device, have the following tools and accessories at
hand:
4 Slotted screwdriver, size 2
Phillips screwdriver, size 3
Crimp pliers
Power supply terminal
24 V DC with sufficient amperage.

See Technical specifications (Page 93)
Procedure
Keep to the following sequence of tasks when connecting the HMI device:
1. Connecting the equipotential bonding circuit (Page 27)
2. Connecting the power supply (Page 29)
3. Connecting the configuration PC (Page 31)
4. Connecting the controller (Page 33)
Note
Strain relief
Contacts can be broken or wires can be torn off if cables are not provided adequate strain
relief.
Provide adequate strain relief for all cables.
See also
Securing the cables (Page 37)

3.3.2 Connecting the equipotential bonding circuit
Differences in electrical potential

Differences in electrical potential can develop between spatially separated system
components. Such electrical potential differences can lead to high equalizing currents on the
data cables and therefore to the destruction of their interfaces. Equalizing currents can
develop if the cable shielding is terminated at both ends and grounded to different system
parts.
Differences in potential may develop when a system is connected to different mains
supplies.
General requirements for equipotential bonding

Differences in potential must be reduced by means of equipotential bonding conductors to
ensure trouble-free operation of the relevant components of the electronic system. The
following must therefore be observed when installing the equipotential bonding circuit:
● The effectiveness of equipotential bonding increases as the impedance of the
equipotential bonding conductor decreases or as its cross-section increases.
● If two system parts are interconnected by means of shielded data cables and their
shielding is bonded at both ends to the grounding/protective conductor, the impedance of
the additionally installed equipotential bonding conductor must not exceed 10% of the
shielding impedance.
● The cross-section of an equipotential bonding conductor must be capable of handling the
maximum equalizing current. The best practical results for equipotential bonding between
two cabinets have been achieved with a minimum conductor cross-section of 16 mm².
● Use equipotential bonding conductors made of copper or galvanized steel. Establish a
large surface contact between the equipotential bonding conductors and the
grounding/protective conductor and protect them from corrosion.
● Clamp the shielding of the data cable from the HMI device flush at the equipotential rail
using suitable cable clamps. The equipotential rail should be very close to the HMI
device.
● Route the equipotential bonding conductor and data cables in parallel and with minimum
clearance between them.
Note
Equipotential bonding conductor
Cable shielding is not suitable for equipotential bonding. Always use the prescribed
equipotential bonding conductors. The cross-section of the equipotential bonding conductor
must not be less than 16 mm². Always use cables with an adequate cross-section when
installing MPI and PROFIBUS DP networks. The interface modules may otherwise be
damaged or destroyed.

Procedure
1. Interconnect the functional earth
connection of the HMI device with
an equipotential bonding
conductor, cross-section 4 mm2.
2. Connect the equipotential bonding

conductor to the equipotential
bonding rail.
3.3.3 Connecting the power supply
Stripping the cable

Use power supply cables with a
maximum cross-section of 1.5 mm2.
1. Strip the ends of two power supply
cables to a length of 6 mm.
2. Attach cable sleeves to the bare
cable ends.
3. Install the end sleeves on the
cable ends using the crimp pliers.

Procedure
NOTICE
24 V DC only
An incorrectly dimensioned power supply can destroy the HMI device.
Use a 24 V DC power supply with adequate amperage; see Technical specifications
(Page 93).
NOTICE
Safe electrical isolation
Use only 24 V DC power supply units with safe electrical isolation in accordance with IEC
60364-4-41 or HD 384.04.41 (VDE 0100, Part 410), for example, to PELV standard.
The supply voltage must be within the specified voltage range. Otherwise, malfunctions at
the HMI device cannot be ruled out.
Applies to non-isolated system configurations:
Connect the connection for GND 24 V from the 24 V power supply output to equipotential
bonding for uniform reference potential. You should always select a central point of
termination.
1. Insert the two power cables into

the mains terminal and secure
them with a slotted screwdriver.
2. Connect the mains terminal to the

HMI device.
3. Switch off the power supply.
4. Insert the two remaining cable

ends into the power supply
terminals and secure them with
the slotted screwdriver.
Ensure correct polarity.

3.3.4 Connecting a programming device

A programming device gives you the following options:
● Transfer a project
● Transfer an HIM device image
Connecting a programming device to a Basic Panel DP

1. Shut down the HMI device.
2. Connect an RS 485 PROFIBUS

connector to the HMI device.
3. Connect an RS 485 PROFIBUS

connector to the programming
device.
3.3.5 Connecting the configuration PC

A configuration PC gives you the following options:
● Transfer a project
● Transfer an HIM device image
● Reset the HMI device to factory settings

Connecting a configuration PC to a Basic Panel with PROFINET interface
NOTICE
Data network security for communication via Ethernet
With Ethernet-based communication via PROFINET, the end user is responsible for the
security of the data network; proper functioning of the data network cannot be guaranteed
under all circumstances, for example, in case of targeted attacks that result in an overload
of the device.
Use a CAT5 Ethernet cable or higher to connect the configuration PC.
2. Connect one RJ45 connector of the

LAN cable to the HMI device.
3. Connect the other RJ45 connector of

the LAN cable to the configuration
PC.
See also
Data transmission options (Page 65)

3.3.6 Connecting the controller

If the HMI device contains an operating system and an executable project, connect the HMI
device to the controller.
Note
Note the following when connecting the controller to a panel:
• Route the data lines parallel to the equipotential bonding conductors
• Connect the shields of the data lines to the ground
Connecting a controller to a Basic Panel DP

You can connect Basic Panels DP via
the RS 422/RS 485 interface to the
following SIMATIC controllers:
• SIMATIC S7-200
• SIMATIC S7-300/400
• SIMATIC S7-1200
• SIMATIC S7-1500
You can connect Basic Panels DP to

the following controllers:
• Modicon Modbus
• Allen Bradley DF1
• Mitsubishi
• Omron

Connecting a controller to a Basic Panel with PROFINET interface
NOTICE
Data network security for communication via Ethernet
With Ethernet-based communication via PROFINET, the end user is responsible for the
security of the data network; proper functioning of the data network cannot be guaranteed
under all circumstances, for example, in case of targeted attacks that result in an overload
of the device.
You can connect Basic Panels with

PROFINET interface to the following
SIMATIC controllers:
• SIMATIC S7-200
• SIMATIC S7-300/400
• SIMATIC S7 with PROFINET
interface
• SIMATIC S7-1200
• SIMATIC S7-1500
The connection is set up via

PROFINET/LAN.
See also
Connecting the equipotential bonding circuit (Page 27)

3.3.7 Connecting a USB device

Below are examples of devices designed for industrial use you can connect to the USB type
A interfaces of the HMI device:
● External mouse
● External keyboard
● USB memory stick
● Industrial USB Hub 4
Additional information is available in the section "Accessories (Page 15)".
Note when connecting
Note
Connect a USB mouse or USB keyboard only for commissioning and servicing purposes to
the USB port.
Note
USB 2.0 certified cable required
If you use a USB cable which is not USB 2.0 certified, errors may occur during data transfer.
Use only USB cables that are labeled "Certified HI-SPEED USB 2.0".
Note
USB cable length maximum 1.5 m
USB cables with lengths more than 1.5 m do not ensure secure data transfer.
The cable may not be longer than 1.5 m.
Note
Functional problem with USB port
If you connect an external device with a 230 V power supply to the USB port without using
an non-insulated installation, you may experience functional problems.
Use a non-insulated system design.

3.4 Switching on and testing the HMI device
Note
Excessive rated load on port
A USB device with too high a power load may possibly cause functional problems.
Observe the values for the maximum load of the USB interface. You can find the values in
the chapter "USB (Page 99)".
Note
USB memory stick is not detected.
Depending on the USB memory stick you use, it may happen that the operating system does
not detect the USB memory stick. In this case, use a different USB stick.
Switching on the HMI device

Switching on the power supply.
The screen lights up shortly after power
is switched on.
If the HMI device fails to start, you have
probably crossed the cables on the
power supply terminal. Check the
connected cables and change their
connection.

The Start Center opens after the operating system has started.
You operate the Start Center using the buttons on the touch screen or a connected mouse or
keyboard.
• Press the "Transfer" button to set the

HMI device to "Transfer" mode.
The "Transfer" mode can only be
activated when at least one data
channel has been enabled for the
transfer.
• Press the "Start" button to start the
project on the HMI device.
• Press the "Settings" button to start
the "Settings" page of the Start
Center.
You can change various settings on
this page, for example, the transfer
settings.
Shutting down the HMI Device

1. Close any active projects on the HMI device.
2. Shut down the HMI device. You have the following shutdown options:
– Switch off the power supply.
– Remove the power supply terminal from the HMI device.

3.5 Securing the cables
3.5 Securing the cables
NOTICE
Strain relief
Contacts can be broken or wires can be torn off if cables are not provided adequate strain
relief.
Provide adequate strain relief for all cables.
The following HMI devices come equipped with a fixing element on the back for strain relief:
● KTP900 Basic
● KTP1200 Basic
After the power-on test, use a cable tie to secure the connected cables to the marked fixing
element in order to provide strain relief.

Operating the device 4
4.1 Overview
All Basic Panels 2nd Generation come equipped with a touch screen and function keys. You
use the touch screen to operate the Start Center or the project running on your HMI device.
You use the function keys to trigger the associated configured functions within a project.
DANGER
Incorrect operation
A project can contain certain operations that require in-depth knowledge about the specific
system on the part of the operator.
Ensure that only trained professional personnel operate the system.
Operating the touch screen
NOTICE
Damage to the touch screen
Pointed or sharp objects can damage the plastic surface of the touch screen.
Operate the touch screen only with your fingers or with a touch pen.
Triggering unintended actions
Touching several operating elements at the same time can trigger unintended actions.
Touch only one operating element on the screen at a time.
Operating elements are touch-sensitive symbols on the screen of the HMI device.
They are basically operated in the same way as mechanical keys. You activate operating
elements by touching them with your finger.
Note
The HMI device returns a visual feedback as soon as it detects that an operating element
has been touched.
The visual feedback is independent of any communication with the controller. The visual
feedback signal therefore does not indicate whether or not the relevant action is actually
executed.

Operating the device
4.1 Overview
Examples:
● Buttons
Buttons can assume the following states:
"Untouched" "Touched"
Shading below Shading on top

● Invisible buttons
The focus of invisible buttons is by default not indicated following selection. No optical
operation feedback is provided in this case.
The configuration engineer may, however, configure invisible buttons so that their outline
appears as lines when touched. This outline remains visible until you select another
operating element.
● I/O fields
A screen keyboard appears as visual feedback after you touch an I/O field, for example,
to enter a password. The type of keyboard depends on the mounting position and the
touched operating element.
The screen keyboard is automatically hidden again when input is complete.
Note
Description of all operating elements
A comprehensive description of all operating elements for your HMI device is provided in
"Display and operating elements" section of the WinCC Online Help.
Operating function keys

The function keys can be assigned global or local functions:
● Function keys with global function assignment
A function key with global function assignment always triggers the same action on the
HMI device or in the controller, regardless of the currently displayed screen. An example
of such an action is the activation of a screen, or the closing of an alarm window.
● Function keys with local function assignment
A function key with local function assignment is screen-specific and is therefore only
effective within the active screen. The function assigned to such a function key can vary
from screen to screen.
The function key can be assigned only a single function, either global or local, within a
screen. Local function assignments override global function assignments.

4.2 General functions of the screen keyboard
4.2 General functions of the screen keyboard

The following keys are available on the screen keyboard of all Basic HMI devices with touch
functionality:
Cursor left
Cursor right
Delete characters left
Cancel input
Delete characters right
Confirm input
Shift to capital letters for the next character to be entered
Permanently switching to capital letters, corresponds to the "CAPS LOCK" function.
Switching to numerical keyboard
Switching to alphanumerical keyboard
Displaying infotext.
This key only appears when an infotext has been configured for the operating element.

4.3 The screen keyboards

A screen keyboard appears on the HMI device touch screen when you touch an operating
element that requires input. Depending on the type of operating element and the required
input, this may be an alphanumerical or a numerical keyboard.
Both keyboards are available in landscape and in portrait.
Alphanumerical screen keyboard

For HMI devices in landscape, the alphanumerical keyboard has the assignment of a
computer keyboard in US layout ("QWERTY"). You can set the keyboard to capital letters.

For HMI devices in portrait, the letters are sorted alphabetically.
Note
Job mailbox has no effect
Job mailbox 51 "Select screen" has no effect while the screen keyboard is open.
Key assignment
The alphanumerical screen keyboard layout is monolingual.
A language change within the project has no effect on the layout of the alphanumerical
screen keyboard.

Numerical screen keyboard

The numerical keyboard only offers numbers and the letters A to F for hexadecimal inputs.

4.4 Entering data
The layout changes accordingly for HMI devices in portrait format.
Checking numerical value limits

Tags can be assigned limit values. Any entry of a value outside this limit is rejected. If an
alarm view is configured, a system event is triggered and the original value is displayed
again.
Decimal places of numerical values

The configuration engineer can define the number of decimal places for a numerical text box.
The number of decimal places is checked when you enter a value in this type of I/O field.
● Decimal places that exceed the limit are ignored.
● Unused decimal places are padded with "0" entries.

4.4 Entering data
4.4 Entering data

You make all entries using the screen keyboard.
Procedure
1. Touch the desired operating element
on the screen.
The alphanumerical or the numerical
screen keyboard opens.
A value existing in the operating
element is applied to the display line
of the keyboard.
2. Change or overwrite the value.
Depending on the settings, the HMI
device outputs an audible signal.
On the alphanumerical keyboard use
the <Shift> key to enter upper-case
letters.
3. Press <123> on the alphanumerical
screen keyboard to switch to numbers
and special characters.
You return with <ABC>.
4. Press <Return> key to confirm your
entries, or cancel them with <ESC>.
Either action closes the screen
keyboard.

Configuring the device 5
5.1 Opening the settings
The Start Center opens after the HMI

device has been switched on.
Use the "Settings" button to open the
settings for parameter assignment of
the device.
You can make the following settings:
• Settings for operation
• Communication settings
• Password protection
• Transfer settings
• Screen saver
• Acoustic signals
The Start Center is divided into a
navigation area and a work area.
If the device is configured in
landscape, the navigation area is on
the left and the work area on the right
in the display.
If the device is configured in portrait,
the navigation area is on the top and
the work area on the bottom in the
display.
Note
Start Center of the 4" device
The buttons "Transfer", "Start" and "Settings" are displayed in a space-saving manner in the
Start Center of the 4" device. The button is located between the navigation area and the
work area to minimize or maximize the navigation area.

Configuring the device
5.2 Overview
Protecting the Start Center with a password

You can protect the Start Center against unauthorized operation. You can read the settings
in the Start Center without having entered a password, however, you are not permitted to
edit the settings.
This prevents inadvertent operations and increases security for the system or machine
because the settings cannot be edited.
Note
If the password is no longer available for the Start Center, you first have to update the
operating system before you can make any changes in the Start Center.
All data on the HMI device is overwritten when you update the operating system.
5.2 Overview
The following table shows the functions available in the Start Center for configuring your HMI
device. Individual functions may be hidden, depending on the device type and device
configuration.
Symbol Function
Configuring the time server (Page 49)
Enter time and date (Page 50)
Activating the acoustic signal (Page 51)
Configuring Autostart or wait time (Page 52)

Changing the password settings (Page 52)
Displaying licensing information for the HMI device (Page 55)
Displaying information about the HMI device (Page 56)
Changing the network configuration (Page 57)
Changing the MPI/DP settings (Page 58)
Enabling a data channel (Page 59)
Calibrating the touch screen (Page 60)
Changing the monitor settings (Page 61)
Setting the screen saver (Page 62)

5.3 Configuring the time server
5.3 Configuring the time server

The HMI device has a buffered realtime clock. The realtime clock is set by using the
configuration or by using a time server.
If you are not using a time server, you can also set the time manually.
To fetch the time-of-day of the HMI device from a time server, you can specify up to four
different time servers. The time-of-day is synchronized via the "Network Time Protocol"
(NTP). The availability of the time server is displayed.
Also specify the update cycle of the time-of-day and, if necessary, a time shift. Update cycle
and time shift are valid for all configured time servers.
Note
Do not enter any additional time shift here, but in the "Date & Time" tab.
1. Press "Date & Time" to open the "Date,

Time & Timezone Settings" dialog.
2. Activate the time-of-day

synchronization.
3. At "Update Rate", enter the time

duration in seconds according to which
the time-of-day will be synchronized.
Value range: 10 to 86400 (1 day)
4. Use the "+" button to enter an additional

time server.
5. Enter the IP address of the time server

under "Address".
The connection is established. If the
connection was successfully
established, date and time are
displayed.
You can detect the availability of the
server by the green or red symbol.
6. Use the "-" button to remove the time

server added last from the configuration.

5.4 Enter time and date
5.4 Enter time and date

You can enter the time and date as well as a time shift in the Start Center.
This time becomes valid when you have switched off "NTP", which means when you do not
fetch the time-of-day from a server.
The time shift also applies for the time fetched by a time server.
1. Press "Date & Time" to open the

"Date & Time" dialog.
2. Open the "Date & Time" tab.
3. Select the date and the required

time in the drop-down lists.
4. If necessary, enter a time shift with

the selection wheel under "Time
shift".
The set time shift applies even if
you fetch the time-of-day from a
time server.
The resulting time is displayed
under "Localtime".

5.5 Activating the acoustic signal
5.5 Activating the acoustic signal
1. Press "Sounds" to open the

"Volume" dialog.
2. Set the "Sound" to "ON".
Once you have set the "Sound" to

"ON" you receive an acoustic
feedback in the running project
each time you touch the touch
screen.

5.6 Configuring Autostart or wait time
5.6 Configuring Autostart or wait time

You specify in the "System Control/Info" dialog if the project starts immediately after
switching on the device or after a wait time.
1. Press "System Control/Info" to

open the "System Control/Info"
dialog.
The "Autostart Runtime" tab is
open.
2. Switch on the "Autostart" function.
3. Set the wait time with the selection

wheel under "Wait".
The wait time is the time in
seconds between the appearance
of the Start Center and automatic
start of the project.
Value range: 0 ... 60 s
Note
Immediate start of the project with a delay time of 0 seconds
The project starts immediately if a delay time of 0 seconds is set. It is now no longer possible
to call the Start Center after switching on the HMI device. To handle this situation, you need
to configure an operating element with the "Close project" function.

5.7 Changing the password settings

Password protection prevents unauthorized access to the Start Center.
Note
The password cannot contain spaces or special characters * ? . % / \ ' "
If the password is no longer available for the Start Center, you first have to update the
operating system before you can make any changes in the Start Center. All data on the HMI
device will be overwritten when you update the operating system.
Activating password protection

1. Press "System Control/Info" to open
the "System Control/Info" dialog.
2. Switch to the "Access Protection" tab.
3. Enter a password in the "Password"

text box. Touch the text box. The
alphanumerical screen keyboard is
displayed.
4. Confirm the password in the "Confirm

Password" text box.

Deactivating password protection

dialog.
2. Switch to the "Access Protection"

tab.
3. Delete the entries in the

"Password" text box.
4. Delete the entries in the

"Confirm Password" text box.

5.8 Displaying licensing information for the HMI device
5.8 Displaying licensing information for the HMI device

dialog.
2. Change to the "License Info" tab.

The "License Info" tab is used to
display the licensing information
for the software of the HMI device.

5.9 Displaying information about the HMI device
5.9 Displaying information about the HMI device

dialog.
2. Shift the bookmarks up in the

navigation area.
3. Change to the "System Info" tab.
The "System Info" tab is used to

display specific information on the
HMI device. You will need this
information when contacting
Technical Support.
– "Device:" HMI device name
– "Image version": Version of the
HMI device image
– "Bootloader version": Boot
loader version
– "Bootloader release date":
Release date of the boot loader
– "PN X1": MAC address, only for
HMI devices with PROFINET
interface

5.10 Changing the network configuration
5.10 Changing the network configuration
Note
Communication errors caused by IP address conflicts
Communication errors can occur if several devices in a network share the same IP address.
Assign a unique IP address to every HMI device in the network.
1. Press "Network Interface" to open the

"Interface PN X1" dialog.
2. Choose either automatic address
assignment via "DHCP", or user-
specific address assignment.
3. If assigning a user-specific address,
use the screen keyboard to enter valid
values in the "IP address", "Subnet
mask" text boxes and if applicable in
the "Default gateway" text box.
4. Select the transmission rate in the
PROFINET network and the
transmission type in the "Mode and
speed" selection box under "Ethernet
parameters".
Valid values are 10 Mbps or
100 Mbps and "HDX" (half duplex) or
"FDX" (full duplex).
5. If the "Auto Negotiation" entry is
selected, the transmission type and
transmission rate in the PROFINET
network will be automatically detected
and set.
6. If the "LLDP" switch is selected, the
HMI device exchanges information
with other HMI devices.
7. Enter a network name for your HMI
device in the "Device name" field
under "Profinet".
The name must meet the following
conditions.
– A maximum of four blocks with up
to 63 characters each. Example:
"Press1.Fender.Bodywork.Hall3"
– Characters "a" to "z", numbers "0"
to "9"; special characters: "-"
and "."

5.11 Changing the MPI/DP settings
5.11 Changing the MPI/DP settings
Note
The settings for MPI or PROFIBUS DP communication are defined in the HMI device project.
Edit the transfer settings only in the following situations:
• Initial transfer of a project.
• Changes made to the project are activated at a later time.
1. Press "Network Interface" to open

the "Profibus" dialog.
2. Enter the bus address for the HMI

device in the "Address" text box. The
bus address must be unique within
the MPI/PROFIBUS DP network.
3. Enter the time limit for the

PROFIBUS communication in the
"Time-out" text box.
Valid values are 1 s, 10 s, 100 s.
4. Select the profile from the "Profile"

selection box.
5. Select the transmission rate from the

"Transmission rate" text box.
6. Enter the highest station address on

the bus in the "Highest station
address" text box. Valid range of
values: 1 to 126.
7. The PROFIBUS profile data is

displayed under "Bus parameters...".

5.12 Enabling a data channel
5.12 Enabling a data channel

You must enable one data channel to transfer a project to the HMI device.
Note
After having completed the project transfer, you can protect the HMI device against
unintentional overwriting of project data and of the HMI device image by locking all data
channels.
1. Press "Transfer Settings" to open

the "Transfer Settings" dialog.
2. Switch on "Enable transfer".
3. To enable automatic transfer,

switch on "Automatic".
When the automatic transfer is
activated, you can start a transfer
from the configuring PC while the
project is running. The running
project is closed in this case and
the new project is transferred.
The new project starts after it is
transferred.
See also
Changing the MPI/DP settings (Page 58)
Changing the network configuration (Page 57)

5.13 Calibrating the touch screen
5.13 Calibrating the touch screen
1. Press "Touch" to open the "Touch"

dialog.
2. Click the "Recalibrate" button.
3. Press any spot on the touch
screen within the next 15 seconds.
4. Touch the five calibration crosses
one after the other.
If you have not touched a
calibration cross within the
expected range, calibration will
start once again.
If you have touched all calibration
crosses within the expected range,
calibration is complete and will be
saved.

5.14 Changing the monitor settings
5.14 Changing the monitor settings
Note
Orientation of the screen (portrait or landscape)
The screen orientation is defined by the configuration engineer in the course of project
creation. The appropriate screen orientation is set automatically when you transfer the
project to the HMI device.
Do not make any changes to the screen orientation if a project exists on the HMI device with
a different orientation. The screen content may otherwise be truncated.
1. Press "Display" to open the

"Display" dialog.
2. Select the screen orientation:

– "0° (Landscape)" for landscape
– "90° (Portrait)" for portrait
3. Use the "Brightness" slider to set

the screen brightness.

5.15 Setting the screen saver
5.15 Setting the screen saver
Note
Burn-in effect
The screen contents may leave a faint version (ghost) of the image in the background if they
appear for too long.
The "ghost" will disappear automatically after some time. The longer the same content is
displayed on the screen, the longer it will take for the burn-in effect to disappear.
The screen saver helps to prevent burn-in.
Always use the screen saver.
1. Press "Screensaver" to open the

"Screensaver" dialog.
2. Switch on the screensaver with

"Enable screensaver".
3. Enter the number of minutes with

the selection wheel before the
screen saver is to be activated
under "Wait".
You may select values between 1
and 120 minutes.

Commissioning a project 6
6.1 Overview
Configuration phase
A project – the process image of the working process – is created during configuration to
visualize automated working processes. The process displays for the project contain
displays for values and messages which provide information about process statuses. The
process control phase follows the configuration phase.
Process control phase

The project must be transferred to the HMI device if it is to be used in process control.
Another prerequisite for process control is that the HMI device is connected online to a
controller. Current working processes - operating and observing - can then be subject to
process control.
Transferring the project to the HMI device

You can transfer a project to an HMI device as follows:
● Transfer from the configuration PC
● Restore from a PC using ProSave
In this case, an archived project is transferred from a PC to the HMI device. The
configuration software does not need to be installed on the PC.
ProSave is a service tool that enables you to manage data on your HMI device. With
ProSave, you can update the operating system of the HMI device, for example, or backup
its data.
● Pack & Go
A project is transferred by means of a storage medium to the HMI device using a PC with
ProSave. The configuration software does not need to be installed on the PC.
Commissioning and recommissioning

Initial startup and recommissioning differ in the following respects:
● With initial startup, there is not project on the HMI device.
The HMI device is also in this state after the operating system has been updated.
● When recommissioning, any project already on the HMI device is replaced.

Commissioning a project
6.2 Operating modes
6.2 Operating modes
Operating modes
The HMI device may be in the following operating modes:
● Offline
● Online
● Transfer
"Offline mode" and "Online mode" can be set on both the configuration PC and the HMI
device. To set these modes on the HMI device, use a corresponding operating element of
the project.
Changing the operating mode

The configuration engineer must have configured an appropriate operating element to allow
a change of the operating mode on the HMI device during ongoing operation.
Additional information may be available in your system documentation.
"Offline" operating mode

In this mode, there is no communication between the HMI device and the controller. Even
though the HMI device can be operated, it cannot exchange data with the controller.
"Online" operating mode

In this mode, the HMI device and the controller communicate with each other. You can
operate the system on the HMI device according to your system configuration.
"Transfer" mode
In this mode, you can transfer a project from the configuration PC to the HMI device, for
example, or backup and restore HMI device data.
The following options are available for setting "Transfer" mode on the HMI device:
● When the HMI device starts up
Start "Transfer" mode manually in the HMI device Loader.
● During ongoing operation
Start the "Transfer" mode manually within the project using an operating element. The
HMI device toggles to "Transfer" mode when automatic mode is set and a transfer is
initiated on the configuration PC.

6.3 Data transmission options
6.3 Data transmission options
Overview
The following table shows the options for data transfer between the HMI device and the
configuration PC.
Project Data channel Basic Panels DP Basic Panels with

PROFINET
interface
Backup/restore MPI/PROFIBUS DP Yes -
Operating system update PROFINET - Yes
Project transfers
Updating the operating system MPI/PROFIBUS DP - -
with "Reset to factory settings" PROFINET - Yes
6.4 Transfer
6.4.1 Overview
Transfer the executable project from the configuration PC to the HMI device.
You can start the "Transfer" mode manually or automatically on the HMI device.
Transferred data is written directly to internal flash memory of the HMI device. Assign
parameters of a corresponding data channel before you start the transfer.
6.4.2 Starting the manual transfer
Introduction
You can manually switch the HMI device to "Transfer" mode as follows:
● At runtime, using a configured operating element.
● In the Start Center of the HMI device.
Requirements
● The project is open in WinCC.
● The project is compiled.
● The HMI device is connected to a configuration PC.
● The data channel parameters are assigned on the HMI device.
● The HMI device is in "Transfer" mode.

6.4 Transfer
Procedure
If you are loading a project to an HMI device for the first time, the "Advanced loading" dialog
is automatically opened. You configure the appropriate interface parameters in this dialog.
For further information, refer to the WinCC documentation.
Proceed as follows:
1. If you want to load a project simultaneously to several HMI devices, use multiple selection
to select all the desired HMI devices in the project tree.
2. Select the "Load to device > Software" command in the shortcut menu of an HMI device.
3. When the "Advanced loading" dialog appears, configure the "Settings for loading":
– Select the interface via which the project will be loaded.
– Configure the corresponding interface parameters.
– Click on "Load".
You can open the "Advanced loading" dialog at any time with the menu command
"Online > Advanced loading to device…".
The "Load preview" dialog" opens. The project is compiled at the same time. The result is
displayed in the "Load preview" dialog.
4. Check the displayed default settings and edit them, if necessary.
5. Click on "Load".
Result
The project is available on the HMI device following successful transfer. If the "Autostart"
function is activated in the Start Center, the transferred project is started automatically.
6.4.3 Starting the transfer automatically
Introduction
If automatic transfer is activated, the HMI device automatically changes to "Transfer" mode
at runtime as soon as a transfer is started on the connected configuration PC.
Automatic transfer is particularly suited for the test phase of a new project because transfer
is completed without interfering with the HMI device.

6.4 Transfer
Note
If automatic transfer is activated on the HMI device and a transfer is initiated on the
configuration PC, the project currently running is automatically stopped. The HMI device then
automatically switches to "Transfer" mode.
After the commissioning phase, deactivate the automatic transfer so that the HMI device
cannot be inadvertently switched to transfer mode. Transfer mode can trigger unintentional
actions in the system.
You can issue a password in the Start Center to restrict access to the transfer settings and
thus avoid unauthorized modifications.
Requirements
● The project is open in WinCC.
● The project is compiled.
● The HMI device is connected to a configuration PC.
● The automatic transfer is enabled in the Start Center.
Procedure
If you are loading a project to an HMI device for the first time, the "Advanced loading" dialog
is automatically opened. You configure the appropriate interface parameters in this dialog.
For further information, refer to the WinCC documentation.
Proceed as follows:
1. If you want to load a project simultaneously to several HMI devices, use multiple selection
to select all the desired HMI devices in the project tree.
2. Select the "Load to device > Software" command in the shortcut menu of an HMI device.
3. When the "Advanced loading" dialog appears, configure the "Settings for loading":
– Select the interface via which the project will be loaded.
– Configure the corresponding interface parameters.
– Click on "Load".
You can open the "Advanced loading" dialog at any time with the menu command
"Online > Advanced loading to device…".
The "Load preview" dialog" opens. The project is compiled at the same time. The result is
displayed in the "Load preview" dialog.
4. Check the displayed default settings and edit them, if necessary.
5. Click on "Load".

6.4 Transfer
Result
The configuration PC checks the connection to the HMI device. The HMI device shuts down
the current project and automatically changes to "Transfer" mode. The project is transferred
to the HMI device. An error message is displayed on the configuration PC if the connection is
not available or disrupted.
The project is available on the HMI device following successful transfer. The transferred
project is started automatically.
6.4.4 Testing a project
Introduction
You have the following options to test a project:
● Test the project on the configuration PC
You can test a project on a configuration PC, using a simulator. You can find more
detailed information on this in the WinCC online help.
● Offline testing of the project on the HMI device
Offline testing means that communication between the HMI device and controller is down
while the test is being carried out.
● Online testing of the project on the HMI device
Online testing means that the HMI device and the controller communicate with each other
during testing.
Perform the tests, starting with the "Offline test", followed by the "Online test".
Note
You should always test the project on the HMI device on which the project will be used.
Check the following:

1. Check the correct layout of the screens.
2. Check the screen navigation.
3. Check the input objects.
4. Enter the tag values.
The test ensures that the project will run as you intended on the HMI device.

6.5 Backup and restore
Requirement for offline testing

● The project has been transferred to the HMI device.
● The HMI device is in "Offline" mode.
Procedure
In "Offline" mode, you can test individual project functions on the HMI device without them
being affected by the controller. Controller tags, therefore, are not updated.
Test the operating elements and visualization of the project as far as possible without
connecting to the controller.
Requirement for online testing

● The project has been transferred to the HMI device.
● The HMI device is in "Online" mode.
Procedure
In "Online" mode, you can test individual project functions on the HMI device without them
being affected by the controller. Controller tags are updated in this case.
You have the option to test all communication-dependent functions, for example alarms, etc.
Test the operating elements and views of the project.
6.5.1 Overview
Backup and restore

You can back up and restore the following data in the internal flash memory of the HMI
device with a PC:
● Project and HMI device image
● Password list
● Recipe data
Use one of the following tools for backup and restore:
● WinCC
● ProSave

General information
Note
Power failure
If a complete restore operation is interrupted due to power failure on the HMI device, the
operating system of the HMI device may be deleted. In this case, you have to reset the HMI
device to its factory settings.
Compatibility conflict
If a message is output on the HMI device warning you of a compatibility conflict during the
restore operation, the operating system must be updated.
Note
A data transfer can take several minutes, depending on data volume and transmission rate.
Observe the status display. Do not interrupt the data transfer.
See also
6.5.2 Backup and restore using ProSave
Requirement
● The HMI device is connected to a PC on which ProSave is installed.
Procedure – Backup
1. From the Windows start menu, start ProSave on the PC.
2. Select the HMI device type in the "General" tab.
3. Select the type of interconnection for the HMI device and the PC.
Set the connection parameters.
4. Select the data to be backed up in the "Backup" tab.
– "Complete backup" generates a backup copy of configuration data, recipe data and
the HMI device image to a file in PSB format.
– "Recipes" generates a backup copy of the HMI device's recipe data records in PSB
format.
– "User management" generates a backup copy of the HMI device's user data in PSB
format.
5. Select a destination folder and a file name for the "*.psb" backup file.

6. Set "Transfer" mode on the HMI device.

If automatic transfer mode is enabled on the HMI device, the HMI device automatically
sets "Transfer" mode when a backup is initiated.
7. Start the backup operation in ProSave with "Start Backup".
Follow the instructions in ProSave.
A progress bar opens to indicate the progress of the operation.
Result
The system outputs a message when the backup is completed.
A backup copy of the data is now available on the PC.
Procedure – Restore
3. Select the type of interconnection for the HMI device and the PC.
4. Set the connection parameters.
5. Select the "*.psb" backup file to be restored from the "Restore" tab.
You can see the HMI device for which the backup file was created and the type of backup
data the file contains.
If automatic transfer mode is enabled on the HMI device, the device automatically sets
"Transfer" mode when a restore operation is initiated.
7. Start the restore operation in ProSave on the PC with "Start Restore".
8. Follow the instructions in ProSave.
A progress bar indicates the progress of the operation.
Result
When the restore is successfully completed, the data backed up on the PC is now on the
HMI device.

6.6 Updating the operating system - Basic Panel DP
6.5.3 Backup and restore using WinCC
Requirement
● The HMI device is connected to the configuration PC or the PC with ProSave.
● The HMI device is selected in the project navigation.
● If a server is used for data backup: The HMI device has access to the server.
Backup of the data of the HMI device

1. Select the "Backup" command from the "Online > HMI device maintenance" menu.
The "SIMATIC ProSave" dialog box opens.
2. Select the data to backup for the HMI device under "Data type".
3. Enter the name of the backup file under "Save as".
4. Click "Start Backup".
This starts the data backup. The backup operation takes some time, depending on the
connection selected.
Restoring the data of the HMI device

1. Select the "Restore" command from the "Online > HMI device maintenance" menu.
2. Enter the name of the backup file under "Save as".
Information about the selected backup file is displayed under "Content".
3. Click "Start Restore".
This starts the restoration. This operation takes some time, depending on the connection
selected.
6.6.1 Overview
Updating the operating system

A compatibility conflict may occur when transferring a project to the HMI device. This is
caused by different versions of the configuration software used and the HMI device image
available on the HMI device. If there are different versions, the transfer is aborted. A
message indicating a compatibility conflict is displayed on the configuration PC.

There are two ways to match the versions:

● Update the HMI device image if the project was created with the most recent version of
the configuration software.
● Transfer a matching version of the HMI device image if you do not want to adapt the
project for the HMI device to the most recent version of the configuration software for the
project.
Note
Data loss
All data on the HMI device, such as the project and licenses, will be deleted when you
update the operating system.
Note
Calibrating the touch screen
After the update, you may have to recalibrate the touch screen.
6.6.2 Resetting the factory settings

In ProSave or WinCC, you can update the operating system with or without resetting to
factory settings.
● Updating the operating system without reset to factory settings
First, switch into "Transfer" mode on the HMI device or use the automatic transfer
function if the project is active. Then start the operating system update in ProSave or
WinCC.
● Updating the operating system with reset to factory setting
Note
Data channel
When resetting to factory settings, all data channel parameters used are reset. The
transfer can only be started following reconfiguration of the data channel.
See also

6.6.3 Updating the operating system using ProSave
Requirement
Procedure
3. Select the type of connection between the HMI device and the PC, then set the
connection parameters.
4. Select the "OS Update" tab.
5. Select whether to update the operating system with or without restoring the factory
settings by setting the "Reset to factory settings" check box accordingly.
6. Select the HMI device image file (file type "*.fwf") under "Image path".
The HMI device image files are available under
"Programs\Siemens\Automation\Portal V<TIA version>\Data\Hmi\Transfer\<TIA
version>\Images".
The output area provides information on the version of the successfully opened HMI
device image file.
"Transfer" mode when an update is initiated.
8. Select "Update OS" on the PC to run the operating system update.
A progress bar indicates the progress of the operating system update.
A message is displayed when the operating system update is successfully completed and
the HMI device is restarted.
Result
The transferred image is available on the HMI device.

6.7 Updating the operating system - Basic Panel with PROFINET interface
6.7 Updating the operating system - Basic Panel with PROFINET

interface
6.7.1 Overview
Updating the operating system

A compatibility conflict may occur when transferring a project to the HMI device. This is
caused by different versions of the configuration software used and the HMI device image
available on the HMI device. If there are different versions, the transfer is aborted. A
message indicating a compatibility conflict is displayed on the configuration PC.
There are two ways to match the versions:
● Update the HMI device image if the project was created with the most recent version of
the configuration software.
● Transfer a matching version of the HMI device image if you do not want to adapt the
project for the HMI device to the most recent version of the configuration software for the
project.
Note
Data loss
All data on the HMI device, such as the project and licenses, will be deleted when you
update the operating system.
Note
After the update, you may have to recalibrate the touch screen.

6.7.2 Resetting the factory settings

In ProSave or WinCC, you can update the operating system with or without resetting to
factory settings.
● Updating the operating system without reset to factory settings
First, switch into "Transfer" mode on the HMI device or use the automatic transfer
function if the project is active. Then start the operating system update in ProSave or
WinCC.
● Updating the operating system with reset to factory setting
Note
Data channel
When resetting to factory settings, all data channel parameters used are reset. The
transfer can only be started following reconfiguration of the data channel.
See also
6.7.3 Updating the operating system using ProSave
Requirement
Procedure
3. Select the type of connection between the HMI device and the PC.
4. Set the connection parameters.
5. Select the "OS-Update" tab.
The HMI device image files are available under
version>\Images".
device image file.

7. Switch to "Transfer" mode on the HMI device.

Transfer mode when an update is initiated.
8. Select "Update OS" on the PC to run the operating system update.
Result
6.7.4 Updating the operating system using WinCC

If possible, you should use the interface with the highest bandwidth for this connection, such
as Ethernet. Updating the operating system via a serial connection can take up to an hour.
NOTICE
Updating the operating system deletes all data on the HMI device
When you update the operating system you delete data on the target system. For this
reason, it is advisable to back up the following data:
• User administration
• Recipes
Resetting to factory settings also deletes the License Keys. You should also back up the
License Keys before resetting to factory settings.
Requirement
● The HMI device is connected to the configuration PC.
● The appropriate data channel is configured on the HMI device.

Procedure
1. Select the "Update operating system" command from the menu under "Online > HMI
device maintenance" on the configuration PC in WinCC.
The "SIMATIC ProSave [OS-Update]" dialog opens. The path to the image of the
operating system has been preset.
2. If necessary, select another path to the operating system image you want to transfer to
the HMI device.
3. Click "Update OS".
This starts the update. The update operation can take time, depending on the connection
selected.
The HMI device is restarted when the operating system update is successfully completed.
Result
6.7.5 Resetting to factory settings with ProSave
Requirement
● The HMI device is connected with a standard Ethernet cable to a PC on which ProSave is
installed.
Procedure for setting the PC interface

1. Select "Start > Control Panel > Set PG / PC interface" on the configuration PC.
2. Select "S7ONLINE (STEP7) -> TCP / IP" from the "Application access point" area.
3. Select the interface which is connected to the HMI device from the "Interface parameter
assignment used" area.
4. Confirm your entries.
Procedure for resetting factory settings

2. Select the HMI device type from the "General" tab, and select "Ethernet" from the
Connection area.

3. Enter an IP address.
Note
Possible address conflicts with incorrect IP address
Do not use a dynamic IP configuration for "Reset to factory settings".
Specify a unique IP address of the subnet in which the configuration PC is located. For
the duration of the update process, the HMI device is automatically assigned to the
specified address of ProSave.
If the HMI device has already been used with WinCC or ProSave use the existing IP
address for "Reset to factory settings".
4. Change to the "OS-Update" tab.

5. Select the "Reset to factory settings" check box.
The HMI device image files are available in the WinCC installation folder under
version>\Images" or on the WinCC installation DVD.
device image file.
7. Select "Update OS" on the PC to start the "Reset to factory settings" process.
Result
The transferred image is available on the HMI device. The factory settings are reset.
Note
If you can no longer open the Start Center on the HMI device because the operating system
is missing, carry out the steps described above to reset the device to the factory settings and
try again.
Note
When the restore operation has been completed, you may have to recalibrate the touch
screen.

6.7.6 Resetting to factory settings with WinCC
NOTICE
Updating the operating system deletes all data on the HMI device
When you update the operating system you delete data on the target system. For this
reason, it is advisable to back up the following data:
• User administration
• Recipes
Note
The following is required to restore factory settings using Ethernet:
• Available IP address
• PG/PC interface of the configuration PC that is set to Ethernet TCP/IP
You configure the PG/PC interface using the Control Panel of the configuration PC. Select
"S7ONLINE (STEP7) -> TCP/IP" under "Application access point".
Requirement
● The HMI device is connected to the configuration PC.
Resetting the HMI device to factory settings

1. Select the "Update operating system" command from the menu under "Online > HMI
device maintenance" on the configuration PC in WinCC.
The "SIMATIC ProSave [OS-Update]" dialog opens. The path to the image of the
operating system has been preset.
2. If necessary, select another path to the operating system image you want to transfer to
the HMI device.
3. Enable "Restore factory settings".
4. Click "Update OS".
This starts the update. The update operation can take time, depending on the connection
selected.
The HMI device is restarted when the operating system update is successfully completed.
Result
The transferred image is available on the HMI device. The factory settings are reset.

Maintenance and care 7
7.1 Maintenance and care
Introduction
The HMI device is designed for maintenance-free operation. Make sure you keep the touch
screen and keyboard membrane clean.
Requirement
Use a cleaning cloth dampened with a cleaning agent to clean the equipment. Only use
water with a little liquid soap or a screen cleaning foam.
Note
Unintentional response
When cleaning the touch screen, an unintentional response in the controller can be triggered
by touching keys.
Switch the HMI device off before cleaning to prevent unintentional responses.
Note
Damage caused by unauthorized cleaning products
The HMI device may be damaged if compressed air, steam jet blowers, aggressive solvents
or scouring powders are used for cleaning purposes.
Do not clean the HMI device with compressed air or steam jet blowers. Do not use
aggressive solvents or scouring powder.
Procedure
Proceed as follows:
2. Spray the cleaning solution onto a cleaning cloth.
Do not spray directly onto the HMI device.
3. Clean the HMI device.
When cleaning the display wipe from the screen edge inwards.

Maintenance and care
7.2 Recycling
7.2 Recycling
Recycling and disposal

The HMI devices described in these operating instructions can be recycled due to the low
levels of pollutants. Contact a certified disposal service company for environmentally sound
recycling and disposal of your old devices.

Technical specifications 8
8.1 Certificates and approvals
Approvals
Note
The following overview shows possible approvals.
The HMI device itself is approved as shown on the rear panel labels.
IEC 61131
The HMI device fulfills requirements and criteria to IEC 61131-2, Programmable Logic
Controllers, Part 2: Operating resource requirements and tests.
CE approval
The HMI device meets the general and safety-related requirements of the following EC
directives and conforms to the harmonized European standards (EN) for programmable logic
controllers published in the official gazettes of the European Union:
● 2004/108/EC "Electromagnetic Compatibility" (EMC Directive)
EC Declaration of Conformity
The EC Declarations of Conformity are available to the relevant authorities at the following
address:
Siemens AG
Industry Sector
I IA AS FA DH AMB
PO Box 1963
D-92209 Amberg, Germany
UL approval
Underwriters Laboratories Inc., to
● UL 508 (Industrial Control Equipment)
● CSA C22.2 No. 142 (Process Control Equipment)
Marking for Australia

The HMI device fulfills the requirements of standard AS/NZS 4665.1-2005 +A1:2009
(Class A).

Technical specifications
8.2 Electromagnetic compatibility
8.2 Electromagnetic compatibility

The device is designed for industrial use.
8.2.1 Emitted interference

The device meets the requirements according to EN 61000-6-4. The device corresponds to
limit class A.
Note
The HMI device is not intended for use in residential areas. Operation of an HMI device in
residential areas can have a negative influence on radio/TV reception.
8.2.2 Immunity to interferences

The device meets the requirements according to EN 61000-6-2.
8.3 Mechanical ambient conditions
8.3.1 Transport and storage conditions

The following information is for a device that is transported and stored in its original
packaging.
The device meets the requirements according to IEC 60721-3-2, Class 2M2 with the
following amendments and limitations:
Type of condition Permitted range

Free fall ≤1m
Vibration to IEC 60068-2-6 5 ... 8.4 Hz, deflection 3.5 mm
8.4 ... 500 Hz, acceleration 1 g
Shock to IEC 60068-2-27 250 m/s2, 6 ms, 1000 shocks

8.4 Climatic ambient conditions
8.3.2 Operating Conditions

The following information applies to a device installed according to the specifications in these
The HMI device is designed for stationary operation in a location protected from the effects
of the weather.
The device meets the requirements according to IEC 60721, Class 3M3 with the following
amendments and limitations:

Vibration to IEC 60068-2-6 5 ... 8.4 Hz, deflection 3.5 mm
8.4 ... 200 Hz, acceleration 1 g
Shock to IEC 60068-2-27 150 m/s2, 11 ms, 3 shocks
8.4.1 Transport and storage conditions

The following information is for a device that is transported and stored in its original
packaging.
The device meets the requirements according to IEC 60721-3-2, Class 2K2 with the

Temperature –20 ... +60 °C
Atmospheric pressure 1080 ... 660 hPa, corresponds to an elevation of 1000 m to 3500 m
Relative humidity 10 ... 90%, without condensation
Pollutant concentration SO2: < 0.5 ppm;
Relative humidity < 60%,
no condensation
H2S: < 0.1 ppm;
no condensation
Note
Ensure that no condensation (dewing) develops on or inside the HMI device after
transporting it at low temperatures or after it has been exposed to extreme temperature
fluctuations.
The HMI device must have acquired room temperature before it is put into operation. Do not
expose the HMI device to direct radiation from a heater in order to warm it up. If dewing has
developed, wait approximately 4 hours until the HMI device has dried completely before
switching it on.

8.4.2 Operating Conditions

The following information applies to a device installed according to the specifications in these
The HMI device is designed for stationary operation in a location protected from the effects
of the weather.
The device meets the requirements according to IEC 60721-3-3, Class 3K3 with the

Temperature, device in landscape
 Vertical mounting 0 ... 50 °C
 Inclined installation, inclination up to 35° 0 ... 40 °C
Temperature, device in portrait
 Vertical mounting 0 ... 40 °C
 Inclined installation, inclination up to 35° 0 ... 35 °C
Atmospheric pressure 1080 ... 795 hPa, corresponds to an elevation of
1000 m to 2000 m
Relative humidity From 10 to 90%, without condensation
Pollutant concentration SO2: < 0.5 ppm;
no condensation
H2S: < 0.1 ppm;
no condensation
8.4.3 Climate diagram

The diagram below shows the extended range for temperature and humidity during operation
based on IEC 60721-3-3 Class 3K3.
The information applies to a device installed in landscape without inclination.

8.5 Protection classes
8.5 Protection classes
8.5.1 Insulation test

The device meets the requirements according to EN 61131-2.
Circuits with a nominal voltage of Ue to other circuits or ground Test voltage

< 50 V 500 V AC
8.5.2 Protection against foreign objects and water

The device meets the requirements according to EN 60529.
Device side Degree of protection

Front When mounted:
• IP65
• Type 4X/Type 12 (indoor use only) 1
Rear panel • IP20
Touch protection test with standard test probes. There is no protection
against ingress by water.
1 Met if specified on the back of the device
The degree of protection of the device front can only be guaranteed if the mounting seal lies
flush against the mounting cutout. Read the corresponding information in section "Making
the mounting cutout".

8.6 Dimension drawings
8.6.1 Dimensional drawing of KTP400 Basic


8.6.3 Dimensional drawing of KTP700 Basic DP


8.6.5 Dimension drawings of KTP1200 Basic

8.6.6 Dimensional drawing of KTP1200 Basic DP

8.7 Technical specifications
8.7.1 Power supply

The following table shows the permitted rated voltage and the corresponding tolerance
range.
Rated voltage Tolerance range

+24 V DC 19.2 ... 28.8 V (–20%, +20%)
8.7.2 KTP400 Basic, KTP700 Basic and KTP700 Basic DP
Weight
KTP400 Basic KTP700 Basic KTP700 Basic DP

Weight without packaging Approx. 360 g Approx. 780 g Approx. 800 g
Display

Type LCD TFT
Active display area 95 x 53.9 mm (4.3") 154.1 x 85.9 mm (7")
Resolution 480 x 272 pixels 800 x 480 pixels
Possible colors 16-bit (65536 colors)
Brightness control Yes
Backlighting LED
Half Brightness Life Time (MTBF 1) 20,000 h
Pixel error class in accordance with II
EN ISO 9241-307
1 MTBF: Operating hours after which the maximum brightness is reduced by half compared to the original value. MTBF is
increased by using the integrated dimming function, for example, time-controlled via screen saver or centrally via
PROFIenergy.
Input device

Type Touch screen, analog resistive
Function keys 4 8
Labeling strips Yes

Memory

Data memory 256 MB
Program memory 512 MB
Interfaces

1 x RS 422/RS 485 - Max. 12 Mbps
1 x Ethernet RJ45 10/100 Mbps -
USB 2.0 Yes
Supply voltage

Rated voltage +24 V DC
Range, permitted 19.2 to 28.8 V (–20%, +20%)
Transients, maximum permitted 35 V (500 ms)
Time between two transients, minimum 50 s
Current consumption
 Typical Approx. 125 mA Approx. 230 mA Approx. 230 mA
 Constant current, maximum Approx. 310 mA Approx. 440 mA Approx. 500 mA
 Inrush current I2 t Approx. 0.2 A2s Approx. 0.2 A2s Approx. 0.2 A2s
Fuse, internal Electronic
Miscellaneous

Buffered real-time clock 1, can be Yes
synchronized
Acoustic feedback Yes
1 Typical buffer time: 3 weeks

8.7.3 KTP900 Basic, KTP1200 Basic and KTP1200 Basic DP
HMI device

Weight without packaging Approx. 1130 g Approx. 1710 g Approx. 1710 g
Display

Type LCD TFT
Display area, active 198.0 mm x 111.7 mm (9") 261.1 mm x 163.2 mm (12")
Resolution, pixels 800 x 480 1280 x 800
Colors, displayable 16-bit (65536 colors)
Brightness control Yes
Pixel error class in accordance II
with
EN ISO 9241-307
Backlighting LED
Half Brightness Life Time 20,000 h
(MTBF 1)
1 MTBF: Operating hours after which the maximum brightness is reduced by half compared to the original value. MTBF is
increased by using the integrated dimming function, for example, time-controlled via screen saver or centrally via
PROFIenergy.
Input device

Type Touch screen, analog resistive
Function keys 8 10
Labeling strips Yes
Memory

Data memory 256 MB
Program memory 512 MB

Interfaces

1 x RS 422/RS 485 - Max. 12 Mbps
1 x Ethernet RJ45 10/100 Mbps -
USB 2.0 Yes
Supply voltage

Rated voltage +24 V DC
Range, permitted 19.2 to 28.8 V (–20%, +20%)
Transients, maximum permitted 35 V (500 ms)
Time between two transients, 50 s
minimum
Current consumption
 Typical Approx. 230 mA Approx. 510 mA Approx. 550 mA
 Constant current, maximum Approx. 440 mA Approx. 650 mA Approx. 800 mA
 Inrush current I2t Approx. 0.2 A2s Approx. 0.2 A2s Approx. 0.2 A2s
Fuse, internal Electronic
Miscellaneous

Buffered real-time clock 1, can be Yes
synchronized
Acoustic feedback Yes
1 Typical buffer time: 3 weeks

8.8 Interface description
8.8.1 Power supply

Name of interface on HMI device: DC24V X80
Plug connector, 2-pin
Pin number Assignment

1 +24 V DC (L+)
2 GND 24 V (M)
8.8.2 PROFIBUS (Sub-D RS422/485)

Name of interface on HMI device: PROFIBUS DP X2
Sub-D socket, 9-pin, with screw lock
Pin Assignment for the RS 422 Assignment for the RS 485

1 n. c. n. c.
2 GND 24 V GND 24 V
3 TxD+ Data channel B (+)
4 RxD+ RTS
5 GND 5 V, floating GND 5 V, floating
6 +5 V DC, floating +5 V DC, floating
7 +24 V DC, out (max. 100 mA) +24 V DC, out (max. 100 mA)
8 TxD– Data channel A (–)
9 RxD– NC

8.8.3 PROFINET (Ethernet)

Name of interface on HMI device: PROFINET (LAN) X1
RJ45 plug connector
Pin Assignment
1 Tx+
2 Tx–
3 Rx+
4 n. c.
5 n. c.
6 Rx–
7 n. c.
8 n. c.
Meaning of LEDs
There is no connection if both LEDs are off.
The green "Link" LED lights up as soon as there is a physical connection.
The yellow "Activity" LED lights up during the data transfer.
8.8.4 USB
Name of interface on HMI device: USB X60
USB socket
The following table shows the pin assignment of the USB port.
Pin Assignment
1 +5 V DC, out, max. 500 mA
2 USB-DN
3 USB-DP
4 GND

8.9 Scope of functions with WinCC

The following tables show the objects that can be integrated in a project for a Basic Panel.
The following tables support you in estimating whether your project is still within the
performance features of the HMI device.
The specified maximum values are not additive. We cannot guarantee proper functioning of
configurations on devices in which all system limits are exploited.
In addition to the limitations specified, allowances must also be made for restrictions in
configuration memory resources.
Tags, values and lists
Object Specification Quantity

Tags Quantity 800
Limit value monitoring Input/output Yes
Linear scaling Input/output Yes
Elements per array Quantity 100
Text lists Quantity 300
Graphics lists Quantity 100
Alarms

Alarms Number of alarm classes 32
Number of discrete alarms 1000
Number of analog alarms 25
Length of the alarm text 80 characters
Number of tags in an alarm Max. 8
Display Alarm window, alarm view
Acknowledge error alarm individually Yes
Acknowledge multiple error alarms simultaneously (group 16 acknowledgment
acknowledgement) groups
Edit alarm Yes
Alarm indicator Yes
Alarm buffer Alarm buffer capacity 256 alarms
Simultaneously queued alarm events Max. 64
View alarm Yes
Delete alarm buffer Yes

Screens

Screens Quantity 250
Fields per screen 100
Tags per screen 100
Template Yes
Objects per screen Complex objects 1) 150
Recipe views 10
Trend views 8
User view 1
Alarm view 20
Diagnostics view 5
System diagnostics view 150
Multiple tags (array elements) 2) 100
1) Complex objects are: bars, sliders, symbol library, clock and all objects from the Controls area.
2) This includes array elements included in recipes.
Recipes
The specified values are maximum values and should not be used additive.

Recipes Quantity 50
Elements per recipe1) 100
Data records per recipe 100
User data length in KB per data record 32
Reserved memory for data records in the internal Flash 256 KB
1) Each element used in arrays represents a recipe element.
Logging

Logs Number of logs 2
Number of tags per log 10
Number of log entries 1) 10,000
Number of segmented circular logs 400
Logging cycle 1s
1) The number of entries for all segmented circular logs is valid for the "segmented circular log" logging method. The
product derived from the number of circular logs times the number of data records in this log may not be exceeded.

Trends
Object Specification Basic Panels

Trends Quantity 25
Text lists and graphics lists

Lists Number of graphics lists 100
Number of text lists 300
Number of entries per text or graphics list 100
Number of graphic objects 1000
Number of text elements 2500
Safety

Safety Number of user groups 50
Number of users 50
Number of authorizations 32
Infotexts

Infotexts Length (no. of characters) 500
For alarms Yes
For screens Yes
For screen objects (for example, for I/O field, switch, button, Yes
invisible button)
Additional functions

Screen settings Touch screen calibration Yes
Brightness setting Yes
Language change Number of runtime languages 10
Graphic objects Vector and pixel graphics Yes
Project

Project file "*.srt" Size 10 MB

Technical Support A
A.1 Service and support
You can find additional information and support for the products described on the Internet at
the following addresses:
● Technical support (http://www.siemens.de/automation/csi_en_WW)
● Support request form (http://www.siemens.com/automation/support-request)
● After-sales information system for SIMATIC PC / PG (http://www.siemens.com/asis)
● SIMATIC Documentation Collection (http://www.siemens.com/simatic-tech-doku-portal)
● Your local representative
(http://www.automation.siemens.com/mcms/aspa-db/en/Pages/default.aspx)
● Training center (http://sitrain.automation.siemens.com/sitrainworld/?AppLang=en)
● Industry Mall (http://mall.automation.siemens.com)
When contacting your local representative or Technical Support, please have the following
information at hand:
● Article number of the device (MLFB)
● BIOS version (industry PC) or image version (HMI device)
● Installed additional hardware
● Installed additional software
Tools & downloads

Please check regularly if updates and hotfixes are available for download to your device. The
downloads are available on the Internet under "After Sales Information System SIMATIC
PC/PG" (see above).

Technical Support
A.2 System events
A.2 System events

System events on the HMI device provide information about internal states of the HMI device
and the controller.
Note
System events are only indicated if an alarm window was configured. System events are
output in the language currently set on your HMI device.
System event parameters

System events may contain encrypted parameters which are relevant to troubleshooting
because they provide a reference to the source code of the runtime software. These
parameters are output after the text "Error code:".
Description of the system events

A listing of all system alarms for your HMI device is provided in the online help of your
configuration software.

Abbreviations B
ANSI American National Standards Institution
CPU Central Processing Unit
CTS Clear To Send
DC Direct Current
DCD Data Carrier Detect
DHCP Dynamic Host Configuration Protocol
DIL Dual-in-Line (electronic chip housing design)
DNS Domain Name System
DP Distributed I/O
DSN Data Source Name
DSR Data Set Ready
DTR Data Terminal Ready
IO Input and Output
ESD Components and modules endangered by electrostatic discharge
EMC Electromagnetic Compatibility
EN European standard
ES Engineering System
ESD Components and modules endangered by electrostatic discharge
GND Ground
HF High Frequency
HMI Human Machine Interface
IEC International Electronic Commission
IF Interface
IP Internet Protocol
LED Light Emitting Diode
MAC Media Access Control
MOS Metal Oxide Semiconductor
MPI Multipoint Interface (SIMATIC S7)
MS Microsoft
MTBF Mean Time Between Failures
n. c. Not connected
NTP Network Time Protocol
OP Operator Panel
PC Personal Computer
PG Programming device
PPI Point-to-Point Interface (SIMATIC S7)
RAM Random Access Memory
PELV Protective Extra Low Voltage

Abbreviations
RJ45 Registered Jack Type 45

RTS Request to send
RxD Receive Data
SD Card Security Digital Card
SELV Safety Extra Low Voltage
SP Service Pack
PLC Programmable Logic Controller
STN Super Twisted Nematic
Sub-D Subminiature D (plug)
TAB Tabulator
TCP/IP Transmission Control Protocol/Internet Protocol
TFT Thin Film Transistor
TTY Teletype
TxD Transmit Data
UL Underwriter’s Laboratory
USB Universal Serial Bus
UPS Uninterruptible power supply
WINS Windows Internet Naming Service

Glossary
"Transfer" mode
HMI device operating mode for transferring an executable project from the configuring PC to
an HMI device.
Acknowledge
Acknowledgment of an alarm confirms that it has been noted.
Alarm, acknowledgment
Acknowledgment of an alarm confirms that it has been noted.
Alarm, activated
Moment at which an alarm is triggered by the PLC or HMI device.
Alarm, deactivated
Moment at which the initiation of an alarm is reset by the PLC.
Alarm, user-specific
User-specific alarms report specific states of a plant that is interconnected with the HMI
device via the PLC.
Automation system
An automation system is a PLC of the SIMATIC S7 product line, e.g. SIMATIC S7-300
Boot loader
The boot loader is used to start the operating system and is started automatically after power
on of the HMI device. The start screen of the Start Center is displayed after the operating
system has loaded.
Configuration software
The configuration software is used to create projects for process visualization. WinCC is an
example of this type of configuration software.

Glossary
Configuring PC
A configuring PC is a programming device or PC on which plant projects are created using
an engineering software.
Display duration
Defines whether a system alarm is displayed on the HMI device and the duration of the
display.
EMC
Electromagnetic compatibility (EMC) is the ability of electrical equipment to function properly
in its electromagnetic environment without influencing this environment.
Event
Incoming events trigger defined functions. Events can be configured. Events which can be
assigned to a button include "Press" and "Release", for example.
Field
Area reserved in configured screens for the input and output of values.
Flash memory
Flash memory is a non-volatile memory with EEPROM chips that is implemented either as
mobile storage medium, or as permanently installed memory module on the motherboard.
Function key
Function keys on the HMI device can be assigned user-specific functions. The functions
assigned to those keys are defined in the engineering phase. The function key assignment
can be specific to an active screen or not.
Half Brightness Life Time

Time period after which brightness is reduced to 50% of the original value. The specified
value depends on the operating temperature.
HMI device
HMI devices are used to operate and monitor machinery and plants. The machine or plant
states are visualized on the HMI device by means of graphic objects or signal lamps. The
operator controls of the HMI device enable intervention in machine or plant processes and
sequences.

Glossary
HMI device image

The HMI device image is a file that can be transferred from the configuring PC to the HMI
device. The HMI device image contains the operating system of the HMI device , including
the elements of the Runtime software required for the executable project file.
I/O field
Enables the input or output of values on the HMI device and their transfer to the PLC.
Infotext
A configured infotext provides information about objects within a project. An alarm infotext,
for example, can contain information on the cause and troubleshooting of faults.
Object
An object is a project element such as a screen or an alarm. Objects are used to view or
enter texts and values on the HMI device.
Operating element
An operating element is a project component that is used to enter values and trigger
functions. An operating element is a button, for example.
Plant
General term referring to machinery, processing centers, systems, plants and processes
which are operated and monitored using an HMI device.
PLC
PLC is a general term for devices and systems with which the HMI device communicates,
e.g. SIMATIC S7.
PLC job
A PLC job triggers a function at the HMI device.
Process visualization
Denotes visualization of technical processes by means of text and graphic elements.
Configured plant screens enable intervention in runtime plant processes by means of data
input and output.

Glossary
Project
A project is the result of a configuration using an engineering software. The project usually
contains several screens with embedded system-specific objects, basic settings and alarms.
The project is saved in the project file.
There is a difference between an offline project on a configuring PC and an online
executable project on an HMI device. A project can be available in more languages on the
configuring PC than can be managed on the HMI device. The project on the configuring PC
can also be set up for different HMI devices. However, on the HMI device you can only
transfer the executable project which has been generated specifically for this HMI device.
Project file
Source file from which the executable project file for the HMI device is generated. The
project file is usually not transferred and is retained on the configuring PC.
Project file, compressed

Compressed format of the project file. The compressed project file can be transferred in
addition to the executable project file to the corresponding HMI device. The upload function
must be activated accordingly on the configuring PC at the time of the transfer. The
compressed project file is usually saved to an external memory card.
A compressed project file has the extension *.pdz.
Project file, executable

An executable project file is generated from the project file for a specific HMI device in the
course of engineering. The executable project file is transferred to the associated HMI device
where it is used to operate and monitor plants.
ProSave
ProSave provides all functions which are necessary to transfer data between the
configuration PC and the HMI device, for example, backup and restoring data or managing
license keys and options.
ProSave is installed by default together with WinCC. The standalone version of ProSave can
also be used for service purposes on a PC without WinCC installation. The standalone
version is available on the installation DVD of WinCC.
Recipe
A recipe represent a combination of tags that form a fixed data structure. The configured
data structure can be assigned data in the configuration software or on the HMI device and
is then referred to as a data record. The use of recipes ensures that all data assigned to a
data record is transferred synchronously to the PLC.

Glossary
Runtime software
The Runtime software is a process visualization software which can be used to test projects
on a configuring PC.
Screen
Mode of visualization of all logically associated process data of a plant. Visualization of the
process data can be supported by means of graphic objects.
Screen object
Refers to objects such as rectangles, I/O fields, or alarm views which are configured for
visualization or operation of the plant.
STEP 7
STEP 7 is the programming software for SIMATIC S7, SIMATIC C7 and SIMATIC WinAC
PLCs.
STEP 7 Micro/WIN
STEP 7 Micro/WIN is the programming software for SIMATIC S7-200 PLCs.
Symbolic I/O field

Symbolic I/O fields are used for the input and output of values. A field contains a list of
default entries from which one can be selected.
System alarms
System alarms are assigned the "System" alarm class. A system alarm reports internal
states of the HMI device and of the PLC.
Tab order
The tab order defined in the course of project engineering determines the sequence for
activating objects by pressing the <TAB> key.
Tags
A tag is a defined memory area that is used to read and write values. Those tags can be
accessed from the PLC or using the HMI device. We distinguish between external tags
(process tags) and internal tags, depending on whether or not the tag is interconnected with
the PLC.

Glossary
Transfer
Transfer of an executable project from the configuring PC to the HMI device.
WinCC
WinCC (TIA Portal) is engineering software for configuring SIMATIC Panels, SIMATIC
Industrial PC and standard PC with the visualization software WinCC Runtime Advanced or
the SCADA system, WinCC Runtime Professional.
A project created with WinCC V13 has the file extension "*.ap13". An executable project file
on a HMI device has the extension "*.fwx".

Index
Configuring PC, 63
Connecting
A Controller, 33
Equipotential bonding, 28
Acoustic feedback, 51
Power supply, 30
Approval for Australia, 83
Programming device, 31
Approvals, 83
USB device, 35
Autostart Runtime, 52
Control cabinet
Working on, 17
B
Backup, 65, 69, 70 D
Data of the HMI device, 72
Decimal places, 45
With ProSave, 70
Degree of protection
with WinCC, 72
Protection against ingress of solid foreign
Basic knowledge
bodies, 87
Required, 4
Protection against water, 87
Display
KTP400 Basic, KTP700 Basic, 94
C
Care, 81 Setting, 61
CE approval, 83 Disposal, 82
Checking
Package content, 21
Power supply, 30 E
Standards and approvals, 83
EC Declaration of Conformity, 83
Clock
Elbow adapter, 15
Electrical isolation, 30
Electrical potential difference, 28
Commissioning engineers, 3
EMC directive, 83
Compatibility conflict, 70
Emission, 19
Conductor cross-section
Equipotential bonding
Equipotential bonding, 28
Conductor, 28
Configuration phase, 63
Connecting, 28
Configuring
Requirements, 28
Date and time, 50
Wiring diagram, 29
MPI/PROFIBUS Settings, 58
ESD, 18
Network settings, 57
Screen saver, 62
Time server, 49

Index
F I
Factory setting Illustrations, 5
With ProSave, 78 Initial startup, 63
with WinCC, 80 Input device
Feedback KTP400 Basic, KTP700 Basic, 94
Acoustic, 51 KTP900 Basic, KTP1200 Basic, 96
Figures, 5 Installation
Functional scope Horizontal mounting, 22
Alarm buffer, 100 Vertical, 23
Alarms, 100 Installation as intended, 17
Graphic objects, 102 Installing
Graphics lists, 102 HMI device, 25
Infotext, 102 Insulation test, 87
Language change, 102 Interfaces
Limit value monitoring, 100 KTP400 Basic, KTP700 Basic, 95
Logging, 101 KTP900 Basic, KTP1200 Basic, 97
Recipes, 101
Safety, 102
Scaling, 100 L
Screen settings, 102
Labeling
Screens, 101
Approvals, 83
Tags, 100
EC Declaration of Conformity, 83
Text lists, 100, 102
Licensing information
Trends, 102
Displaying, 55
Limit value check, 45
List of abbreviations, 105
H
High frequency radiation, 17
HMI device M
Connecting, 27
Maintenance, 81
Data backup, 72
Maintenance technicians, 3
Mounting, 25
Memory
Performance features, 100
Restoring data, 72
KTP900 Basic, TP1200 Basic, 96
Shutting down, 37
Mounting clips
Switching on, 36
Inserting, 26
System limits, 100
Mounting position, 22
Technical specifications, 94, 96
Testing, 36
Updating the operating system, 78
N
Non-isolated system configuration, 30

Index
O R
Offline Radiation
Operating mode, 64 High frequency, 17
Test, 69 Radio interference, 19
Online Rated load
Operating mode, 64 USB port, 36
Test, 69 Rated voltage, 94
Operating instructions Recommissioning, 63
Purpose of, 3 Recycling, 82
Scope, conventions, 4 Registered trademarks, 6
Operating mode, 64 Regulations for the prevention of accidents, 17
Changing, 64 Restore, 69, 71
Offline, 64 Data of the HMI device, 72
Online, 64 With ProSave, 71
Transfer, 64 with WinCC, 72
Operating system Restoring, 65
Update using ProSave, 76 Restoring data
Updating, 72, 75 HMI device, 72
Operators, 3 RS 422 to RS 232 converter, 15
Runtime
Autostart, 52
P
Package content
S
Checking, 21
Password protection Safe electrical isolation, 30
Activating, 53 Safety
Deactivating, 54 Standards, 83
Password protection, 48 Safety instruction
PELV, 30 Compatibility conflict, 70
Performance features Data channel, 73, 76
HMI device, 100 Data loss, 73, 75
Pin assignment Equipotential bonding conductor, 28
USB socket, 99 Functional problem, 35
Power failure, 70 General, 19
Process control phase, 63 High frequency radiation, 17
PROFIBUS connector, 15 Operation indoors, 19
PROFINET connector, 15 Power failure, 70
Project Preventing inadvertent operation, 81
Offline testing, 69 Storage, 85
Testing online, 69 Transportation, 85
Protective film, 15 unauthorized cleaning products, 81
Unintentional response, 81
USB port, 36
Working on the control cabinet, 17
Safety regulations, 17

Index
Screen U
Setting, 61
UL approval, 83
Screen keyboard
Updating
Alphanumerical, 42
Operating system, 72, 75
Key assignment, 42
Operating system of the HMI device, 78
KTP700 Basic, KTP900 Basic, KTP1200 Basic, 42
Using ProSave, 74, 76
Screen saver, 62
with WinCC, 78
Securing device
Usage
With mounting clips, 26
In residential areas, 19
Service packages, 15
Industrial, 19
Service technicians, 3
With additional measures, 19
Shutting down
USB device
HMI device, 37
Connecting, 35
Spare part
USB hub, 15
Mounting clips, 15
USB memory stick, 15
Power supply terminal, 15
at USB port, 36
Start Center
USB port
Overview, 48
Memory stick not detected, 36
Password protection, 48
Rated load, 36
Strain relief, 38
USB socket
Stripping insulation, 29
Pin assignment, 99
Supply voltage
KTP400 Basic, KTP700 Basic,
W
Switching on
HMI device, 36 Weight
System configuration KTP400 Basic, KTP700 Basic, 94
Non-isolated, 30 KTP900 Basic, KTP1200 Basic, 96
System event Working on the control cabinet, 17
in the online help, 104
Parameters, 104
System information
Displaying, 56
System limits
HMI device, 100
T
Display, 94, 96
Input device, 94, 96
Interfaces, 95, 97
Memory, 95, 96
Supply voltage, 95, 97
Testing
HMI device, 36
Trademarks, 6
Transfer, 63, 64, 65
Automatic, 66
Manual, 65
Project, 63
Transfer settings, 59


ATTACHMENT 2
CPU OPERATING INSTRUCTIONS
▹▹▷

HARDWARE DESIGN SPECIFICATION
IM 151-8 PN/DP CPU interface ___________________
Preface
module ___________________
Description 1
Operating and display
___________________
elements 2
SIMATIC
___________________
Communication 3
ET 200S distributed I/O
IM 151-8 PN/DP CPU interface module ___________________
PROFINET 4
___________________
Memory concept 5
Operating Instructions
___________________
___________________
Addressing 7
___________________
Commissioning 8
___________________
Service and maintenance 9
___________________
Functions 10
Debugging functions,
___________
11
diagnostics and
troubleshooting
___________________
Technical data 12
___________________
Appendix A
06/2010
A5E02049034-02
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG A5E02049034-02 Copyright © Siemens AG 2010.

Industry Sector Ⓟ 08/2010 Technical data subject to change
Postfach 48 48
90026 NÜRNBERG
GERMANY
Preface
Purpose of the operating instructions

These operating instructions are intended to supplement the ET 200S Distributed I/O System
Operating Instructions. It contains a description of all the functions performed by the
IM 151-8 PN/DP CPU interface module. The operating instructions do not include functions
that relate generally to ET 200S. These can be found in the ET 200S Distributed I/O System
Operating Instructions.
The information contained in these operating instructions and the ET 200S Distributed I/O
System Operating Instructions allows you to commission ET 200S with the IM 151-8 PN/DP
CPU interface module and to run it as an IO controller on the PROFINET.
You will also find information on how the IM 151-8 PN/DP CPU interface module can be
operated together with the DP master module on the PROFIBUS DP.
Basic knowledge required

To understand these operating instructions you should have general experience in the field
of automation engineering.
Range of validity of these operating instructions

These Operating Instructions are valid for
● the IM 151-8 PN/DP CPU interface module (order number 6ES7151-8AB01-0AB0)
● the DP master module (order number 6ES7138-4HA00-0AB0)
● the components of the ET 200S distributed I/O system specified in the ET 200S
Distributed I/O System Operating Instructions.
Note
A description of the special features of the interface module IM151-8F PN/DP CPU can be
found in the product information on the Internet
(http://support.automation.siemens.com/WW/view/en/29713139).
These operating instructions contain a description of the components that was valid at the
time of publication. We reserve the right to issue a Product Information which contains up-to-
date information about new components and new versions of components.
IM 151-8 PN/DP CPU interface module

Operating Instructions, 06/2010, A5E02049034-02 3
Preface
Changes since the previous version

The following changes have been made compared with the previous version of these
Distributed I/O ET 200S, interface module IM151-8 PN/DP CPU operating instructions,
edition 06/2008, A5E02049033-01:
● PROFINET
– Support of isochronous real-time communication with "high performance"
– Support of isochronous mode on PROFINET
– Media redundancy
– can be configured as an I device
– Shared Device
– IP parameters are configurable via the DCP (Discovery and Configuration Protocol) or
SFB 104 "IP_CONF"
– Configuration and operation of I/O transfer areas in the case of operation as an I
device (direct access by a higher level IO controller to the local IM151-8 CPU I/O as
an I device)
– Initialized for PROFIenergy (SFB 73 / SFB 74)
– Keep Alive function supported
● Open communication via Industrial Ethernet
– Increased data lengths during open communication
– Several connections can be established for each port
– Using TCP/IP: several passive connections can be established for a port (multi-port)
– Extended system diagnostics of PROFINET interface:
Overview and detailed diagnostics of connections of "open communication via
Industrial Ethernet"

4 Operating Instructions, 06/2010, A5E02049034-02
Preface
● Additional web server functionality

– Users can be configured for login
– Connections via http(s)
– Module state
– Display of the communication connections during open communication via Industrial
Ethernet (OUC)
– Extended connection diagnostics during open communication
– Display of resources during communication
– Display of the port statistics of IO devices
– Topology
– User pages (new SFC 99 required)
– Link to Web servers of other configured devices
– Status overview of all configured devices of the PROFINET IO system
– Automatic page update for all dynamic pages on the Web server
– Diagnostic buffer entries and messages can be downloaded as CSV file.
● Further functionalities
– Increased work memory
– Increased performance due to shorter instruction processing times
– Reading out service data
– Number of blocks that can be monitored using the status block increased from 1 to 2
– Effective from STEP 7 V5.5, increase in the status information that can be monitored
using the status block
– Number of breakpoints increased from 2 to 4
– Supports the status byte for power modules
– Encryption of blocks using S7 Block Privacy
– Local data stack size increased (32 kB per execution level/2 kB per block)
– Expansion of the block number range
– Time-delay interrupts: uniform OB 21 / OB 22
– Cyclic interrupts: uniform OB 32 - OB 35
– Number of displayed diagnostic buffer entries in CPU RUN mode is configurable
– Extension of the diagnostic buffer entries in the event of problems on the local I/O bus
of the IM151-8 PN/DP CPU
– Extension of the SFC 12 by 2 new modes for triggering the OB 86 when activating /
deactivating PROFIBUS slaves or PROFINET IO devices

Preface
Guide
The operating instructions contain the following guides which provide quick access to the
specific information you need:
● At the beginning of the documentation you will find a comprehensive table of contents.
● Important terms are explained in the glossary.
● Navigate to the most important topics in our documents using the index.
Recycling and disposal

The IM 151-8 PN/DP CPU interface module is recyclable due to its non-toxic materials. For
environmentally compliant recycling and disposal of your electronic waste, please contact a
company certified for the disposal of electronic waste.
Further support
If you have any questions relating to the products described in these operating instructions,
and do not find the answers in this document, please contact your Siemens partner at our
local offices.
You will find information on who to contact on the Web
(http://www.siemens.com/automation/partner).
A guide to the technical documentation for the various SIMATIC products and systems is
available in the Internet (http://www.siemens.com/automation/simatic/portal).
The online catalog and ordering systems are available on the Internet
(http://www.siemens.com/automation/mall).
Training center
We offer courses to help you get started with the ET 200S and the SIMATIC S7 automation
system. Please contact your regional training center or the central training center in
D -90327, Nuremberg, Germany.
You will find more information on the Web (http://www.siemens.com/sitrain).

Preface
Service & Support on the Internet

In addition to our documentation, we offer a comprehensive knowledge base on the Internet
(http://www.siemens.com/automation/service&support).
There you will find:
● Our Newsletter, which constantly provides you with the latest information about your
products.
● The right documentation for you using our Service & Support search engine.
● The bulletin board, a worldwide knowledge exchange for users and experts.
● Your local contact for Automation & Drives in our contact database.
● Information about on-site service, repairs, spare parts, and much more is available under
"Repairs, spare parts, and consulting".
See also
Support (http://support.automation.siemens.com/WW/view/en/11669702/133300)

Preface

Table of contents
Preface ...................................................................................................................................................... 3
1 Description............................................................................................................................................... 15
1.1 Function of the IM 151-8 PN/DP CPU interface module .............................................................15
1.2 Properties of the IM 151-8 PN/DP CPU interface module...........................................................16
1.3 Properties of the DP master module............................................................................................19
1.4 Example configurations................................................................................................................20
2 Operating and display elements .............................................................................................................. 23
2.1 Operating and display elements of the IM 151-8 PN/DP CPU interface module ........................23
2.2 Status and error displays of the IM 151-8 PN/DP CPU interface module ...................................25
2.3 Display elements of the DP master module.................................................................................26
3 Communication........................................................................................................................................ 27
3.1 Interfaces .....................................................................................................................................27
3.1.1 PROFINET (PN)...........................................................................................................................27
3.1.2 PROFIBUS DP.............................................................................................................................32
3.2 Communication services..............................................................................................................33
3.2.1 Overview of communication services ..........................................................................................33
3.2.2 PG communication.......................................................................................................................35
3.2.3 OP communication.......................................................................................................................36
3.2.4 S7 communication .......................................................................................................................36
3.2.5 Routing.........................................................................................................................................37
3.2.6 Data set routing............................................................................................................................38
3.2.7 Data consistency..........................................................................................................................40
3.3 SNMP communication service .....................................................................................................40
3.4 Open communication via Industrial Ethernet ...............................................................................41
3.5 S7 connections ............................................................................................................................44
3.5.1 S7 connection as communication path ........................................................................................44
3.5.2 Assignment of S7 connections.....................................................................................................45
3.5.3 Distribution and availability of S7 connection resources .............................................................47
3.5.4 Connection resources for routing.................................................................................................48
3.6 DPV1............................................................................................................................................49
3.7 .....................................................................................................................................................51
3.7.1 Language settings........................................................................................................................54
3.7.2 Settings in HW Config, "Web" tab................................................................................................56
3.7.3 Updating and saving information .................................................................................................59

Table of contents
3.7.4 Web pages .................................................................................................................................. 60

3.7.4.1 Start page with general CPU information.................................................................................... 60
3.7.4.2 Identification ................................................................................................................................ 62
3.7.4.3 Diagnostic buffer ......................................................................................................................... 64
3.7.4.4 Module state................................................................................................................................ 66
3.7.4.5 Messages .................................................................................................................................... 72
3.7.4.6 Communication ........................................................................................................................... 73
3.7.4.7 Topology...................................................................................................................................... 80
3.7.4.8 Variable status ............................................................................................................................ 87
3.7.4.9 Variable tables ............................................................................................................................ 88
3.7.4.10 User pages .................................................................................................................................. 91
4 PROFINET .............................................................................................................................................. 95
4.1 Communication by means of PROFINET ................................................................................... 95
4.1.1 Introduction ................................................................................................................................. 95
4.1.2 PROFINET IO and PROFINET CBA .......................................................................................... 96
4.1.3 PROFINET IO System ................................................................................................................ 98
4.1.4 Blocks for PROFINET IO .......................................................................................................... 100
4.2 Isochronous real time communication ...................................................................................... 103
4.3 Prioritized startup ...................................................................................................................... 103
4.4 Device replacement without removable media / PD ................................................................. 104
4.5 IO devices that can be switched during operation .................................................................... 105
4.6 Isochronous mode..................................................................................................................... 105
4.7 I-Device ..................................................................................................................................... 106
4.8 Shared Device........................................................................................................................... 107
4.9 Media redundancy..................................................................................................................... 108
5 Memory concept .................................................................................................................................... 109
5.1 Memory areas and retentive memory ....................................................................................... 109
5.1.1 Memory areas of the IM 151-8 PN/DP CPU interface module ................................................. 109
5.1.2 Retentivity of load memory, system memory and RAM............................................................ 110
5.1.3 Retentivity of memory objects ................................................................................................... 111
5.1.4 Address areas of system memory ............................................................................................ 113
5.1.5 Properties of the SIMATIC Micro Memory Card ....................................................................... 116
5.2 Memory functions...................................................................................................................... 117
5.2.1 General: Memory functions ....................................................................................................... 117
5.2.2 Downloading user programs via SIMATIC Micro Memory Card to the IM 151-8 PN/DP
CPU interface module ............................................................................................................... 118
5.2.3 Handling blocks......................................................................................................................... 119
5.2.3.1 Encryption of blocks .................................................................................................................. 119
5.2.3.2 Download of new blocks or delta downloads ............................................................................ 120
5.2.3.3 Uploading blocks....................................................................................................................... 120
5.2.3.4 Deleting blocks.......................................................................................................................... 121
5.2.3.5 Compressing blocks.................................................................................................................. 121
5.2.3.6 Promming (RAM to ROM) ......................................................................................................... 121
5.2.4 CPU memory reset and restart ................................................................................................. 121
5.2.5 Recipes ..................................................................................................................................... 122
5.2.6 Measured value log files ........................................................................................................... 124
5.2.7 Backup of project data to SIMATIC Micro Memory Card.......................................................... 126

Table of contents
6 Mounting and connecting....................................................................................................................... 127

6.1 Content.......................................................................................................................................127
6.2 Installing the IM 151-8 PN/DP CPU interface module ...............................................................127
6.3 Connecting the IM 151-8 PN/DP CPU interface module ...........................................................128
6.4 Installing and connecting the DP master module ......................................................................131
7 Addressing............................................................................................................................................. 133
7.1 Addressing the I/O modules.......................................................................................................133
7.1.1 Slot-oriented addressing of the centralized I/O modules...........................................................133
7.1.2 User-oriented addressing of the I/O Modules ............................................................................136
7.2 Addressing on PROFIBUS DP...................................................................................................137
7.3 Addressing PROFINET IO .........................................................................................................138
7.3.1 Addressing on PROFINET IO ....................................................................................................138
7.3.2 Assignment of the IP address parameters and device name ....................................................139
8 Commissioning ...................................................................................................................................... 143
8.1 Overview ....................................................................................................................................143
8.2 Commissioning procedure .........................................................................................................143
8.2.1 Procedure: Commissioning the hardware..................................................................................143
8.2.2 Procedure: Software commissioning .........................................................................................145
8.3 Commissioning check list...........................................................................................................147
8.4 Commissioning the modules......................................................................................................148
8.4.1 Inserting/Replacing a SIMATIC Micro Memory Card.................................................................148
8.4.2 Initial power on ...........................................................................................................................150
8.4.3 Reset the IM 151-8 PN/DP CPU interface module using the mode selector switch .................151
8.4.4 Formatting the SIMATIC Micro Memory Card ...........................................................................155
8.4.5 Resetting to the as-delivered state ............................................................................................156
8.4.6 Connecting a programming device / PC to the integrated PROFINET interface of the IM
151-8 PN/DP CPU interface module .........................................................................................158
8.4.7 Starting SIMATIC Manager........................................................................................................160
8.4.8 Monitoring and modifying I/Os ...................................................................................................161
8.5 Commissioning PROFIBUS DP .................................................................................................165
8.5.1 Commissioning the PROFIBUS DP network .............................................................................165
8.5.2 Commissioning the IM 151-8 PN/DP CPU interface module with DP master module as a
DP master ..................................................................................................................................166
8.5.3 Direct data exchange .................................................................................................................170
8.6 Commissioning PROFINET IO ..................................................................................................172
8.6.1 Requirements for commissioning PROFINET ...........................................................................172
8.6.2 Configuring and commissioning the PROFINET IO system ......................................................173
9 Service and maintenance ...................................................................................................................... 181
9.1 Overview ....................................................................................................................................181
9.2 Backing up firmware on a SIMATIC Micro Memory Card..........................................................181
9.3 Updating the firmware................................................................................................................182
9.3.1 When should you update the IM 151-8 PN/DP CPU interface module? ...................................182
9.3.2 Firmware update using a SIMATIC Micro Memory Card ...........................................................183
9.3.3 Updating the firmware online (via networks)..............................................................................185
9.4 Backing up project data on a SIMATIC Micro Memory Card.....................................................186
9.5 Replacing the IM 151-8 PN/DP CPU interface module .............................................................188
9.6 Replacing the DP master module ..............................................................................................190

Table of contents
10 Functions ............................................................................................................................................... 193

10.1 Assigning parameters of the reference junction for the connection of thermocouples ............. 193
10.2 Removal and insertion of modules during operation ................................................................ 195
10.2.1 Overview ................................................................................................................................... 195
10.2.2 What happens when modules are removed during operation .................................................. 196
10.2.3 Procedure when modules are inserted during operation .......................................................... 196
10.3 Switching power modules off and on during operation ............................................................. 198
10.4 Power module with status byte ................................................................................................. 199
11 Debugging functions, diagnostics and troubleshooting .......................................................................... 201
11.1 Overview ................................................................................................................................... 201
11.2 Reading/saving service data ..................................................................................................... 201
11.3 Identification and maintenance data of the IM 151-8 PN/DP CPU interface module ............... 202
11.4 Debugging functions ................................................................................................................. 204
11.4.1 Overview: Debugging functions ................................................................................................ 204
11.4.2 Overview: Diagnostics............................................................................................................... 207
11.4.3 Diagnostic functions available in STEP 7 ................................................................................. 210
11.4.4 Network infrastructure diagnostics (SNMP) .............................................................................. 211
11.5 Diagnostics using status and error LEDs.................................................................................. 213
11.5.1 Introduction ............................................................................................................................... 213
11.5.2 Status and error displays of the IM 151-8 PN/DP CPU interface module ................................ 213
11.5.3 Evaluating the SF LED in case of software errors .................................................................... 215
11.5.4 Evaluating the SF LED in case of hardware errors................................................................... 217
11.5.5 Status and error displays for the PN interface .......................................................................... 219
11.5.6 Status and Error Indicators: PROFINET IO Devices ................................................................ 222
11.5.7 Status and error displays of the DP master module ................................................................. 223
11.6 Diagnostics on the PROFIBUS DP ........................................................................................... 224
11.6.1 Diagnostics of the IM 151-8 PN/DP CPU interface module as a DP master............................ 224
11.7 Defective configuration statuses of the ET 200S...................................................................... 227
11.8 Failure of the load voltage from the power module................................................................... 227
11.9 Basics of diagnostics in PROFINET IO..................................................................................... 228
12 Technical data ....................................................................................................................................... 229
12.1 General technical data .............................................................................................................. 229
12.2 IM 151-8 PN/DP CPU interface module.................................................................................... 229
12.2.1 IM 151-8 PN/DP CPU with DP master module block diagram ................................................. 229
12.2.2 IM 151-8 PN/DP CPU technical specifications ......................................................................... 230
12.3 DP master module .................................................................................................................... 242
12.3.1 Technical specifications - DP master module ........................................................................... 242

Table of contents
A Appendix................................................................................................................................................ 243
A.1 Order numbers ...........................................................................................................................243
A.1.1 Module order numbers...............................................................................................................243
A.1.2 Order numbers of accessories...................................................................................................244
A.2 Dimension drawings...................................................................................................................245
A.2.1 IM 151-8 PN/DP CPU interface module ....................................................................................245
A.2.2 DP master module .....................................................................................................................246
A.3 Cycle and response times..........................................................................................................246
A.3.1 Overview ....................................................................................................................................246
A.3.2 Cycle time ..................................................................................................................................247
A.3.2.1 Overview: Cycle time .................................................................................................................247
A.3.2.2 Calculating the cycle time ..........................................................................................................250
A.3.2.3 Communication load ..................................................................................................................252
A.3.2.4 Cycle time extension as a result of testing and commissioning functions.................................254
A.3.3 Response time ...........................................................................................................................255
A.3.3.1 Overview: Response time ..........................................................................................................255
A.3.3.2 Shortest response time ..............................................................................................................257
A.3.3.3 Longest response time...............................................................................................................258
A.3.4 Interrupt response time ..............................................................................................................259
A.3.4.1 Overview: Interrupt response time .............................................................................................259
A.3.4.2 Reproducibility of Time-Delay and Watchdog Interrupts ...........................................................260
A.4 Additional documentation...........................................................................................................261
Glossary ................................................................................................................................................ 263
Index...................................................................................................................................................... 295

Table of contents

Description 1
1.1 Function of the IM 151-8 PN/DP CPU interface module
The IM 151-8 PN/DP CPU interface module is a component of the ET 200S distributed I/O
system with degree of protection IP20. The IM 151-8 PN/DP CPU interface module is an
"intelligent preprocessor". It enables you to decentralize control tasks.
Therefore, an ET 200S with IM 151-8 PN/DP CPU can exercise full and, if necessary,
independent control over a process-related functional unit.
● Functions of the IM151-8 PN/DP CPU on PROFINET:
– IO controller
– I-Device
– I device and IO controller
– PROFINET CBA device with or without proxy functionality for PROFIBUS DP (for
proxy functionality for PROFIBUS DP, the DP master module must additionally be
plugged in)
● Functions of the IM151-8 PN/DP CPU on PROFIBUS DP:
– DP master together with the optional DP master module
The use of the IM 151-8 PN/DP CPU interface module leads to further modularization and
standardization of process-related functional units and simple, clear machine concepts.

Description
1.2 Properties of the IM 151-8 PN/DP CPU interface module
Properties of the IM 151-8 PN/DP CPU interface module

The IM 151-8 PN/DP CPU interface module has the following special features:
● The interface module has PLC functionality (integrated CPU component with 192 kB work
memory).
● The interface module can only be used with the load memory inserted (SIMATIC Micro
Memory Card).
● The interface module can be enhanced with up to 63 I/O modules from the ET 200S
range.
● The maximum bus length is 2 m.
● Connection to PROFINET via a PROFINET interface with integrated switch and 3 RJ45
ports.
– The IP address for PROFINET can be saved, for example, on the SIMATIC Micro
Memory Card during the hardware configuration but can also be assigned by the user
program (SFB 104) or assigned externally via DCP (for instance, using the Setup Tool
or even by a higher level IO controller).
– Ports 1 and 2 can also be used as ring ports for the creation of redundant ring
structures on the Ethernet (media redundancy)
– Communication is established via PROFINET, for which PROFINET IO is supported
as an IO controller (to which up to 128 IO devices can be connected) and / or and I
device or PROFINET CBA.
– The PROFINET interface allows both PD/OP communication and other types of
communication, such as open communication and S7 communication.
● As a PROFINET IO controller, the IM 151-8 PN/DP CPU interface module also supports
– the real-time communication via RT and IRT
– the prioritized start-ups of PROFINET IO devices
– the replacement of devices without exchangeable medium/PD
– the exchange of IO devices during operation (changing partner ports)
– Isochronous mode on PROFINET
– Shared Device.
● The IM151-8 PN/DP CPU interface module can also be used as an I device at the
PROFINET IO. It can then exchange data with a higher level controller and thus be used
as an intelligent pre-processing unit for subprocesses.
– An IM151-8 PN/DP interface module used as an I device can at the same time
function as an IO controller and thus power a lower level PROFINET IO subnet of its
own.
– An IM151-8 PN/DP interface module used as an I device can also be used as a
shared I device.
– When used as an I device, I/O transfer areas can be configured which allow a higher
level IO controller to access an IM151-8 PN/DP interface module directly via the local
I/O.

Description
● Down times are minimized thanks to the integrated diagnostics.

● It is possible to update the firmware via SIMATIC Micro Memory Card or online via the
network.
● An integrated web server for user-defined web pages, information, status and diagnostics
provides the respective data to any location.
● The interface module has a mode selector with positions for RUN, STOP and MRES.
● There are 10 LEDs on the front of the interface module to indicate the following:
– ET 200S faults (SF)
– bus faults on PROFINET (BF-PN)
– available maintenance information (MT)
– Supply voltage for electronic components (ON)
– Force requests (FRCE)
– operating mode of the IM 151-8 PN/DP CPU interface module (RUN and STOP)
– Connection status at ports 1 and 3 of the PROFINET interface (P1 - LINK, P2 - LINK,
P3 - LINK)
● The IM 151-8 PN/DP CPU interface module can be expanded by one DP master module.
This also lends it the functionality of a DP master.
Integration of the IM 151-8 PN/DP CPU interface module in ET 200S

The IM 151-8 PN/DP CPU interface module is integrated in ET 200S just like any other
module; i. e. same configuration concept, installation and expansion capability.
Information on this can be found in the ET 200S distributed I/O system Operating
Instructions.
How do I configure and program the ET 200S with IM 151-8 PN/DP CPU ?
To configure an ET 200S with IM 151-8 PN/DP CPU (configuration and parameter
assignment) and to program the IM 151-8 PN/DP CPU interface module you will need the
STEP 7 project design software, V5.5 or later.
The procedure for configuring the ET 200S with IM 151-8 PN/DP CPU is described in the
Commissioning (http://support.automation.siemens.com/WW/view/en/31977679) section of
these Operating Instructions. In the S7-300 Instruction List you will find the STEP 7
instruction set for programming the IM151-8 PN/DP CPU interface module. The instruction
list is available as a download from the Internet

Description
Constraints on using motor starters and ET 200S modules

With central use in an ET 200S with IM 151-8 PN/DP CPU the following motor starters and
ET 200S modules can cause disturbing responses. The product versions specified of these
motor starters and ET 200S modules should not be used in an ET 200S with IM
151-8 PN/DP CPU.
Table 1- 1 Constraints on using motor starters and ET 200S modules
Motor starter / module Order number Up to and

including product
version
DS1e-x direct-on-line starter; HF 3RK1301-0❑B10-❑AA2 E06
RS1e-x reversing starters; HF
F-DS1e-x fail-safe direct starters; HF 3RK1301-0❑B13-❑AA2 E06
F-RS1e-x fail-safe reversing starters; HF
DS1e-x direct-on-line starter; HF 3RK1301-0❑B❑0-❑AA3 E03
DSS1e-x direct soft starters; HF
DS1e-x direct-on-line starter; HF 3RK1301-0❑B❑❑-❑AA4 E02
DSS1e-x direct soft starters; HF
F-DS1e-x fail-safe direct starters; HF
F-RS1e-x fail-safe reversing starters; HF
2AI I 2WIRE HS analog electronic module 6ES7134-4GB52-0AB0 E03
2 AI I 4WIRE HS analog electronic module 6ES7134-4GB62-0AB0 E01
Analog electronic module 2AI U HS 6ES7134-4FB52-0AB0 E01
2AO I HS analog electronic module 6ES7135-4GB52-0AB0 E01
2AO U HS analog electronic module 6ES7135-4FB52-0AB0 E03

Description
1.3 Properties of the DP master module
1.3 Properties of the DP master module

Together with the DP master module you can operate the IM 151-8 PN/DP CPU interface
module as a DP master.
Note
The IM 151-8 PN/DP CPU interface module can be expanded by no more than one DP
master module.
Properties of the DP master module

The DP master module has the following special features:
● The PROFIBUS DP address is saved alongside the HW Config configuration on the
SIMATIC Micro Memory Card in the IM 151-8 PN/DP CPU interface module.
● There is 1 LED on the front of the DP master module to indicate bus faults on the
PROFIBUS DP (BF).
● Connection to PROFIBUS DP via the DP interface (RS 485) on the DP master module
Integration of the DP master module in ET 200S

The DP master module is connected to the IM 151-8 PN/DP CPU from the right and hence
integrated in the ET 200S.
How do I configure and program the ET 200S with IM 151-8 PN/DP CPU and master module?
To configure an ET 200S with IM 151-8 PN/DP CPU and DP master module (configuration
and parameter assignment) and to program the IM 151-8 PN/DP CPU interface module you
will need the STEP 7 project design software, V5.5 or later.
The procedure for configuring the ET 200S with IM 151-8 PN/DP CPU and DP master
module is described in the Commissioning (Page 172) section of these Operating
Instructions.

Description
1.4 Example configurations
Example configuration of an ET 200S with IM 151-8 PN/DP CPU

The figure below shows an example configuration of an ET 200S with IM 151-8 PN/DP CPU.

Figure 1-1 View of the ET 200S distributed I/O system with IM 151-8 PN/DP CPU
① IM 151-8 PN/DP CPU interface module ④ Terminating module

② PM-E power module for electronic ⑤ TM-E terminal modules for electronic
modules modules
③ Electronic modules ⑥ TM-P terminal modules for PM-E power
modules

Description
Example configuration of an ET 200S with IM 151-8 PN/DP CPU and DP master module
The figure below shows an example configuration of an ET 200S with IM 151-8 PN/DP CPU
and DP master module.

Figure 1-2 View of the ET 200S distributed I/O system with IM 151-8 PN/DP CPU and DP master module
① IM 151-8 PN/DP CPU interface module ⑦ Reversing starter

② DP master module ⑧ Terminating module
③ PM-E power module for electronic ⑨ Power bus
modules
④ Electronic modules ⑩ TM-P terminal module for PM-D power
modules
⑤ PM-D power module for motor starters ⑪ TM-E terminal modules for electronic
modules
⑥ Direct starters ⑫ TM-P terminal modules for PM-E power
modules

Description

Operating and display elements 2
2.1 Operating and display elements of the IM 151-8 PN/DP CPU
interface module

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Number Designation
① RJ45 socket (port 1 of the PROFINET interface)

R: Ring port for creation of ring topology with media redundancy
② RJ45 socket (port 2 of the PROFINET interface)
R: Ring port for creation of ring topology with media redundancy
③ RJ45 socket (port 3 of the PROFINET interface)
④ Mode selector switch
⑤ Status and error displays of the IM 151-8 PN/DP CPU interface module
⑥ Status displays of the PROFINET interface
⑦ Slot for the SIMATIC Micro Memory Card
⑧ Connection for supply voltage

Operating and display elements
2.1 Operating and display elements of the IM 151-8 PN/DP CPU interface module
Slot for the SIMATIC Micro Memory Card

Memory module is a SIMATIC Micro Memory Card. You can use MMCs as load memory and
as portable storage media. The slot for the SIMATIC Micro Memory Card can be accessed
from the front of the interface module. The Inserting/Replacing a Micro Memory Card section
contains detailed information on inserting the SIMATIC Micro Memory Card.
Note
The IM151-8 PN/DP CPU interface module does not have an integrated load memory, so
you will need to connect a SIMATIC Micro Memory Card to the IM 151-8 PN/DP interface
module in order to use it.
Mode selector switch

You can use the mode selector switch to set the current operating mode of the
IM 151-8 PN/DP CPU .
Table 2- 1 Mode selector switch settings
Position Meaning Description

RUN RUN mode The IM 151-8 PN/DP CPU interface module processes the user
program.
STOP STOP mode The IM 151-8 PN/DP CPU interface module does not process the
user program.
MRES Memory reset Mode selector switch setting for
 Memory reset of the IM 151-8 PN/DP CPU interface module
 Backing up the firmware to the SIMATIC Micro Memory Card
 Resetting to the as-supplied state
A memory reset using the mode selector requires a number of
steps to be carried out in a set order.
Reference
● Operating modes of the IM 151-8 PN/DP CPU interface module: STEP 7 Online Help.
● Information on performing a memory reset of the IM 151-8 PN/DP CPU interface module:
Section Resetting the IM 151-8 PN/DP CPU interface module using the mode selector
switch)
● Evaluation of the LEDs for errors or diagnostics: See the Diagnostics using status and
error LEDs section.
See also
Inserting/Replacing a SIMATIC Micro Memory Card (Page 148)

2.2 Status and error displays of the IM 151-8 PN/DP CPU interface module
2.2 Status and error displays of the IM 151-8 PN/DP CPU interface
module
General status and error displays
Table 2- 2 General status and error displays of the IM 151-8 PN/DP CPU interface module
LED designation Color Meaning

SF Red Group fault for hardware or software error
MT Yellow Maintenance information
ON Green Supply voltage for the IM 151-8 PN/DP CPU
FRCE Yellow LED is lit: Active force job
LED flashes at 2 Hz: Node flash test function.
RUN Green IM 151-8 PN/DP CPU in RUN
The LED flashes during STARTUP at a rate of 2 Hz, and in HOLD
state at 0.5 Hz.
STOP Yellow IM 151-8 PN/DP CPU in STOP or in HOLD or STARTUP
The LED flashes at 0.5 Hz when the CPU requests a memory reset,
and during the reset at 2 Hz.
Status and error displays for the bus interfaces
Table 2- 3 Status and error displays for the bus interfaces of the IM 151-8 PN/DP CPU interface
module
LED designation Color Meaning

BF-PN Red Bus fault on the PROFINET
P1 - LINK Green Connection at port 1 is active
Reference
● Operating modes of the IM 151-8 PN/DP CPU interface module: STEP 7 Online Help
● Information on performing a memory reset of the IM 151-8 PN/DP CPU interface module:
Section Resetting the IM 151-8 PN/DP CPU interface module using the mode selector
switch)
● Evaluation of the LEDs for errors or diagnostics: See the Diagnostics using status and
error LEDs section

2.3 Display elements of the DP master module
2.3 Display elements of the DP master module
Display elements
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Figure 2-1 Display elements of the DP master module
The figure shows ... the following elements of the DP master module
① Status and error displays
② 9-pin sub D socket for PROFIBUS DP

Communication 3
3.1 Interfaces
3.1.1 PROFINET (PN)
Availability
The IM151-8 PN/DP CPU interface module has a PROFINET interface with integral switch
and 3 ports (RJ45 sockets).
● At these ports, the network can be configured with a line structure with no additional
external switch.
● When ports 1 and 2 are designated as ring ports (P1 R, P2 R), they can be used to
create a redundant ring topology.
● You can also connect an additional PROFINET device, such as a PD for commissioning
or an OP for operation and monitoring.
Connecting to Industrial Ethernet

You can use the integrated PROFINET interface of the IM 151-8 PN/DP CPU interface
module to establish a connection to Industrial Ethernet.
The integrated PROFINET interface of the IM 151-8 PN/DP CPU interface module is
configured via the PROFINET interface.
Time Synchronization using PROFINET

The IM 151-8 PN/DP CPU interface module can be used as a time client at the PROFINET
interface by using the NTP method. This is set in HW Config. The default setting is no time
synchronization.
As the time client, the IM 151-8 PN/DP CPU receives synchronization message frames from
a time NTP server (e.g. SICLOCK TS) and accepts this time as its own internal time.
In addition to time synchronization at the PROFINET interface, there is also time
synchronization at the DP interface of the DP master module. The IM 151-8 PN/DP CPU
interface module can be the time slave on only one of these interfaces.
At the PN interface, there is only the functionality as a time client (functionality is the same
as that of a time slave at the DP interface).
Example:The IM 151-8 PN/DP CPU interface module is synchronized by a time server over
NTP via the PN interface (corresponding to the functionality as a time slave). The
IM 151-8 PN/DP CPU interface module can then only be used as a time master at the DP
interface.

Communication
3.1 Interfaces
Devices capable of PROFINET (PN) communication

● PROFINET IO controller
● PROFINET IO devices (for example, interface module IM 151-3 PN in an ET 200S)
● PROFINET CBA components
● S7-300 / S7-400 with PROFINET interface (for example, CPU 317-2 PN/DP or CP 343-1)
● Active network components (a switch, for example)
● IE/PB link
● Programming device / PC with network card
Properties of the PROFINET interface
Properties
IEEE standard 802.3
Connector design
 Ports 1 to 3 RJ45
Transmission speed Up to 100 Mbps
Media Twisted pair Cat5 (100 BASE-TX)
Media redundancy to IEC 61158
Note
Networking PROFINET components
The use of switches, rather than hubs, for networking PROFINET components brings about
a substantial improvement in decoupling bus traffic, and improves runtime performance
under higher bus load. PROFINET CBA with cyclic PROFINET interconnections requires the
use of switches in order to maintain compliance with performance specifications. Full duplex
mode at 100 Mbps is mandatory for cyclic PROFINET interconnections.
PROFINET IO also requires the use of switches and 100 Mbps full duplex mode.
For PROFINET IO in IRT mode (Isochronous Real Time) all PROFINET devices in the sync
domain must be IRT-capable, even the switches.

Communication
3.1 Interfaces
Configuring the port properties of the PROFINET interface in STEP 7

The PROFINET interfaces in our devices are preset to a default "automatic setting"
(Autonegotiation). Ensure that all devices connected to the PROFINET interface of the IM
151-8 PN/DP CPU interface module are also set to the "Autonegotiation" operating mode.
This is the default setting of standard PROFINET / Ethernet components.
If you connect a device to the PROFINET interface of the IM 151-8 PN/DP CPU interface
module that does not support the "automatic setting" (Autonegotiation) operating mode, or if
you select a setting other than the "automatic setting" (Autonegotiation), note the following:
● PROFINET IO and PROFINET CBA require operation with 100 Mbps full-duplex, i.e.
when the PROFINET interface of the IM 151-8 PN/DP CPU interface module for
PROFINET IO / CBA communication and Ethernet communication is used at the same
time, the PROFINET interface can only be operated with 100 Mbps full-duplex.
● If the PROFINET interface of the IM 151-8 PN/DP CPU interface module is used only for
Ethernet communication, alongside the "automatic setting" (Autonegotiation) 100 Mbps
full-duplex or 10 Mbps full-duplex operating modes can be used. Half-duplex mode is not
allowed in any situation.
Reason: If, for example, a switch permanently set to "10 Mbps half-duplex" is connected to
the PROFINET interface of the IM 151-8 PN/DP CPU interface module, due to the
"Autonegotiation" setting the IM 151-8 PN/DP CPU interface module forwards this setting to
the partner device - i.e. the communication operates de facto with "10 Mbps half-duplex".
However, since PROFINET IO and PROFINET CBA require operation with 100 Mbps full-
duplex, this operating mode is not allowed.
Note
To configure the ports of IO devices which are to perform a prioritized start-up refer to the
special information under PROFINET System Description.
Disabling a port of the PROFINET interface with IM 151-8 PN/DP CPU

In STEP 7 HW Config you can disable a port of the PROFINET interface of an IM
151-8 PN/DP CPU interface module. This is enabled as default.
The IM 151-8 PN/DP CPU interface module cannot be reached via a disabled port in the
PROFINET interface.
Note that it is not possible to perform communication functions, like for example, PD / OP
functions, open IE communications or S7 communication, via a disabled port.
Note
In the case of an IM 151-8 PN/DP CPU interface module one port must always be enabled
so that access to the module is always guaranteed.

Communication
3.1 Interfaces
Addressing the ports

To diagnose the individual ports of a PROFINET interface, these ports must each have a
separate diagnostics address. The addressing is done in HW Config.
For further information, refer to the PROFINET System Description.
The diagnostic message (fault and maintenance information) can be enabled using OB 82
(enable in HW Config) and then analyzed using SFB 54, for example, in order to diagnose
any problems identified in the user program. There are also various data records (read using
SFB 52) and system status lists (read using SFC 51) provided for more detailed diagnostics.
Diagnostics is also possible in STEP 7 (e.g. communication diagnostics, network connection,
Ethernet statistics, IP parameters).
Send clock and send cycle

Controllers and devices with a standardized send clock can be used in a PROFINET IO
subnet. For devices that do not support a faster controller send clock, the send clock is
adapted to the capabilities of the device. That is, you could operate devices both at a send
clock of 250 µs and 1 ms on a IM151-8 PN/DP CPU interface module (IO controller) which
operates at a send clock of 250 µs.
The device send cycle can be set within a relatively large range. This, in turn, depends on
the send clock. The following update times can be configured when using the
IM151-8 PN/DP CPU interface module:
Real-time communication Send clock Update Time

For RT: 250 µs ⇒ 250 µs to 128 ms
500 µs ⇒ 500 µs to 256 ms
1 ms ⇒ 1 ms to 512 ms
2 ms ⇒ 2 ms to 512 ms
4 ms ⇒ 4 ms to 512 ms
For IRT with the "high 250 µs ⇒ 250 µs to 128 ms

flexibility" option: 500 µs ⇒ 500 µs to 256 ms
1 ms ⇒ 1 ms to 512 ms
For IRT with the "high 250 µs ⇒ 250 µs to 4 ms

performance" option: 500 µs ⇒ 500 µs to 8 ms
1 ms ⇒ 1 ms to 16 ms
The minimum send cycle depends on the number of devices in use, the amount of
configured user data and the communication portion for PROFINET IO. STEP 7
automatically considers these dependencies during configuration.

Communication
3.1 Interfaces
Non-whole number send clocks for IRT systems with the "high performance" option:
For IRT systems with the "High Performance" option, as well as the "whole number" send
clocks (250 µs, 500 µs, 1 ms, 2 ms, 4 ms), any number of "non-whole number" send clocks
can be set up in multiples of 125 µs in the range between 250 µs and 4 ms: 375 µs, 625 µs
… 3.875 ms.
For "non-whole number" send clocks, the rule for all PROFINET IO devices is:
● Update time = send clock
● IRT systems cannot be extended by RT devices into the "High performance" option
NOTICE
Communication shutdown during memory reset / firmware updates / after POWER OFF on
CPUs with integrated switch
Note that the PROFINET interface and integrated switch are shut down during CPU
memory reset and firmware updates, or after POWER OFF.
If a CPU is configured for operation in a line topology, communication to the following
devices is shut down.
Reference
● Details of how to configure the integral PROFINET interface of the IM 151-8 PN/DP CPU
interface module are given in the Connecting a PD/PC to the integrated PROFINET
interface of the IM 151-8 PN/DP CPU interface module and Commissioning
PROFINET IO sections.
● For additional information on PROFINET, refer to PROFINET System Description
● For more information on Ethernet networks, network configuration and network
components, refer to the SIMATIC NET twisted pair and fiber optic networks
(http://support.automation.siemens.com/WW/view/en/8763736) manual:
● Commissioning Component Based Automation Systems
(http://support.automation.siemens.com/WW/view/en/18403908)
● Additional information about PROFINET can be found on the Internet
(http://www.profinet.com).
See also
Connecting a programming device / PC to the integrated PROFINET interface of the IM
151-8 PN/DP CPU interface module (Page 158)
Configuring and commissioning the PROFINET IO system (Page 173)

Communication
3.1 Interfaces
3.1.2 PROFIBUS DP
Availability
Together with the optional DP master module, the IM 151-8 PN/DP CPU interface module
has an RS 485 interface with DP master functionality.
Properties
The PROFIBUS DP interface on the DP master module is mainly used to connect distributed
I/O. PROFIBUS DP allows you to create large subnets, for example.
You can configure the PROFIBUS DP interface as master or to be inactive. It allows a
transmission rate of up to 12 Mbps.
The IM 151-8 PN/DP CPU broadcasts its bus parameters (such as the baud rate) to the
PROFIBUS DP interface when it is used as the master. A programming device, for example,
can thus receive the correct parameters and automatically connect to a PROFIBUS subnet.
In your configuration you can specify to disable bus parameter broadcasting.
Time synchronization using PROFIBUS

Time synchronization is possible via the DP interface on the DP master module of the IM
151-8 PN/DP CPU interface module. The IM 151-8 PN/DP CPU may act as the time master
(with suitably programmed synchronization interval) or time slave. This is set in HW Config.
The default setting is no time synchronization.
As the time master, the IM 151-8 PN/DP CPU interface module sends synchronization
message frames to the DP interface at the configured synchronization interval in order to
synchronize other stations on the connected PROFIBUS DP subnet.
If the IM151-8 PN/DP CPU interface module is configured on the DP interface as time
master, then there will be no time synchronization of the connection time slaves, as the clock
of the IM 151-8 PN/DP CPU interface module is still set to default.
Note that the clock of the IM151-8 PN/DP CPU interface module is not yet set when it ships,
after a reset to factory setting by means of the mode selector switch or after a firmware
update.
As soon as the time of day is set the first time, the time synchronization starts as the time
master by means of:
● PD function
● SFC call or
● a different time master (if the IM 151-8 PN/DP CPU interface module has also be
configured as a time client by the PROFINET interface).
As the time slave, the IM 151-8 PN/DP CPU interface module receives synchronization
message frames from a different time master and accepts this time as its own internal time.
In addition to time synchronization at the DP interface of the DP master module, there is also
time synchronization at the PROFINET interface. The IM 151-8 PN/DP CPU interface
module can be the time slave on only one of these interfaces. At the PN interface, it can only
act as a time client (functionality is the same as that of a time slave at the DP interface).
Example: The IM 151-8 PN/DP CPU interface module is time synchronized by a time server
over NTP via the PN interface. The IM 151-8 PN/DP CPU interface module can then only be
used as a time master at the DP interface.

Communication
3.2 Communication services
Devices capable of PROFIBUS DP communication

● Programming device / PC
● OP/TP
● DP slaves
● Actuators/Sensors
● S7-300/S7-400 with PROFIBUS DP interface
Reference
Additional information on PROFIBUS: " PROFIBUS (http://www.profibus.com)"
3.2.1 Overview of communication services
Selecting the communication service

You need to decide on a communication service, based on functionality requirements. Your
choice of communication service will have no effect on:
● The functionality available
● Whether an S7 connection is required or not
● The time of connecting
The user interface can vary considerably (SFC, SFB, ...), and is also determined by the
hardware used (IM 151-8 PN/DP CPU, PC, ...).
Overview of communication services

The table below provides an overview of the communication services provided by the
IM 151-8 PN/DP CPU interface module.
Table 3- 1 Communication services of the IM 151-8 PN/DP CPU interface module
Communication service Functionality Time at which the S7 connection is via PN via DP

established ... (optional)
Programming device Commissioning, test, From the programming device, X X
communication diagnostics starting when the service is used
OP communication Control and monitoring From the OP at Power ON X X
S7 communication Data exchange in server and from the active partner at power on. X Only in
client mode: Configuration of server
communication required mode
Global data communication Cyclic data exchange (for Does not require an S7 connection – –
example, bit memory)

Communication
Communication service Functionality Time at which the S7 connection is via PN via DP

established ... (optional)
Routing programming for example testing, From the programming device, X X
device functions diagnostics on other networks starting when the service is used
also
Data set routing e.g. configuration and from the PD, starting when the X X
diagnostics of field devices on service is being used
PROFIBUS DP, if the PD with
the associated configuration
tool (e.g. PDM) is not
connection to the same
PROFIBUS DP subnet as that
of the field device, but, for
example, on the PROFINET
subnet at which the PN
interface of the IM 151-8
PN/DP CPU interface module
is also connected.
PROFIBUS DP Data exchange between Does not require an S7 connection – X
master and slave only as DP
master
PROFINET CBA Data exchange by means of Does not require an S7 connection X –
component based
communication
PROFINET IO Data exchange between IO Does not require an S7 connection X –
controllers and the IO devices
Web server Diagnostics Does not require an S7 connection X –
SNMP Standard protocol for network Does not require an S7 connection X –
(Simple Network diagnostics and configuration
Management Protocol)
Open communication by Data exchange via Industrial Does not require an S7 connection, is X –
means of TCP/IP Ethernet with TCP/IP protocol handled in the user program by
(by means of loadable FBs) means of loadable FBs
means of ISO on TCP Ethernet with ISO-on-TCP handled in the user program by
protocol (by means of loadable means of loadable FBs
FBs)
means of UDP Ethernet with UDP protocol (by handled in the user program by
means of loadable FBs) means of loadable FBs
Time synchronization Broadcast telegrams Does not require an S7 connection – X
Time synchronization NTP protocol Does not require an S7 connection X –
See also
Distribution and availability of S7 connection resources (Page 47)
Connection resources for routing (Page 48)

Communication
3.2.2 PG communication
Properties
Programming device communication is used to exchange data between engineering stations
(programming device, PC, for example) and SIMATIC modules which are capable of
communication. This service is available via PROFIBUS and Industrial Ethernet subnets.
Transition between subnets is also supported.
Programming device communication provides the functions needed to download / upload
programs and configuration data, to run tests and to evaluate diagnostic information. These
functions are integrated in the operating system of the IM 151-8 PN/DP CPU interface
module.
An IM 151-8 PN/DP CPU interface module can maintain several simultaneous online
connections to one or multiple programming devices.
IM 151-8 PN/DP CPU without configured PROFINET interface

If your IM 151-8 PN/DP CPU interface module still does not have a configured PROFINET
interface (IP address), you can nevertheless communication from the PD with the IM 151-8
PN/DP CPU interface module.
● The IM 151-8 PN/DP CPU interface module logs on to the SIMATIC Manager with its
MAC address via "Available nodes".
If the Ethernet interface of the PD is set to "TCP/IP (Auto)", then during the first
establishment of a communication connection (e.g. call of the module status or the online
table of contents of the CPU), a temporary IP address is automatically assigned by the
PD to the PG interface of the IM 151-8 PN/DP CPU interface module. This is then
maintained until the next power off / power on or memory reset, or until a HW
configuration with a differing (retentive) IP address is loaded.
● Whilst downloading the parameters of the HW Config, the correct IP address can be
allocated to IM 151-8 PN/DP CPU interface module during the loading process. The
procedure for this can be found in section Connecting a PD / PC to the integrated
PROFINET interface of the an IM151-8 PN/DP CPU interface module.
● An IP address can be assigned to a PN interface in the SIMATIC manager under "Target
system > Edit Ethernet node". From V3.2 onward, this remains permanently stored.

Communication
3.2.3 OP communication
Properties
OP communication is used to exchange data between operator CPUs (OP, TP, WinCC, for
example) and SIMATIC modules which are capable of communication. This service is
available via PROFIBUS and Industrial Ethernet subnets.
OP communication provides functions you require for monitoring and modifying. These
functions are integrated in the operating system of the IM 151-8 PN/DP CPU interface
module.
An IM 151-8 PN/DP CPU interface module can maintain several simultaneous online
connections to one or different OPs.
It is only after the PN interface of the IM 151-8 PN/DP CPU interface module has been
operated with a configured IP address that an OP be run on the interface.
3.2.4 S7 communication
Properties
The IM 151-8 PN/DP CPU interface module can act as either a server or a client in S7
communication. A distinction is made between:
● Communication with unilateral configuration (for PUT/GET only)
● Communication with bilateral configuration (for USEND, URCV, BSEND, BRCV, PUT,
GET)
The available functionality is described in the following table.
Table 3- 2 client and server in S7 communication, using connections with unilateral / bilateral
configuration
Interface module Use in server mode for Use in server mode for Use as client
connections with unilateral connections with
configuration bilateral configuration
IM 151-8 PN/DP CPU Usually possible at the Possible at the PN Possible at the PN
DP/PN interface without interface with loadable interface with
programming the user FBs loadable FBs
interface
The user interface is implemented using standard function blocks (FBs) under
communication blocks in the standard STEP 7 library.
Reference
For additional information on communication, refer to the Communication with SIMATIC
manual.

Communication
3.2.5 Routing
Properties
Using STEP 7 you can use the PD / PC via your IM 151-8 PN/DP CPU interface module
(with DP master module) to reach a CPU in a different subnet, in order, for example, to
● download user programs
● download a hardware configuration or
● perform tests and diagnostics functions.
Routing network nodes: PROFINET - PROFIBUS

Gateways between subnets are routed in a SIMATIC station that is equipped with interfaces
to the respective subnets. The figure below shows the access from PROFINET to
PROFIBUS. The CPU 1 (IM 151-8 PN/DP CPU with DP master module) is the router
between subnet 1 and subnet 2.
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Number of connections for routing

A maximum of 4 connections are available on the PROFINET interface of the IM
151-8 PN/DP CPU interface module for the routing function.

Communication
Requirements
● The station modules are "capable of routing" (CPUs or CPs).
● The network configuration does not exceed project limits.
● The modules have loaded the configuration data containing the latest "knowledge" of the
entire network configuration of the project.
Reason: All modules participating in the network transition must receive the routing
information defining the paths to other subnets.
● In your network configuration, the programming device/PC you want to use to establish a
connection via network node must be assigned to the network it is physically connected
to.
Reference
Additional information
● About configuring with STEP 7 can be found in the Configuring Hardware and
Connections in STEP 7 manual
● On communication are found in the Communication with SIMATIC Manual.
● On SFCs, refer to the S7-300 Instruction List.
A detailed description is given in the STEP 7 Online Help or System and Standard
Functions for S7-300/400 Reference Manual.
3.2.6 Data set routing
Availability
The IM 151-8 PN/DP CPU interface module supports data set routing if a DP master module
is connected to it.
Routing and data set routing

Routing is the transfer of data beyond network boundaries. You can send information from a
transmitter to a receiver across several networks.
Data record routing is an expansion of the "standard routing" and is used, for example, by
SIMATIC PDM. The data sent through data set routing includes the parameters for the
participating field devices (slaves) as well as device-specific information (e.g. setpoint
values, limit values, etc.). The structure of the target address for data record routing depends
on the data contents, i.e. the slave to which the data is to be sent.
With the PD, e.g. a parameter set that already exists on the field device can be read, edited
and then sent back to the field device if the PD is not connected to the same PROFIBUS DP
subnet as that of the field device.
The field devices themselves do not have to support data set routing, since they do not
forward the information received.

Communication
Data set routing

The following figure shows the access of the PD to a variety of field devices. In doing so, the
PD is connected via PROFINET to the IM 151-8 PN/DP CPU interface module. The
IM 151-8 PN/DP CPU interface module communicates via PROFIBUS with the field devices.
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Figure 3-1 IM 151-8 PN/DP CPU data set routing
See also
You can find additional information on SIMATIC PDM in the The Process Device Manager
Manual.

Communication
3.3 SNMP communication service
3.2.7 Data consistency
Properties
A data area is consistent if it can be read or written to from the operating system as a
consistent block. Data exchanged collectively between the stations should belong together
and originate from a single processing cycle, that is, be consistent. If the user program
contains a programmed communication function, for example,
FB 12 "BSEND" / FB 13 "BRCV", which accesses shared data, access to that data area can
be coordinated by means of the "BUSY" parameter itself.
With PUT/GET functions

For S7 communication functions, such as PUT / GET or write / read via OP communication,
which do not require a block in the user program on the IM151-8 PN/DP CPU interface
module (acting as a server), allowances must be made in the programming for the extent of
the data consistency. The PUT / GET functions for S7 communication, or for read / write
variables via OP communication, are executed at the IM151-8 PN/DP CPU interface
module´s cycle control point. In order to ensure a defined process interrupt reaction time,
communication variables are copied consistently in blocks of up to 240 bytes to/from the
user memory at the operating system's cycle control point. Data consistency is not
guaranteed for larger data areas.
Note
If defined data consistency is required, the length of the communication variables in the
IM151-8 PN/DP CPU interface module operating system's user program must not exceed
240 bytes.
3.3 SNMP communication service
Availability
The SNMP communication service is available for the IM 151-8 PN/DP CPU interface
module with integrated PROFINET interface.
Properties
SNMP (Simple Network Management Protocol) is a standard protocol for TCP/IP networks.
Reference
For additional information on the SNMP communication service and diagnostics with SNMP,
refer to the PROFINET System Description.

Communication
3.4 Open communication via Industrial Ethernet
Requirement
● STEP 7 V5.4 + Servicepack 4 or higher
Functionality
The IM 151-8 PN/DP CPU interface module with integrated PROFINET interface supports
open communication functionality via Industrial Ethernet (abbreviated to open IE
communication).
The following services are available for open IE communication:
● Connection oriented protocols
– TCP to RFC 793, connection type B#16#01
– TCP to RFC 793, connection type B#16#11
– ISO on TCP to RFC 1006
● Connectionless protocols
– UDP according to RFC 768
Features of the communication protocols

The following distinctions are made between protocol types in data communication:
● Connection oriented protocols:
Prior to data transmission these establish a (logical) connection to the communication
partner and close this again, if necessary, after transmission is completed. Connection
oriented protocols are used when security in especially important in data transmission. A
physical cable can generally accommodate several logical connections.
For the FBs to open communication by means of Industrial Ethernet, the following
connection oriented protocols are supported:
– TCP according to RFC 793 (connection types B#16#01 and B#16#11)
– ISO on TCP according to RFC 1006 (connection type B#16#12)
● Connectionless protocols:
These operate without a connection. There is also no establishing or terminating a
connection to remote partner. Wireless protocols transmit data to the remote partner
without any acknowledgement; data transfer is, therefore, not secure.
The FBs for open communication over Industrial Ethernet support the following wireless
protocol:
– UDP according to RFC 768 (connection type B#16#13)

Communication
How to use open IE communication

To allow data to be exchanged with other communication partners, STEP 7 provides the
following FBs and UDTs under "Communication Blocks" in the "Standard Library":
● Connection oriented protocols: TCP/ISO-on-TCP
– FB 63 "TSEND" for sending data
– FB 64 "TRCV" for receiving data
– FB 65 "TCON", for connecting
– FB 66 "TDISCON", for disconnecting
– UDT 65 "TCON_PAR" with the data structure for the configuration of the connection
● Connectionless protocol: UDP
– FB 67 "TUSEND" for sending data
– FB 68 "TURCV" for receiving data
– FB 65 "TCON" for establishing the local communication access point
– FB 66 "TDISCON" for resolving the local communication access point
– UDT 65 "TCON_PAR" with the data structure for configuring the local communication
access point
– UDT 66 "TCON_ADR" with the data structure of the address parameters of the remote
partner
Data blocks for the configuration of the connection

● Data blocks for assigning parameters for TCP and ISO-on-TCP connections
To assign parameters for your connection at TCP and ISO-on-TCP, you need to create a
DB that contains the data structure of UDT 65 "TCON_PAR." This data structure contains
all parameters you need to establish the connection. You need to create such a data
structure for each connection, and you can also organize it in a global DB.
Connection parameter CONNECT of FB 65 "TCON" reports the address of the
corresponding connection description to the user program (for example,
P#DB100.DBX0.0 byte 64).
● Data blocks for the configuration the local UDP communication access point
To assign parameters for the local communication access point, create a DB containing
the data structure from the UDT 65 "TCON_PAR" This data structure contains the
required parameters you need to establish the connection between the user program and
the communication level of the operating system
The CONNECT parameter of the FB 65 "TCON" contains a reference to the address of
the corresponding connection description (e.g. P#DB100.DBX0.0 Byte 64).
Note
Setting up the connection description (UDT 65)
You must enter the interface to be used for communication in the "local_device_id"
parameter in UDT 65 "TCON_PAR" (e.g. B#16#01: Communication via the integrated PN
interface of the IM 151-8 PN/DP CPU interface module).

Communication
Establishing a connection for communication

● Use with TCP and ISO-on-TCP
Both communication partners call FB 65 "TCON" to establish the connection. In your
connection configuration, you define which communication partner activates the
connection, and which communication partner responds to the request with a passive
connection. To determine the number of possible connections, refer to your
IM 151-8 PN/DP CPU interface module´s technical specifications.
The IM 151-8 PN/DP CPU interface module automatically monitors and maintains the
established connection.
If the connection is broken, for example by line interruption or by the remote
communication partner, the active partner tries to reestablish the connection. You do not
have to call FB 65 "TCON" again.
FB 66 "TDISCON" disconnects the IM 151-8 PN/DP CPU interface module from a
communication partner, as does STOP mode. To reestablish the connection to have to
call FB65 "TCON" again.
● Use with UDP
Both communication partners call FB 65 "TCON" to set up their local communication
access point. This establishes a connection between the user program and operating
system's communication level No connection is established to the remote partner.
The local access point is used to send and receive UDP message frames.
Disconnecting
● Use with TCP and ISO-on-TCP
FB 66 "TDISCON" disconnects the communication connection between the
IM 151-8 PN/DP CPU interface module and a communication partner.
● Use with UDP
FB 66 "TDISCON" disconnects the local communication access point, i.e., the connection
between the user program and the communication layer of the operating system is
interrupted.
Options for interrupting the communication connection

Events causing interruptions of communication:
● You program the cancellation of connections at FB 66 "TDISCON."
● The IM 151-8 PN/DP CPU interface module changes from RUN to STOP.
● With POWER OFF / POWER ON
Reference
For detailed information on the blocks described earlier, refer to the STEP 7 Online Help.

Communication
3.5 S7 connections
3.5 S7 connections
3.5.1 S7 connection as communication path

An S7 connection is established when S7 modules communicate with one another. This S7
connection is the communication path.
Note
No S7 connections are required for communication via PROFIBUS DP, PROFINET CBA,
PROFINET IO, web server, TCP/IP, ISO on TCP, UDP and SNMP.
Each communication link requires S7 connection resources on the IM151-8 PN/DP CPU
interface module for the entire duration of this connection.
Thus, each IM151-8 PN/DP CPU interface module is provided with a specific number of S7
connection resources. These are used by various communication services (PG / OP
communication or S7 communication).
Connection points
An S7 connection between modules with communication capability is established between
connection points. The S7 connection always has two connection points: The active and
passive connection points:
● The active connection point is assigned to the module that establishes the S7 connection.
● The passive connection point is assigned to the module that accepts the S7 connection.
Any module that is capable of communication can thus act as an S7 connection point. At the
connection point, the established communication link always uses one S7 connection of the
module concerned.
Transition point
If you use the routing functionality, the S7 connection between two modules capable of
communication is established across a number of subnets. These subnets are
interconnected via a network transition. The module that implements this network transition
is known as a router. The router is thus the point through which an S7 connection passes.
Each IM 151-8 PN/DP CPU interface module (with DP master module) can be a route for an
S7 connection. You can establish a certain maximum number of routing connections. This
does not limit the data volume of the S7 connections.
See also
Connection resources for routing (Page 48)

Communication
3.5 S7 connections
3.5.2 Assignment of S7 connections

There are several ways to allocate S7 connections on a communication-capable module:
● Reservation during configuration
● Assigning connections in the program
● Allocating connections during commissioning, testing and diagnostics routines
● Allocating connection resources to HMI services
Reservation during configuration

One connection resource each is automatically reserved on the IM151-8 PN/DP CPU
interface module for programming device and OP communication. Whenever you need more
connection resources (for example, when connecting several OPs), configure this increase in
the IM151-8 PN/DP CPU interface module properties dialog box in STEP 7.
Connections must also be configured (using NetPro) for the use of S7 communication. For
this purpose, connection resources have to be available, which are not allocated to
programming device/OP or other connections. The required S7 connections are then
permanently allocated for S7 communication when the configuration is uploaded to the
IM151-8 PN/DP CPU interface module.
Assigning connections in the program

In open Industrial Ethernet communication with TCP/IP, the user program establishes the
connection. In doing so, the operating system of the IM151-8 PN/DP CPU interface module
initiates the connection. The open IE communication does not use any S7 connections. The
maximum number of eight connections also applies to this type of communication.
Using connections for commissioning, testing and diagnostics

An active online function on the engineering station (programming device /PC with STEP 7)
assigns S7 connections for programming device communication:
● An S7 connection resource for programming device communication which was reserved
in your IM151-8 PN/DP CPU interface module hardware configuration is assigned to the
engineering station, that is, it just needs to be allocated.
● If all reserved S7 connection resources for programming device communication are
allocated, the operating system automatically assigns a free S7 connection resource
which has not yet been reserved. If no more connection resources are available, the
engineering station cannot communicate online with the IM151-8 PN/DP CPU interface
module.

Communication
3.5 S7 connections
Allocating connection resources to HMI services

An online function on the HMI station (OP/TP/... with WinCC) is used for assigning S7
connection resources for the OP communication:
● An S7 connection resource for programming device communication which was reserved
in your IM151-8 PN/DP CPU interface module hardware configuration is assigned to the
HMI station, that is, it just needs to be allocated.
● If all reserved S7 connection resources for OP communication are allocated, the
operating system automatically assigns a free S7 connection resource which has not yet
been reserved. If no more connection resources are available, the HMI station cannot
communicate online with the IM151-8 PN/DP CPU interface module.
Chronological order in which S7 connection resources are assigned

When you program your project in STEP 7, the system generates parameter assignment
blocks which are read by the modules in the startup phase. This allows the module's
operating system to reserve or assign the relevant S7 connection resources. This means, for
example, that OPs cannot access an S7 connection resource that has been reserved for
programming device communication. If the IM151-8 PN/DP CPU interface module has S7
connection resources that have not been reserved, these can be used freely. These S7
connection resources are allocated in the order they are requested.
Example
If there is only one free S7 connection left on the IM151-8 PN/DP CPU interface module, you
can still connect a programming device to the bus. The programming device can then
communicate with the IM151-8 PN/DP CPU interface module. However, the S7 connection
will always be used if the PD is communicating with the IM151-8 PN/DP CPU interface
module. If you connect an OP to the bus while the programming device is not
communicating, the OP can establish a connection to the IM151-8 PN/DP CPU interface
module. Since an OP maintains its communication link at all times, in contrast to the PG, you
cannot subsequently establish another connection via the PG.
See also
Open communication via Industrial Ethernet (Page 41)

Communication
3.5 S7 connections
3.5.3 Distribution and availability of S7 connection resources
Distribution of connection resources
Table 3- 3 Distribution of connections
Communication service Distribution

Programming device communication In order to avoid allocation of connection resources being dependent only on
OP communication the chronological sequence in which various communication services are
requested, connection resources can be reserved for these services.
S7 basic communication
For PG and OP communication, at least one connection resource is reserved
by default.
The following table and the technical specifications for the IM151-
8 PN/DP CPU interface module contain the configurable S7 connections and
the default setting. You "redistribute“ the connection resources by setting the
relevant IM151-8 PN/DP CPU interface module parameters in STEP 7.
S7 communication Available connection resources that are not specially reserved for a service
(programming device / OP communication, S7 basic communication) are used
for this.
Routing PG functions Together with the DP master module, the IM 151-8 PN/DP CPU interface
module has a number of connection resources available for routing purposes.
These connections are available in addition to the connection resources.
The subsection below shows the number of connection resources.
PROFIBUS DP This communication service requires no S7 connection resources.
PROFINET CBA This communication service requires no S7 connection resources.
PROFINET IO This communication service requires no S7 connection resources.
Web server This communication service requires no S7 connection resources.
Open communication via TCP/IP This communication service requires no S7 connection resources.
Open communication by means of ISO on Independently of the S7 connections, a total of 8 own resources are available
TCP for connections or local access points (UDP) for TCP/IP, ISO on TCP, UDP.
Open communication by means of UDP
SNMP This communication service requires no S7 connection resources.

Communication
3.5 S7 connections
Availability of connection resources
Table 3- 4 Availability of connection resources
Interface module Total number Reserved for Free

connection S7 connections
Programming OP S7 basic
resources device communication communication
communication
IM 151-8 PN/DP CPU 12 1 to 11 1 to 11 0 to 10 Displays all non-
default 1 default 1 default 0 reserved S7
connections as free
connections.
Note
If you are using the IM151-8 PN/DP CPU interface module, you can configure up to 10
connection resources for S7 communication in NetPro. These connections are then
reserved.
3.5.4 Connection resources for routing
Number of connection resources for routing

In addition to the S7 connection resources, a maximum of 4 connections are available on the
PROFINET interface of the IM151-8 PN/DP CPU interface module for the routing function.
Routing is only possible if the DP master module is connected and configured.
Example for the IM 151-8 PN/DP CPU

The IM 151-8 PN/DP CPU interface module makes available 12 connection resources:
● Reserve two connection resources for programming device communication.
● Reserve two connection resources for OP communication.
● In NetPro you configure 3 S7 connection resources for S7 communication via the
integrated PROFINET interface.
This leaves 5 S7 connections available for any communication services, e.g. S7
communication, OP communication, etc.
However, no more than 10 connection resources for S7 communication at the integrated PN
interface can be configured in NetPro.
There are also 4 routing connections available for the IM151-8 PN/DP CPU interface module
that do not affect the S7 connection resources mentioned above.

Communication
3.6 DPV1
3.6 DPV1
New automation and process engineering tasks require the range of functions performed by
the existing DP protocol to be extended. In addition to cyclical communication functions,
acyclical access to non-S7 field devices is another important requirement of our customers,
and was implemented in the EN 50170 standard. In the past, acyclic access was only
possible with S7 slaves. The standard concerning distributed I/Os (EN 50170) has been
further developed. All the changes concerning new DPV1 functions are included in IEC
61158/ EN 50170, volume 2, PROFIBUS.
Definition DPV1
The term DPV1 is defined as a functional extension of the acyclic services (to include new
interrupts, for example) provided by the DP protocol.
Availability
Together with the DP master module you can operate the IM 151-8 PN/DP CPU interface
module as a DP master via the expanded DPV1 functionality.
Requirement for using the DPV1 functionality with DP slaves

For DPV1 slaves from other vendors, you will need a GSD file conforming to EN 50170,
revision 3 or later.
Extended functions of DPV1

● Use of any DPV1 slaves from external vendors (in addition to the existing DPV0 and S7
slaves, of course).
● Selective handling of DPV1-specific interrupt events by new interrupt blocks.
● Reading/writing SFBs that conform to standards to the data record (although this can only
be used for centralized I/O modules).
● User-friendly SFB for reading diagnostics.

Communication
3.6 DPV1
Interrupt blocks with DPV1 functionality
Table 3- 5 Interrupt blocks with DPV1 functionality
OB Functionality
OB 40 Process interrupt
OB 55 Status interrupt
OB 56 Update interrupt
OB 57 Vendor-specific interrupt
OB 82 Diagnostic interrupt
Note
You can now also use organization blocks OB40 and OB82 for DPV1 interrupts.
System blocks with DPV1 functionality
Table 3- 6 System function blocks with DPV1 functionality
SFB Functionality
SFB 52 Read data record from DP slave / IO device or centralized I/O module
SFB 53 Write data record to DP slave / IO device or centralized I/O module
SFB 54 Read additional alarm information from a DP slave / IO device or a centralized I/O
module in the relevant OB
SFB 75 Set any interrupts for intelligent slaves
Note
You can also use SFB 52 to SFB 54 for centralized I/O modules. SFBs 52 to 54 can also be
used for PROFINET IO.
Reference
For additional information on the above blocks can be found in the System and Standard
Functions for S7-300/400 reference manual, or in the STEP 7 Online Help.
See also
PROFIBUS DP (Page 32)

Communication
3.7 Web server
3.7 Web server
Introduction
The web server allows you to monitor your IM 151-8 PN/DP CPU interface module over the
Internet or your company's intranet. This allows analyses and diagnostics to be carried out
remotely.
Messages and status information are displayed on HTML pages.
Web browser
You will need a web browser to access the HTML pages for the IM 151-8 PN/DP CPU
interface module .
The following web browsers are suitable for communication with the IM 151-8 PN/DP CPU
interface module:
● Internet Explorer (version 6.0 or later)
● Mozilla Firefox (version 1.5 or later)
● Opera (version 9.0 or later)
● Netscape Navigator (version 8.1 or later)
Reading information via the web server

Via the web server, you can read the following information from the IM 151-8 PN/DP CPU
interface module:
● firmware V2.7 or later
– Start page with general information
– Identification data
– Contents of the diagnostics buffer
– Messages (without acknowledgment option)
– - PROFINET (communication)
– Variable status
– Variable tables
● from firmware V3.2 and configuration with STEP 7 V5.5
– Module state
– Communication: Display the OUC connections and the resources
– Topology: Display the setpoint and current topology from the configuration
– User pages (WEB2PLC required)
The following pages describe the HTML pages and contain detailed explanatory notes.

Communication
3.7 Web server
Web access to the IM 151-8 PN/DP CPU interface module via PD / PC

Proceed as follows to access the web server:
1. Connect the client (programming device or PC) to the IM 151-8 PN/DP CPU interface
module via the PROFINET interface.
2. Open the web browser (e.g. Internet Explorer).
Enter the IP address of the IM 151-8 PN/DP CPU interface module in the "Address" field
of the web browser in the format http://a.b.c.d or https://a.b.c.d (for example:
http://192.168.3.141).
The start page of the IM 151-8 PN/DP CPU interface module opens. From the start page
you can navigate to additional information.
Note
Up to 5 http / https connections are possible.
Web access to the IM 151-8 PN/DP CPU interface module via HMI devices and PDA
The web server also supports the Windows terminal service which means that thin client
solutions with mobile devices (e.g. PDA or MOBIC T8) and robust local stations (e.g.
SIMATIC MP370 with the ThinClient/MP option) can be implemented under Windows CE, in
addition to the use of programming devices and PCs.
Proceed as follows to access the web server:
1. Connect the client (HMI device, PDA) to the IM 151-8 PN/DP CPU interface module via
the PROFINET interface.
2. Open the web browser (for example, Internet Explorer).
Enter the IP address of the IM 151-8 PN/DP CPU interface module in the "Address" field
of the web browser in the format http://a.b.c.d/basic or https://a.b.c.d/basic (for example:
http://192.168.3.141/basic).
The start page of the IM 151-8 PN/DP CPU interface module opens. From the start page
you can navigate to additional information.
The IM 151-8 PN/DP CPU interface module information is processed in a specially-designed
browser for HMI devices running under Windows CE earlier than V 5.x. The information
appears in a simplified format in this browser. The following illustrations show the detailed
form respectively.

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Web servers without SIMATIC Micro Memory Card
Note
Using SIMATIC Micro Memory Card together with Web server
The configuration data for the Web server is stored on the SIMATIC Micro Memory Card. We
therefore recommend that you use a SIMATIC Micro Memory Card with at least 512 kB.
You can also use the web server without the SIMATIC Micro Memory Card inserted The
condition for operation is that you have assigned an IP address to the IM 151-8 PN/DP CPU
interface module.
 The content of the diagnostics buffer is displayed in hex code.
 Start page, identification and communication information as well as variable status are
displayed in plain text.
 Following displays remain empty:
– Module state
– Messages
– Topology
– Variable tables
– User pages
 Automatic page updating is activated by default with no need for configuration.
Security
The web server offers the following security functions:
● Access via the secure transmission protocol https
● configurable user rights via the user list
In addition, protect your web-compliant IM 151-8 PN/DP CPU interface module against
unauthorized access by means of a firewall.
See also
Language settings (Page 54)

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3.7.1 Language settings
Display languages
The web server provides messages and diagnostics information in the following languages:
● German (Germany)
● English (United States)
● French (France)
● Italian (Italy)
● Spanish (traditional sorting)
● Simplified Chinese
● Japanese
Both Asian languages can be combined as follows:
● Chinese with English
● Japanese with English
Conditions for the availability of Asian languages

The following conditions must be fulfilled for the Asian languages Chinese and Japanese:
● The respective language package has been installed on the viewing device (e.g. PC).
● STEP 7 for Asian languages (V5.5) is installed on the PD for the configuration of the
IM 151-8 PN/DP CPU interface module.
Note
SIMATIC HMI devices running the Windows CE operating system do not support any
Asian languages.
What you need to display texts in different languages

You must make two language settings in STEP 7 so that the web server displays the various
languages correctly.
● Setting the language for display devices in SIMATIC Manager
● Set the language for the web in the IM 151-8 PN/DP CPU interface module Properties
dialog. For further information, refer to section Settings in HW Config, "Web" tab.

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Setting the language for display devices in SIMATIC Manager

Select the languages for display devices in SIMATIC Manager:
Options > Language for display devices
Figure 3-2 Example for selecting the display device language

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3.7.2 Settings in HW Config, "Web" tab
Requirements
You have opened in HW Config the Properties dialog for the IM 151-8 PN/DP CPU interface
module.
To use the full functionality of the web server, carry out the following settings in the "Web"
tab:
● Activating the web server
● Set the language for Web
● Adding to the user list
● Access activation for HTTPS
● Activate automatic update
● Display classes of the messages
① Activate the web server

The web server is deactivated in HW Config by default. You activate the web server in HW
Config.
In the CPU properties dialog:
● Check the "Activate web server on this module" check box.

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② Set the language for web

Select up to two languages for the Web from the languages installed for display devices.
In the CPU properties dialog:
● Check the "Activate Web server on this module" check box
● Select up to two languages for the Web.
Note
If you activate the web server and do not select a language, messages and diagnostic
information will be displayed in hexadecimal code.
③ User list
The user list offers you the options to:
● create users,
● specify execution rights,
● assign passwords.
This assignment ensures that the users have access to precisely those options that are
specified for those execution rights.
● If no users are specified in the hardware configuration, read-only access is granted to all
web pages.
● If users are configured, until a user has logged in he/she has access only to the intro and
the start page.
● Once a user is configured and logged in, he/she can access the web pages in
accordance with his access rights.
● If a special user is configured with the login "everybody", a user who has not logged in
has access without prior input of the password to those pages that are enabled for
access by "everybody".
If, for instance, "everybody" has the access right to "Read variables", the "Variables table"
web page is displayed by default in the main menu bar without prior input of the
password.
A maximum of 20 users and "everybody" users can be set up.
④ Access only by HTTPS

https ensures encryption of the communication between the browser and web server.
For error-free https access to the IM, the following is required:
● The current time must be set in the IM.
● IP address of the IM (for example, input https://192.168.3.141)
● You require an installed and valid certificate
If no certificate is installed, a warning is displayed with the recommendation not to use the
page. To view the page, the user must then explicitly "Add an exception".
A valid certificate (Certification Authority) can be obtained as a download from the "Intro"
web page under "Download certificate". For instructions on how to install the certificate, see
the "Help" for your respective web browser.
An encrypted connection is shown by a padlock icon in the status bar of the web page.

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⑤ Activate automatic update

The following web pages can be updated automatically:
● Start page
● Diagnostics buffer
● Module state
● Messages
● Information about communication
● Topology
● Variable status
● Variable table
To enable automatic updates, proceed as follows:

● Set the "Activate" check box at "Automatic update" in the properties dialog of the IM
(under the "Web" tab)
● Enter the update interval.
Note
Update time
The activation interval set in the HW Config represents the shortest update time. Larger
amounts of data or several http / https connections increase the update time.
⑥ Display classes of the messages

All message display classes are activated in the basic configuration in HW Config. The
messages for the selected display classes are displayed later on the "Messages" web page.
Messages for display classes that are not selected are shown as hexadecimal code and not
as plain text.
How to configure the message classes:
● For "Report system error" in HW Config under Options > Report system error
● For block-specific messages in STEP 7
Information about configuring message texts and classes can be found in STEP 7.
Note
Reducing the memory requirement of web SDBs
You can reduce the memory requirement of web SDBs by selecting just the message display
classes that are to be filled in the web SDB.

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3.7.3 Updating and saving information
Screen content refresh status and printing

Screen content
Automatic updating is deactivated in HW Config by default.
This means that the screen of the Web server outputs static information.
Refresh the Web pages manually using the <F5> function key or the following icon:
Update status of printouts

Data output to the printer always returns the current interface module information. It is
therefore possible that the information output to the printer may be more current than the
screen contents.
To obtain a print preview of the web page, click the icon:
Filter settings have no effect on the print-out, The printout of the "Messages" and "Module
status" web pages always shows the complete content of the pages.
Disabling automatic update for an individual web page

To deactivate automatic refresh for a Web page for a short time, select the following icon:
Enable automatic refresh again using the <F5> function key or the following icon:
Saving messages and entries of the diagnostics buffer

Messages and diagnostics buffer entries can be saved to a csv file. Use the following symbol
to save the data.
A dialog box opens in which you can enter the file name and target directory.
To prevent incorrect display of the data in Excel, do not open the csv file with double-click.
Import the file in Excel by selecting the "Data" and "Import external data" menu command.

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3.7.4 Web pages
3.7.4.1 Start page with general CPU information
Establishing a connection to the web server

Connect to the web server by entering the IP address of the configured IM151-8 PN/DP CPU
interface module on the web browser's address bar (e.g. http: //192.168.1.158 or https:
//192.168.1.158). The connection is established and the "Intro" page opens.
Note
Here we show and explain by way of examples, how the various web pages may appear.
Intro
The web server calls the following page upon start-up:
Figure 3-3 Intro

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Click on the ENTER link to access the web server pages.
Note
Skip website intro
Check the "Skip Intro" check box to skip the intro. You will then access the web server's start
page directly in future. You can reverse the "Skip intro" setting by clicking on the "Intro" link
on the start page.
Start page
The start page contains information as shown below. The image of the IM151-8 PN/DP CPU
interface module with LEDs reflects your current status at the time of checking the data.
Figure 3-4 Start page before login
Login
In order to use the full functionality of the web pages, you must be logged in: Log in using
one of the user names and passwords specified in the WEB configuration for the hardware.
You then have the user's access rights to the web pages assigned to them. For further
information, refer to section Settings in HW Config, "Web" tab (Page 56).

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① "General"
Information about the IM151-8 PN/DP CPU interface module, the web server with which you
are currently connected, is combined in this group.
② "Status"
Status information about the IM151-8 PN/DP CPU interface module at the time of the query
is displayed in the "Status" info field.
Reference
Further information about http / https connections can be found in section Settings in HW
Config, "Web" tab (Page 56).
3.7.4.2 Identification
Characteristics
The "Identification" web page contains the characteristic data for the IM151-8 PN/DP CPU
interface module.
Figure 3-5 Identification

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① "Identification"
The "Identification" info field contains the system and location designations as well as the
serial number.
Plant and location designations can be configured in HW Config in the properties dialog box
of the IM, "General" tab.
② "Order number"
The "Order number" info field contains order numbers for the hardware and software.
③ "Version"
The hardware, firmware and boot loader versions are displayed in the "Version" info field.

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3.7.4.3 Diagnostic buffer
Diagnostics buffer
The browser displays the content of the diagnostics buffer on the "Diagnostics buffer" web
page.
Figure 3-6 Diagnostics buffer
Requirement
You must have activated the web server, made the language setting and compiled and
loaded the project in STEP 7.

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① "Diagnostics buffer entries 1-100"

The diagnostics buffer may contain up to 500 messages. Select an interval for the buffer
entries from the list box. Each interval contains 100 entries.
For interface modules ≥ V3.2, the number of the displayed diagnostic buffer entries in the
RUN can be assigned parameters between 10 and 499 in the properties dialog of the CPU
("Diagnostics / Clock" tab). In RUN, 10 entries are set as default.
② "Events"
The "Events" info field contains the diagnostic events with the date and time.
③ "Details"
This box contains detailed information about the selected event.
Select the event from the ② "Events" info field.
Configuration
Configuration involves the following steps:
1. Select the "Object properties" dialog box from the context menu of the relevant IM151-
8 PN/DP CPU interface module.
2. Select the "Web" tab and check the "Activate web server on this module" check box.
3. Select up to two languages to be used to display plaintext messages.
4. Save and compile the project and download it to the IM151-8 PN/DP CPU interface
module.
Point to note when changing between languages

You can change the language, e.g. from German to English, in the top right-hand corner. If
you select a language that you have not configured, then the information will appear as
hexadecimal code, rather than in plaintext.

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3.7.4.4 Module state
Requirements
● You have carried out the following settings in HW Config:
– Web server activated
– Language settings carried out
– "Report system error" generated and activated
● You have compiled the project using STEP 7 HW Config, loaded the SDB container and
the user program (in particular the user program blocks generated by "Report system
error")
● The IM is in RUN mode.
Note
"Report system error"
 Duration of the display: Depending on the plant extension level, the "Report system
error" display requires some time to create the initial evaluation of the state of all the
configured I/O modules and I/O systems. During this time there is no concrete display
of the status on the "Module status" web page. A "?" is displayed in the "Status"
column.
 Dynamic response: "Report system error" has to be called up cyclically at least every
100 ms.
Calling up can take place in OB 1, or if the cycle time amounts to more than 100 ms,
in the watchdog interrupt OB 3x (≤ 100 ms) and in the restart OB 100.
 Diagnostics support: In the "Report system error" dialog box, the "Diagnostic status
DB" tab must be selected in the "Diagnostics support" tab and a DB number entered.
This check box is normally selected as default with configured Web servers. During
the migration of old project, it may however be necessary to select this check box.

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Status of the modules

The state of a station is indicated by means of symbols and comments on the "Module
status" web page.
Figure 3-7 Module status - station
Meaning of the symbols in the "Status" column
Symbol Color Meaning

green Component OK
gray Disabled PROFIBUS slaves or PROFINET devices

Support conditions:
 IM151-8 PN/DP CPU ≥ V3.2 and STEP 7 V5.5
 Enabling/disabling the PROFIBUS slaves and PROFINET IO devices using
SFC12 mode 3/4
 In the "Report System Error" dialog, in the "Diagnostics support" tab, area
"Status activated/deactivated", a check must be set in the "Device
interrogation for status 'activated/deactivated' after CPU start-up" check box,
optionally also in the "Generate alarm at change of status" check box.
black Component cannot be accessed/Status cannot be determined
 The "Status cannot be determined" is, for example, always displayed in the
STOP mode of the CPU or during the initial evaluation of "Report system
error" for all the configured I/O modules and I/O systems after the CPU has
been restarted.
 However, this status can also be displayed temporarily during operation if a
diagnostic interrupt burst occurs at all modules.
 For modules of a subsystem, which is connected to a CP, no status can be
determined.
green Maintenance required
yellow Maintenance requested
red Error - component failed or faulty
- Error in a lower module level

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Navigation to further module levels

The status of individual components/modules/submodules is displayed when you navigate to
the further module levels:
● To higher module levels using the links in the display of the module levels ②
● To lower module levels using the links in the "Name" column
Figure 3-8 Module status - module
① "Module status"
Depending on the selected level, the table contains information about the rack, the DP
master system, the PNIO master system, about the nodes, the individual modules, or also
the modules or submodules of the station.
② "Display of the module levels"

The links are used to access the "Module status" of the higher module levels.
③ "Details"
Further information about the selected module is provided in the "Status" and "Identification"
tabs via the "Details" link.

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④ "IP address"
If a link is available here, clicking on it will take you to the web server of the selected
configured device.
⑤ "Topology"
The two web pages, "Topology" and "Module status", are linked. When you click on the
"Topology" of the selected module, you automatically jump to this module in the graphic view
of the setpoint topology on the "Topology" web page. The module appears in the visible area
of the "Topology" web page and the device head of the selected module flashes for a few
seconds.
⑥ "Filter"
You can search in the table by selecting specific criteria:
1. Select a parameter from the drop-down list box.
2. If applicable, enter the value of the selected parameter.
3. Click on "Filter".
The filter criteria are also retained when you update a page.
To deactivate the filter settings, click "Filter" again.
⑦ "Status" tab
The tab contains information about the status of the selected module when a fault or
message exists.
⑧ "Identification" tab
The tab contains data on the identification of the selected module.
Note
This tab displays only data configured offline, no online data of modules.

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⑨ "Statistics" tab
The tab is shown only for PROFINET IO devices. It contains the following information about
the communications statistics of the selected IO device:
● Overall Statistics - "Transmitted Data Packets"
The quality of the data transmission on the transmission line can be determined from the
key figures in this info box.
● Overall Statistics - "Received Data Packets"
The quality of the data transmission on the reception line can be determined from the key
figures in this info box.
● Statistics port x - "Sent data packets"
The quality of the data transmission on the transmission line can be determined from the
key figures in this info box.
● Statistics port x - "Received data packets"
See also the tab "Statistics in the section "Communication (Page 73)".

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Example: Module status - module
Figure 3-9 Module status - module
Example: Module status - submodule
Figure 3-10 Module status - submodule

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Reference
For further information about the "Module status" and about the topic "Configuring 'Signaling
system errors'", refer to the STEP 7 Online Help.
3.7.4.5 Messages
Requirement
The message texts must have been configured in the correct languages. For information
about configuring message texts, refer to STEP 7 and to the Service&Support pages
Messages
The browser displays the content of the message buffer on the "Messages" web page.
You cannot acknowledge the messages via the web server.
Figure 3-11 Messages
① "Filter"
It offers the ability to filter using certain criteria.
1. Select a parameter from the drop-down list box.
2. If applicable, enter the value of the selected parameter.
3. Click on "Filter".
The filter criteria are retained even when a page is automatically updated.
To deactivate the filter settings, click "Filter" again.
Effects
● The filter settings are also retained when you update a page.
● Filter settings have no effect on the print-out. The print-out always shows the entire
contents of the message buffer.

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② "Messages"
Interface module messages are displayed in chronological order in the info field ②, together
with the date and time.
The Message text parameter relates to the entering of message texts configured for the
particular error definitions.
Sort
You also have the option of displaying the individual parameters in ascending or descending
order. To do this, click on one of the parameters in the column header:
● Message number
● Date
● Time-of-day
● Message text
● State
● Acknowledgement
If you click "Date", the messages will be displayed in chronological order.
Incoming and outgoing events are output in the Status parameter.
③ "Details for message number"

This info field is used to display detailed information about a message. Select the message
for which you are interested in the details from the info field ②.

You can change the language, e.g. from German to English, in the top right-hand corner. If
you select a language that you have not configured or for which no message text was
configured, then the information will appear as hexadecimal code, rather than in plaintext.
3.7.4.6 Communication
Overview
On the "Communication" web page you can find detailed information about the following
tabs:
● Parameters
● Statistics
● Resources
● Open user communication

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"Parameters" tab
The "Parameters" tab ① of this web page contains a summary of information about the
integrated PROFINET interface of the interface module.
The designations of the modules are for illustrative purposes only.
Figure 3-12 Parameters of the integrated PROFINET interface
② "Network connection"
Here you will find information that will help you to identify the integrated PROFINET interface
of the IM151-8 PN/DP CPU interface module.
③ "IP parameters"
Information about the configured IP address and number of the subnet containing the IM151-

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④ "Physical properties"
The following information is available in the "Physical properties" info field:
● Port number
● Link status
● Settings
● Mode

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"Statistics" tab
Information about the quality of the data transmission can be found in the tab ① "Statistics".
Figure 3-13 Key data transmission figures
② "Data packets since"

This shows the time at which the first data packet was sent or received after the last Power
on/memory reset.

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③ "Total statistics - Sent Data Packets"

The quality of the data transmission on the transmission line can be determined from the key
④ "Overall Statistics - Received Data Packets"

⑤ "Statistics Port 1 / Port 2 / Port 3- Sent Data Packets"

The quality of the data transmission on the transmission line can be determined from the key
⑤ "Statistics Port 1 / Port 2 / Port 3 - Received Data Packets"

Tab "Resources"
Information on resource consumption by the connections can be found under the
"Resources" tab ①.
② Number of connections
Here you can find information about the maximum number of connections and the number of
non- assigned connections.

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③ Connections
Here you can find information about the number of reserved connections and assigned
connections for PD, OP, S7 basic communication, S7 communication and other
communications.
"Open communications" tab

Information on the status of the communication connections can be found in the "Open
communications" tab ①.

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② Status information
Here you can find an overview of the connections being established and the connections
already established or set up for open communication via industrial Ethernet.
The table contains the following information for each connection:
● "Status" column: Connection status incl. symbol
● "ID" column: Connection ID
● "Remote IP" column: Remote IP address
● "Type" column: Connection type
The connection statuses available depend on the connection type. This dependency is
shown in the following table:
Connection type Available connection statuses Meaning

TCP, Connection is established The user has triggered the connection
ISO on TCP actively / passively request for an active / passive
connection using the TCON block.
The connection is established The connection triggered using the
actively / passively TCON block has been established.
UDP Connection is established -
The following symbols are used for the connection status:
Icon Color Meaning

green  connection is established (using UDP)
 Connection is established actively / passively (at TCP and ISO on TCP)
red  Connection is established actively / passively (at TCP and ISO on TCP)
③ Details
Here you can find detailed information on the selected connection.
Reference
The explanation of the error messages that may be reported when a connection is lost or
when an attempt to establish a connection fails, can be found in the online Help for STEP 7.

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3.7.4.7 Topology
Topology of the PROFINET nodes

The "Topology" web page gives you information about the topological structure and the
status of the PROFINET devices in your PROFINET IO system.
There are three tabs for the following views:
● Graphical view (setpoint and actual topology)
● Tabular view (only actual topology)
● Status overview (omitting the topological relationships)
The tabular view and the status overview can be printed out. Before printing, use the print
preview of your browser and, if necessary, correct the format.
Set topology
Displays the topological structure configured using the STEP 7 Topology-Editor for the
configured PROFINET devices in a PROFINET IO system, with the corresponding status
displays. Adjacent PROFINET devices are also shown, insofar as their topological structure
was also configured. For these, however, no status display is shown.
The topological assignment of defective PROFINET devices, together with setpoint-actual
variations and the display of transposed ports can also be seen in this view.
Note
In the following scenarios, the configured setpoint topology is always shown:
 When the "Topology" web page is called via the navigation bar
 during switch from the "Module status" web page, from the overview of the PROFINET IO
devices, via the "Topology" link to the "Topology" web page
If no design topology is configured, by default the actual topology is called up.
Actual topology
Displays the current topological structure of the "configured" PROFINET devices of a
PROFINET IO system and the directly adjacent non-configured PROFINET devices insofar
as they can be determined (display of the relationships to adjacent devices, insofar as they
can be determined; for these adjacent PROFINET devices, however, no status display is
shown).

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Topology - graphical view
Requirements
For error-free use of the topology, the following preconditions must be satisfied:
● The language settings have been made.
● The topological interconnection of the ports has been configured in the topology editor of
STEP 7. (Precondition for the display of the setpoint topology and the corresponding
topological setpoint connections).
● The project has been implemented in HW config.
● "Report system errors" has been generated.
● The project has been fully downloaded (configuration and program).
Setpoint topology and actual topology - graphical view
Figure 3-14 Graphical view - setpoint and actual topology

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Meaning of the colored connections in the setpoint/actual topology:
Connection Meaning
Set topology Actual topology
green The current actual connection corresponds to the configured Recognized
setpoint connection. connections
red The current actual connection does not correspond to the -
configured setpoint connection (e.g. ports transposed).
Yellow The connection cannot be diagnosed. Causes: -
 The communication with a device has been lost (e.g.
cable unplugged),
 this is a connection to a passive component,
 this is a connection to devices/PROFINET devices of
another IO controller or IO subsystem.
① Configured and accessible PROFINET nodes

Configured and accessible PROFINET nodes are displayed in dark gray. Connections show
through which ports the PROFINET nodes of a CPU are connected.
② Configured but inaccessible PROFINET nodes

Pink with a red border shows the configured but inaccessible PROFINET nodes (e.g. device
defective, cable unplugged)
③ Deactivated nodes
Pale gray shows all deactivated configured PROFINET nodes.
④ Transposed ports
Transposed ports are shown red in the setpoint topology view. The actual topology shows
the ports actually connected, and the setpoint topology shows the configured setpoint
connection.

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⑤ PROFINET devices in another PROFINET IO subsystem

● In the setpoint topology:
A PROFINET device in another PROFINET IO subsystem is shown with a green
connection (with in the case of transposed ports a red connection), if it adjoins directly a
configured accessible PROFINET device ① and is itself also accessible.
If the PROFINET device in another PROFINET IO subsystem is not accessible, a yellow
connection line is shown.
The connection between two PROFINET devices which both belong to another
PROFINET IO subsystem, cannot be determined and is always shown yellow.
● In the actual topology:
A PROFINET device in another PROFINET IO subsystem is shown only if it directly
adjoins a configured PROFINET device. Such devices are shown pale gray and with a
dashed line.
For PROFINET devices in another PROFINET IO subsystem, no status display is shown in
the device head.
⑥ Displaying faulty neighbor relationships

The nodes whose neighbor relationships are incomplete or can only be read out with an
error are displayed in pale gray with a red border.
Note
Displaying faulty neighbor relationships
A firmware update of the affected component is required.
Views for changes to the structure

● If a device becomes defective, that device remains in the same place on the "Setpoint
Topology" view, but the device head is bordered with red and displays a red screwdriver
.
● If a device becomes defective, that device is segregated to a lower area on the "Actual
Topology" view, and the device head is bordered with red and displays a red screwdriver
.
Link between the "Topology" and "Module state" Web pages

The two web pages, "Topology" and "Module status", are linked. Clicking on the head of a
configured module in a topology view skips automatically to this module on the "Module
status" web page.
See also Section "Module status (Page 66)".

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Topology - tabular view

The "Tabular view" always shows the "Actual topology".
Figure 3-15 Topology - tabular view
① Meaning of the symbols relating to the status of the PROFINET nodes
Symbol Meaning
Configured and accessible PROFINET nodes
Unconfigured and accessible PROFINET nodes
Configured but inaccessible PROFINET nodes
Nodes for which neighbor relations cannot be determined or for which the neighbor
relationship could not be read out completely or only with errors

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① Meaning of the symbols relating to the module status of the PROFINET nodes
Symbol Color Meaning

green Component OK
gray Disabled PROFIBUS slaves or PROFINET devices

Requirement for support:
 IM151-8 PN/DP CPU ≥ V3.2 and STEP 7 V5.5
 Enabling/disabling the PROFIBUS slaves and PROFINET IO devices
using SFC12 mode 3/4
 In the "Report System Error" dialog, in the "Diagnostics support" tab,
area "Status activated/deactivated", a check must be set in the
"Device interrogation for status 'activated/deactivated' after CPU start-
up" check box, optionally also in the "Generate alarm at change of
status" check box.
black Component cannot be accessed/Status cannot be determined
 The "Status cannot be determined" is, for example, always displayed
in the STOP mode of the IM or during the initial evaluation of "Report
system error" for all the configured I/O modules and I/O systems after
the IM has been restarted.
 However, this status can also be displayed temporarily during
operation if a diagnostic interrupt burst occurs at all modules.
 For modules of a subsystem that is connected to a CP, no status can
be determined.
green Maintenance required
yellow Maintenance requested
red Error - component failed or faulty
- Error in a lower module level

Communication
3.7 Web server
Topology - status overview

The "Status overview" shows a clear representation of all PROFINET IO devices /
PROFINET devices (without connection relationships) on one page. A quick error
diagnostics is possible based on the symbols that show the module statuses.
Here, too, there is a link to the modules on the "Module status (Page 66)" web page.
Figure 3-16 Topology - status overview

Communication
3.7 Web server
3.7.4.8 Variable status
Variable status
The variable status is displayed by the browser via the web page of the same name. You
can monitor the status of up to 50 variables.
Figure 3-17 Variable status
① "Address"
In the "Address" text box, enter the address of the operand whose behavior you wish to
monitor. If you enter an invalid address, it is displayed in red.
② "Display format"
Select the required display format for the variable from this drop-down list box. If the variable
cannot be displayed in the required display format, it will be displayed in hexadecimal code.
③ "Value"
This displays the value of the operand in the selected format.

Communication
3.7 Web server

You can change the language, e.g. from German to English, in the top right-hand corner.
Please note that the mnemonic for German differs from that for the other languages. This
means that the operand that you entered may have the wrong syntax when you change
between languages. For example: ABxy rather than QBxy. Incorrect syntax is displayed in
red in the browser.
3.7.4.9 Variable tables
Variable tables
The browser displays the content of the configured, web-compatible variable tables on the
web page of the same name.
You can monitor up to 200 variables with each variable table.
Figure 3-18 Variable tables
① Selection
Select one of the configured variable tables from the drop-down box.
② "Name" and "Address"

This info field displays the name of an operand and its address.

Communication
3.7 Web server
③ "Format"
Select the display format for the operand from this drop-down list box. The drop-down list
box contains all the permitted display formats.
④ "Value"
This column shows the values in the display format.
⑤ "Comment"
The comment that you enter is displayed to make it easy to recognize the importance of an
operand.
Configuring variable tables for web servers

The web server allows you to monitor up to 50 variable tables with up to 200 variables. As
the available interface module memory is shared by messages and variables, the actually
available number of variable tables may be reduced.
Example: The available memory is sufficient for around 400 messages and 50 variable
tables with 100 variables (with symbol names, but without symbol comments).
If the permitted memory is exceeded by configured messages and variables, the variable
tables displayed in the web browser will be incomplete. In this case, you will have to replace
the memory needed by your messages and symbol comments. If at all possible, you should
only use one language for the display.
You should also configure your variable tables with as few variables as possible, with short
names and comments, in order to ensure that the variable tables are displayed in full by the
web server and will also be updated faster than tables containing a large number of variables
(limited memory).

Communication
3.7 Web server
Creating a variable table for web servers

1. Create a variable table with STEP 7.
2. Open the properties dialog of the variable table and select the "General - Part 2" tab.
3. Activate the "Web server" check box.
4. Save and compile the project and download the configuration data to the interface
module.

Communication
3.7 Web server
3.7.4.10 User pages
User pages
On this Web page, you will find the link to your freely programmed user page.
Figure 3-19 User pages
You can use the web server to create user-specific HTML pages which contain data from the
CPU. For this purpose, you can use any web editor to create the web page, using the
symbols from the STEP 7 user program. The Web2PLC program supplied with STEP 7 then
converts the user page created into DBs. The DBs that are generated are downloaded to the
CPU. The system function SFC 99 "WWW" links the user program to the internal web server
on the CPU, and when SFC 99 "WWW" is called for the first time, the link to the user page is
shown on the web page of the CPU. Clicking on the link starts the user page in a new
window.
You can activate a maximum of two configured user pages concurrently.

Communication
3.7 Web server
Requirements
● You have created the symbols for the input/output variables in your STEP 7 project that
you wish to use on your user page.
● In the properties dialog of the IM151-8 PN/DP CPU, under the "Web" tab, you have at
least
– activated the web server
– entered a user in the user list
– assigned this user (and any others) user read rights or read-write rights (see section
"Settings in HW config, "Web" tab (Page 56)")
● You have performed the necessary settings for communications (IP address parameters,
subnet mask, ...).
● You have saved and loaded the hardware configuration.
● You have created your user page by means of your chosen HTML editor:
– automatic HTML pages, if control of the page structure is not desired by the user
program (one-off call up of SFC 99 is required)
– manual HTML pages, if control of the page structure is not desired by the user
program (cyclical call up of SFC 99 is required)
● You have installed the Web2PLC program supplied on the CD for the STEP 7 (installation
path: CD2: \Optional Components\S7 Web2PLC\)
Creating a dynamized user page

To dynamize your user page you must use AWP (Advanced Web Programming) commands
on your HTML user page. AWP commands are a command set from Siemens, by means of
which CPU information can be accessed. The AWP- commands are described in the online
Help for Web2PLC.
Procedure
1. Select the directory "Blocks" in the SIMATIC Manager in the S7 program for the
IM151-8 PN/DP CPU, and from the context menu select "S7-Web2PLC".
The program S7-Web2PLC starts.
2. Select the File > New Project... menu commend and enter the desired project name.
3. Select the File > Change Project Settings... menu command.
The configuration settings dialog opens.
4. In the "General" tab, enter the path of your HTML folder.
5. Enter the HTML file to be started as the user page, and the desired name of the
application.
Confirm with OK. The dialog for the STEP 7 / web project opens.
6. In the "STEP 7" tab enter the desired DB numbers (default setting 333 and 334)
Confirm with OK. The dialog for the STEP 7 / Web project opens.
7. Open your user page with the HTML editor and reference the variables that you wish to
use in your user page, using the AWP commands and the symbolic names from STEP 7.
To do this, use the online Help for the Web2PLC.

Communication
3.7 Web server
8. Once the HTML page has been edited and saved, return to your S7 Web2PLC project.
Click successively on the following buttons:
– "Export symbols"
– "Generate DB source"
– "Compile DB source"
The corresponding actions are performed and a control DB ("Web DB") and at least one
fragment DB in the S7 program of the IM151-8 PN/DP CPU, directory "Blocks", are
created.
9. Click on the "Load to CPU" button to load the DBs into the CPU.
Note
During this procedure the IM should be in STOP mode. If the WEB DBs are transferred in
Run mode, synchronization errors can occur during the loading period when access is
gained from the user program to the control DB.
Reference
Further information on this and a description of the areas that can be modified can be found
in the online Help for the Web2PLC.
For more detailed information on the SFC 99 block, refer to the online Help for STEP 7.

Communication
3.7 Web server

PROFINET 4
4.1 Communication by means of PROFINET
4.1.1 Introduction
What is PROFINET?
Within the framework of Totally Integrated Automation (TIA), PROFINET represents a
consequent enhancement of:
● PROFIBUS DP, the established field bus, and
● Industrial Ethernet, the communication bus for the cell level
Experience gained from both systems was and is being integrated into PROFINET.
PROFINET is an Ethernet-based automation standard of PROFIBUS International
(previously PROFIBUS Users Organization e.V.), and defines a multi-vendor communication,
automation, and engineering model. PROFINET has been part of the standard IEC 61158
since 2003.
Objectives in PROFINET
The objectives in PROFINET are:
● Open Ethernet Standard for automation based on Industrial Ethernet.
Although Industrial Ethernet and Standard Ethernet components can be used together,
the Industrial Ethernet devices are more sturdy and therefore better suited for industrial
environments (temperature, immunity to interference, etc.)
● Using TCP / IP and IT standards
● Automation with real-time Ethernet
● Total integration of field bus systems

PROFINET
Implementation of PROFINET in SIMATIC

We have integrated PROFINET as follows:
● We have implemented communication between field devices in SIMATIC with
PROFINET IO.
● In SIMATIC, communication between controllers as components in distributed systems is
implemented with PROFINET CBA (Component based Automation).
● Installation engineering and network components are available in SIMATIC NET.
● Established IT standards from the Office environment (e.g., SNMP=Simple Network
Management Protocol for network parameter assignment and diagnosis) are used for
remote maintenance and network diagnostics.
Documentation from PROFIBUS International on the Internet

At the website of PROFIBUS International (previously PROFIBUS User Organization, PNO),
you will find numerous documents on the topic of PROFINET. "PROFINET
(http://www.profinet.com)"
For more information, go to: "Siemens PROFINET (http://www.siemens.com/profinet)"
4.1.2 PROFINET IO and PROFINET CBA
What is PROFINET IO?

Within the framework of PROFINET, PROFINET IO is a communication concept for the
implementation of modular, distributed applications.
PROFINET IO allows you to create automation solutions, which are familiar to you from
PROFIBUS.
This means that you have the same application view in STEP 7, regardless of whether you
are configuring PROFINET or PROFIBUS devices.
What is PROFINET CBA (Component Based Automation)?

Within the framework of PROFINET, PROFINET CBA is an automation concept for the
implementation of applications with distributed intelligence.
PROFINET CBA lets you create distributed automation solutions, based on default
components and partial solutions.
Component Based Automation allows you to use complete technological modules as
standardized components in large systems.
The components are also created in an engineering tool which may differ from vendor to
vendor. Components of SIMATIC devices are created, for example, with STEP 7.

PROFINET
Extent of PROFINET CBA and PROFINET IO

PROFINET IO and CBA represent two different views of automation devices on Industrial
Ethernet.
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Component Based Automation divides the entire system into various functions. These
functions are configured and programmed.
PROFINET IO provides you with a view of the system that is very similar to the view
obtained in PROFIBUS. You continue to configure and program the individual automation
devices.
Reference
● Details on PROFINET IO and PROFINET CBA are available in the PROFINET System
Description. (http://support.automation.siemens.com/WW/view/en/19292127)
● Differences between and common properties of the PROFIBUS DP and PROFINET IO
are described in the From PROFIBUS DP to PROFINET IO
(http://support.automation.siemens.com/WW/view/en/19289930) Programming Manual.
● For additional information on PROFINET CBA, refer to the documentation on SIMATIC
iMAP and Component Based Automation.

PROFINET
4.1.3 PROFINET IO System
Functions of PROFINET IO
The following graphic shows the new functions in PROFINET IO.
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PROFINET
The graphic shows Examples of connection paths

The connection of company You can access devices at the field level from PCs in your company network
network and field level Example:
 PC - Switch 1 - Router - Switch 2 - CPU 319-3 PN/DP ①.
Connections between the You can also access other areas on the Industrial Ethernet from a programming device at
automation system and field the field level.
level Example:
 PD - integrated switch IM 154-8 PN//DP CPU ② - Switch 2 - integrated switch
CPU 319-3 PN/DP ① - integrated switch IO device ET 200S ⑥ - on IO
device ET 200S ⑦.
The IO controller of the CPU At this point, you can see IO features between the IO controller, I device and IO device(s)
IM 154-8 PN/DP CPU ② on the Industrial Ethernet:
powers the PROFINET IO  The IM 154-8 PN/DP CPU ② is the IO controller for the two IO devices ET 200S ③
system 1 and directly controls and ET 200 S ④, for the switch 2 and also for the I device CPU 317-2 PN/DP ⑤.
devices on the Industrial
Ethernet and on the  The IO device ET200S ③ is thus operated as a shared device, so that the IM 154-8
PROFIBUS CPU ② as controller can access only those (sub)modules of this IO device which are
assigned to it as the controller.
 Via the IE/PB link, the IM 154-8 CPU ② is also the IO controller for the ET 200 (DP
slave) ⑩.
The CPU 319-3 PN/DP ① Here you can see that a CPU can be both the IO controller for an IO device and the DP
powers the PROFINET master for a DP slave:
system 2 as its IO controller  The CPU 319-3 PN/DP ① is the IO controller for the two IO devices ET 200S ⑥ and
and is at the same time the ET 200 S ⑦ and also for the I device CPU 319-3 PN/DP ⑧.
DP master on PROFIBUS. As
well as other  Furthermore, the CPU319-3 PN/DP ① shares the
IO devices, this controller also IO device ET 200S operated as a shared device ③ with the IO controller IM 154-8
operates a CPU 319-3 PN/DP PN/DP CPU ②, so that the
⑧ as an CPU 319-3 PN/DP ① as controller can access only those (sub)modules
I device, which in turn powers of this IO device, which are assigned to it as the controller.
a lower level PROFINET
system as the IO controller.  The CPU 319-3 ⑧, which is operated as an I device at the CPU 319-3 PN/DP ①, is
also at the same time an IO controller and powers its own PROFINET system 3 on
which the IO device ET 200S ⑨ is operated.
 The CPU 319-3 PN/DP ① is the DP master for one DP slave ⑪. The DP slave ⑪ is
assigned locally to the CPU 319-3 PN/DP ① and is not visible on the Industrial
Ethernet.
Reference
You will find further information about PROFINET in the documents listed below:
● in the system description PROFINET
● In the programming manual From PROFIBUS DP to PROFINET IO.
(http://support.automation.siemens.com/WW/view/en/19289930)
programming manual. This manual also provides a clear overview of the new PROFINET
blocks and system status lists.

PROFINET
See also
PROFINET (PN) (Page 27)
4.1.4 Blocks for PROFINET IO
Content of this Section

This section explains the following:
● Which blocks are intended for PROFINET
● Which blocks are intended for PROFIBUS DP
● Which blocks are intended for both PROFINET IO and PROFIBUS DP
Compatibility of the New Blocks

For PROFINET IO, it was necessary to create some new blocks, among other things,
because larger configurations are now possible with PROFINET. You can also use the new
blocks with PROFIBUS.
Comparison of the System and Standard Functions of PROFINET IO and PROFIBUS DP

For the IM 151-8 PN/DP CPU interface module with an integrated PROFINET interface, the
table below provides an overview of:
● System and standard functions for SIMATIC that you may need to replace when
converting from PROFIBUS DP to PROFINET IO.
● New system and standard functions
Table 4- 1 New System and Standard Functions/System and Standard Functions to be Replaced
Blocks PROFINET IO PROFIBUS DP

SFC 5 (determine logical start No (replacement: SFC70) Yes
address of a module)
SFC 12 (deactivation and Yes Yes
activation of DP slaves/IO
devices)
SFC 13 (read diagnostic data of No Yes
a DP slave) Substitute:
 Event-related: SFB 54
 State-related: SFB 52
SFC 49 (determine the slot No Yes
belonging to a logical address) Substitute: SFC 71
SFC 58/59 (write/read data No Yes
record in I/O) Substitute: SFB 53/52 You should use SFB 52 / 53
under DPV1.

PROFINET

SFC 70 (determine start Yes Yes
address of a module)
SFC 71 (determine the slot Yes Yes
belonging to a logical address)
SFC 102 (read predefined No Yes
parameters) Substitute: SFB 81
SFB 52/53 (read/write data Yes Yes
record)
SFB 54 (evaluate interrupt) Yes Yes
SFB 73 ((PROFIenergy) data Yes No
blocks in the I device received
by the higher level controller)
SFB 74 ((PROFIenergy) data Yes No
blocks in the I device available
to the higher level controller)
SFB 81 (read predefined Yes Yes
parameters)
SFB 104 (assignment of the IP Yes No
suite and / or the device name
from the user program)
The following table provides you with an overview of the system and standard functions for
SIMATIC, whose functionality must be implemented by other functions when converting from
PROFIBUS DP to PROFINET IO.
Table 4- 2 System and Standard Functions in PROFIBUS DP that must be Implemented with
Different Functions in PROFINET IO

SFC 55 (write dynamic No Yes
parameters) Replicate via SFB 53
SFC 56 (write predefined No Yes
parameters) Replicate via SFB 81 and SFB
53
SFC 57 (assign module No Yes
parameters) Replicate via SFB 81 and SFB
53
You cannot use the following SIMATIC system and standard functions with PROFINET IO:
● SFC 11 (synchronize groups of DP slaves)
● SFC 72 (read data from a communication partner within local S7 station)
● SFC 73 (write data to a communication partner within local S7 station)
● SFC 74 (cancel an existing connection to a communication partner within local S7
station)
● SFC 103 (determine the bus topology in a DP master system)

PROFINET
Comparison of the Organization Blocks of PROFINET IO and PROFIBUS DP

Here, there are changes to OB 83 and OB 86, as shown in the following table.
Table 4- 3 OBs in PROFINET IO and PROFIBUS DP

OB 83 New error information The removal and insertion of
(removal and insertion of modules during operation is
modules during operation) signaled by slaves added using
a GSD file by means of a
diagnostic interrupt, in other
words OB 82.
In the case of S7 slaves, a
swapping interrupt causes a
CPU stop to be reported and
OB 86 to be called.
OB 83 corresponding info for the Not applicable
Return of submodule alarm for submodules
submodules in the transfer
areas of an I device
OB 86 New error information Unchanged
(CPU stop)
OB 86 may occur when used as a Not applicable
(partial CPU stop / partial CPU shared I device
restart)
Detailed Information
For detailed descriptions of the individual blocks, refer to the System and Standard
Functions for S7-300/400 manual.

PROFINET
4.2 Isochronous real time communication
4.2 Isochronous real time communication

Synchronized transmission procedure for the cyclic exchange of IRT data between
PROFINET devices. A reserved bandwidth is available within the send cycle for IRT IO data.
The reserved bandwidth ensures that the IRT data can be transmitted at reserved,
synchronized intervals while remaining uninfluenced even by other greater network loads
(e.g. TCP / IP communication or additional real-time communication).
PROFINET with IRT can be operated using either of the two following options:
● IRT option "high flexibility":
Maximum flexibility in planning and extending the system.
Topological configuration is not required.
● IRT option "high performance":
Topological configuration is required.
Note
IO controller as a sync master at IRT communication with the IRT option "high
performance"
We recommend also operating the IO controller as a Sync-Master if you configure the IRT
communication with the option "high performance". Otherwise, IRT and RT configured IO
devices may fail if the sync master fails.
For further information about configuring PROFINET devices, refer to the STEP 7 online
Help and the PROFINET System Description
4.3 Prioritized startup

Prioritized startup describes the PROFINET functionality for the acceleration of IO devices
(distributed I/O) in a PROFINET IO system with RT and IRT communication.
The function shortens the time required by the respective configured IO devices to reach the
cyclic user data communication in the following cases:
● After restoration of power (not for a CPU that is operated as an I device with prioritized
start-up)
● After a CPU has restarted
● After IO Devices have been activated
Note
Startup times
The startup time depends on the number and type of modules.

PROFINET
4.4 Device replacement without removable media / PD
Note
Prioritized startup and media redundancy
The inclusion of a IO device with prioritized startup in a ring topology with media redundancy
is not possible.
For additional information, refer to the STEP 7 online help and the PROFINET System
Description (http://support.automation.siemens.com/WW/view/en/19292127).
4.4 Device replacement without removable media / PD

IO devices with this function can be exchanged easily:
● A removable medium (such as Micro Memory Card) with stored device name is not
required.
● The device name does not have to be assigned with the PD.
The substituted IO device is given a device name by the IO controller and not by the
removable media or the PD. To do this, the IO controller uses the configured topology and
the neighborhood classifications established from the IO devices. In doing so, the configured
set topology must agree with the actual topology.
Reset the IO devices, which were already in operation, back to the factory settings before
using them again.

PROFINET
4.5 IO devices that can be switched during operation
4.5 IO devices that can be switched during operation

Functionality of a PROFINET device. If the IO controller and IO devices support this
functionality, "switchable partner ports" of different devices can be assigned to an IO device
port by means of configuration, so that communication with each of these switchable IO
devices is possible at a particular time via the IO device port. However, only the switchable
device that is currently being communicated with may be physically connected to the
switchable port.
Note
The ports of a CPU can be assigned as "switchable partner ports" only if the CPU is being
operated as an I device. This is not the case, if it is operated as an IO controller.
4.6 Isochronous mode

Process data, transfer cycle via PROFINET IO and user program are synchronized with
each other to achieve the highest deterministics. The input and output data of distributed I/O
devices in the system are detected and output simultaneously. The constant bus cycle times
of the PROFINET IO cycle forms the clock generator for it.
Note
The following components cannot be operated in isochronous mode:
 A shared device.
 An I device at the higher-level IO controller
Note
Constraints on the send clocks for isochronous applications
Isochronous operation can be performed by the IM 151-8 PN/DP CPU when the send clock
is ≥ 1 ms. Depending on the size of the user data and the topology, it may be necessary to
increase the application cycle factor or the send clock, in order to satisfy the timing
requirements.

PROFINET
4.7 I-Device
4.7 I-Device
The "I-Device" (intelligent IO device) functionality of an IM151-8 PN/DP CPU permits the
exchange of data with an IO controller, thereby allowing the IM151-8 PN/DP CPU, for
example, to be used as an intelligent pre-processing unit for subprocesses. For this the I
device is linked in the role of an IO device to a "higher level" IO controller.
The pre-processing is performed by the user program in the IM151-8 PN/DP CPU with the I
device functionality. The centralized or decentralized (PROFINET IO or PROFIBUS DP)
process values are pre-processed by the user program and delivered to a higher level CPU
by a PROFINET IO device interface of the CPU.
Note
Isochronous mode
An I device at the higher-level IO controller cannot be operated isochronously.
Combination of functionalities
A CPU that is operated as an I device at a "higher-level" IO controller can operate in its own
right as an IO controller and thus operate IO devices in a lower-level subnet.
An I device can also be operated as a shared device.
Transfer areas
Communication between an IO controller and I device is established via the configured
submodules of a transfer area. The transfer of user data is thus performed consistently in
relation to the submodules.
There are two types of transfer areas:
● Application transfer areas form the interface for the user data transfer between the
higher-level IO controller and the user program of the I device CPU. Inputs are processed
in the user program and outputs are the result of processing in the user program.
● I/O transfer areas deliver data from higher-level IO controllers to I/O devices or vice
versa. No values are processed in the I device.
Special considerations when using I/O transfer areas

Information on the behavior within the IO controller and the I device during processing,
diagnostics, insert/remove module interrupts and load voltage diagnostics of modules, that
are configured in the I/O transfer area of an I device can be found in the PROFINET System
Description. Section "Diagnostics and alarm behavior" and "Supplementary conditions for
use of I devices".
Further information about the I device and configuration of an I device can be found in the
STEP 7 online Help and the PROFINET System Description

PROFINET
4.8 Shared Device
4.8 Shared Device

The "Shared Device" functionality permits the sub-modules of an IO device to be distributed
between various IO controllers. An I device can also be operated as a shared device.
The IO controller and the shared device have to be located on the same Ethernet subnet so
that the shared device function can be used.
The IO controllers can be located in the same STEP 7 project or in different STEP 7 projects.
If they are located in the same STEP 7 project, the consistency checking is performed
automatically.
Note
A shared device cannot be operated isochronously.
Note
Please note that power modules and electronics modules of a potential group of a shared IO
device (such as an ET200S) must be assigned to the same IO controller, so that a loss of
load voltage can be diagnosed.
Further information about the shared device and configuration can be found in the STEP 7
online Help and the PROFINET System Description

PROFINET
4.9 Media redundancy
4.9 Media redundancy

Function for ensuring the network and system availability. Redundant transmission links (ring
topology) ensure that an alternative communication path is made available if a transmission
link fails.
For the IO devices, switches and CPUs from V3.2 onward, the media redundancy protocol
(MRP) can be activated, which is part of the PROFINET standardization in accordance with
IEC 61158.
Structure of a ring topology

To set up a ring topology with media redundancy, you bring together at a single device the
two free ends of a linear bus topology. Closing the linear bus topology to form a ring is
achieved with two ports (ring ports) of a device in the ring. For the IM 151-8 PN/DP CPU, two
ring ports (port 1 and port 2) are available for selection and configuration.
On the module the ring ports are indicated by an "R" after the port number.
Note
IRT communication / prioritized start-up
If IRT communication or prioritized start-up is used, media redundancy is not supported.

Memory concept 5
5.1 Memory areas and retentive memory
5.1.1 Memory areas of the IM 151-8 PN/DP CPU interface module
The three memory areas of your IM 151-8 PN/DP CPU interface module
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Load memory
The load memory is located on the SIMATIC Micro Memory Card. The size of the load
memory corresponds exactly to the size of the SIMATIC Micro Memory Card. It is used to
store code blocks, data blocks and system data (configuration, connections, module
parameters, etc.). Blocks that are identified as non runtime-related are stored exclusively in
load memory. You can also store all the configuration data for your project on the SIMATIC
Micro Memory Card.
Note
User programs can only be downloaded and thus the IM151-8 PN/DP CPU interface module
can only be used if the SIMATIC Micro Memory Card is inserted in the interface module.
System memory
The system memory is integrated in the IM151-8 PN/DP CPU interface module and cannot
be extended.
It contains
● The address areas for address area memory bits, timers and counters
● The process image of the I/Os
● Local data

Memory concept
Work memory
The working memory is integrated in the IM 151-8 PN/DP CPU interface module and cannot
be extended. It is used to run the code and process user program data. Programs only run in
work memory and system memory.
5.1.2 Retentivity of load memory, system memory and RAM

Your IM151-8 PN/DP CPU interface module is equipped with a maintenance-free retentive
memory, i.e. its operation does not require a back-up battery. Data is kept in retentive
memory across POWER OFF and restart (warm start).
Retentive data in load memory

Your program in the load memory is always retentive. It is stored on the SIMATIC Micro
Memory Card, where it is protected against power failure or CPU memory restart
The configuration data for the interface of the IM151-8 PN/DP CPU interface module will be
stored retentively in the load memory of an SDB.
Retentive data in system memory

In your configuration (IM151-8 PN/DP CPU interface module Properties, Retentivity tab),
specify which parts of the bit memory, timers and counters should be kept retentive and
which should be reinitialized to "0" on restart (warm restart).
The operating hour counter is usually stored in the retentive memory area on the IM151-
Only the last 100 entries in the diagnostics buffer are retentive with POWER OFF / POWER
ON.
Retentive data in RAM

Therefore, the contents of retentive DBs are always retentive at restart and POWER OFF /
POWER ON. Retentive data blocks can be uploaded to the work memory in accordance with
the maximum limit allowed by the work memory.
The IM 151-8 PN/DP CPU interface module also supports non-retentive DBs. Non-retentive
DBs are initialized from the load memory with their initial values whenever a restart is
performed or with POWER OFF / POWER ON. Non-retentive data blocks and code blocks
can be loaded in accordance with the maximum work memory limit.
64 KB of RAM can be used for retentive data blocks in the IM 151-8 PN/DP CPU interface
module.
See also
Properties of the SIMATIC Micro Memory Card (Page 116)

Memory concept
5.1.3 Retentivity of memory objects
Retentive behavior of the memory objects

The table below shows the retentive behavior of memory objects during specific operating
state transitions.
Table 5- 1 Retentive behavior of the memory objects
Memory object Operating state transition

POWER OFF / STOP → Memory reset
POWER ON RUN
User program / data (load memory) X X X
 Retentive behavior of the DBs for Can be set in the Properties of the –
the IM 151-8 PN/DP CPU DBs in STEP 7 .
interface module
Bit memory, timers and counters X X –
configured as retentive data
Diagnostics buffers, operating hour X1 X X
counters
IP suite / device name of the PN Depending on the type X Depending on the
interface of assignment of IP type of assignment of
address parameters IP address
and device names. parameters and
device names.
X = retentive; – = not retentive
1Only the last 100 entries in the diagnostics buffer are retained in the event of a POWER
OFF / POWER ON.
Reference
More detailed information about assignment of IP address parameters and device names
can be found in the section "Assignment of IP address parameters and the device name
(Page 139)".

Memory concept
Retentive behavior of a DB with the IM 151-8 PN/DP CPU interface module

For the IM 151-8 PN/DP CPU interface module you can specify in STEP 7 or via SFC 82
"CREA_DBL" (parameter ATTRIB -> NON_RETAIN bit), whether, in response to a POWER
ON / OFF or RUN-STOP, a DB
● Keeps the actual values (retentive DB), or
● Accepts the initial values from load memory (non-retentive DB)
Table 5- 2 Retentive behavior of the DB with the IM 151-8 PN/DP CPU interface module
After a POWER OFF / POWER ON or restart of the IM 151-8 PN/DP CPU interface module, the DB
should...
Receive the initial values Retain the last actual values
(non-retentive DB) (retentive DB)
Reason: Reason:
After a POWER OFF / POWER ON and restart After a POWER OFF / POWER ON and restart
(STOP-RUN) of the IM 151-8 PN/DP CPU (STOP-RUN) of the IM 151-8 PN/DP CPU
interface module, the actual values of the DB are interface module, the actual values of the DB are
non-retentive. The DB receives the start values retained.
from load memory.
Requirement in STEP 7: Requirement in STEP 7:
 The "Non-retain" check box must be  The "Non-retain" check box must be
activated in the block properties of the DB, or deactivated in the block properties of the DB,
 a non-retentive DB was generated with SFC or
82 "CREA_DBL" and the associated block  A retentive DB was generated with SFC 82.
attribute (ATTRIB -> NON_RETAIN bit).

Memory concept
5.1.4 Address areas of system memory

The system memory of the IM 151-8 PN/DP CPU interface module is broken down into
operand areas (refer to the table below). In a corresponding operation of your user program,
you address data directly in the relevant address area.
Address areas of system memory
Table 5- 3 Address areas of system memory
Address areas Description

Process image of inputs At every start of an OB 1 cycle, the IM 151-8 PN/DP CPU
interface module reads the inputs from the input modules and
saves the values to the process image input.
Process image of outputs During its cycle, the program calculates the values for the outputs
and writes these to the process image of outputs. At the end of
the OB 1 cycle, the IM 151-8 PN/DP CPU interface module writes
the calculated output values to the output modules.
Bit memory This area provides memory for saving the intermediate results of
a program calculation.
Timers Timers are available in this area.
Counters Counters are available in this area.
Local data Temporary data in a code block (OB, FB, FC) is saved to this
memory area while the block is being edited.
Data blocks See Recipes and Measured value logs
Reference
The address areas of your IM 151-8 PN/DP CPU interface module are listed in the S7-300
Instruction List.
I/O process image

When the user program addresses the input (I) and output (Q) operand areas, it does not
query the signal states of digital electronic modules. Instead, it accesses a memory area in
the IM 151-8 PN/DP CPU interface module system memory. This particular memory area is
the process image.
The process image is organized in two sections: The process image of inputs, and the
process image of outputs.
Advantages of the process image
In contrast to direct access of the input / output modules, accessing the process image has
the advantage that a consistent image of the process signals is made available to the
IM 151-8 PN/DP CPU interface module during cyclic program execution. When the signal
status at an input module changes during program execution, the signal status in the
process image is maintained until the image is updated in the next cycle. Moreover, since
the process image is stored in the IM 151-8 PN/DP CPU interface module system memory,
access is significantly faster than direct access to the electronic modules.

Memory concept
Process image update

The operating system updates the process image periodically. The figure below shows the
sequence of this operation within a cycle.
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XSGDWHVWKHGDWDLQWKHSURFHVVLQSXW
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Variable process image

In STEP 7, you can set the size of the I/O process image to any value from 0 to 2048 bytes
for the IM151-8 PN/DP CPU.
Please observe the following::
Note
Currently, the dynamic setting of the process image only affects its update at the scan cycle
control point. That is, the process input image is only updated up to the set PII size with the
corresponding values of the peripheral input modules existing within this address area, or the
values of the process output image up to the set POI size are written to the peripheral output
modules existing within this address area.
This set size of the process image is ignored with respect to the STEP 7 commands used to
access the process image (for example U I100.0, L IW200, = Q20.0, T AD150, or the
corresponding indirect addressing commands). However, up to the maximum size of the
process image (that is, up to I/O byte 2047), these commands do not return any
synchronous access errors, but rather access the permanently available internal memory
area of the process image.
The same applies to the use of actual parameters of block calls from the I/O area (area of
the process image).
Particularly if these process image limits were changed, you should check to which extent
your user program continues to access the process image in the area between the set and
the maximum process image size. If such access is to continue to take place, this means
that inputs on the I/O module that change may not be detected or that outputs may not really
be written to the output module without an error message being generated.

Memory concept
Local data
Local data store:
● The temporary variables of code blocks
● The start information of the OBs
● Transfer parameters
● Intermediate results
Temporary Variables
When you create blocks, you can declare temporary variables (TEMP) which are only
available during block execution and then overwritten again. These local data have fixed
length in each OB. Local data must be initialized prior to the first read access. Each OB also
requires 20 bytes of local data for its start information.
The IM 151-8 PN/DP CPU interface module has memory for storing temporary variables
(local data) of recently executed blocks. This memory is divided among the priority classes
into partitions of equal size. Each priority class has its own local data area.
CAUTION
All temporary variables (TEMP) of an OB and its nested blocks are stored in local data.
When using complex nesting levels for block processing, you may cause an overflow in the
local data area.
The IM 151-8 PN/DP CPU interface module will change to STOP mode if the permissible
length of the local data for a priority class is exceeded.
Make allowances for local data space required for synchronous error OBs. This is assigned
to the respective triggering priority class.
See also
Retentivity of load memory, system memory and RAM (Page 110)

Memory concept
5.1.5 Properties of the SIMATIC Micro Memory Card
The SIMATIC Micro Memory Card as a memory module for the IM 151-8 PN/DP CPU interface
module
The memory module used in your IM 151-8 PN/DP CPU interface module is a SIMATIC
Micro Memory Card. It can be used as load memory or as a portable storage medium.
Note
The IM 151-8 PN/DP CPU interface module requires the SIMATIC Micro Memory Card for
operation.
The following data are stored on the SIMATIC Micro Memory Card.
● User programs (all blocks)
● Archives and recipes
● Configuration data (STEP 7 projects)
● Data for operating system update and backup
Note
You can either store user and configuration data or the operating system on the SIMATIC
Micro Memory Card.
Properties of a SIMATIC Micro Memory Card

The SIMATIC Micro Memory Card ensures maintenance-free and retentive operation of the
IM 151-8 PN/DP CPU interface module .
SIMATIC Micro Memory Card copy protection

Your SIMATIC Micro Memory Card has an internal serial number that implements an MMC
copy protection. You can read this serial number from the SSL partial list 011CH index 8
using SFC 51 "RDSYSST." If the reference and actual serial number of your SIMATIC Micro
Memory Card are not the same, program a STOP command in a know-how-protected
module, for example.
Reference
● on the SSL partial list refer to the S7-300 Instruction list or the System and standard
functions for S7-300/400 Reference Manual.
● to memory reset the IM 151-8 PN/DP CPU interface module, refer to section Resetting
the IM 151-8 PN/DP CPU interface module using the mode selector switch.

Memory concept
5.2 Memory functions
Useful life of a SIMATIC Micro Memory Card

The life of an SIMATIC Micro Memory Card depends mainly on the following factors:
1. The number of delete or programming cycles
2. External influences such as ambient temperature
At ambient temperatures up to 60 °C, up to 100,000 delete/write operations can be
performed on a SIMATIC Micro Memory Card.
CAUTION
To prevent data losses, do not exceed this maximum of delete/write operations.
See also
Retentivity of load memory, system memory and RAM (Page 110)
Operating and display elements of the IM 151-8 PN/DP CPU interface module (Page 23)
5.2.1 General: Memory functions
Memory functions
Memory functions are used to generate, modify or delete entire user programs or specific
blocks. You can also ensure that your project data are retained by archiving these. If you
created a new user program, use a programming device/PC to download the complete
program to the SIMATIC Micro Memory Card.

Memory concept
5.2.2 Downloading user programs via SIMATIC Micro Memory Card to the
User program download

The entire user program is downloaded from your PD / PC to the IM 151-8 PN/DP CPU
interface module via the SIMATIC Micro Memory Card. The previous content of the SIMATIC
Micro Memory Card is deleted in the process. Blocks use the load memory area as specified
under "Load memory requirements" in "General block properties".
The figure shows the load and work memory of the IM 151-8 PN/DP CPU interface module .
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1: If not all of the work memory area is retentive, the retentive part is indicated in the STEP 7
module status as retentive memory. You cannot run the program until all the blocks are
downloaded.
Note
This function is only permissible if the IM 151-8 PN/DP CPU interface module is in STOP
mode. Load memory is cleared if the load operation could not be completed due to power
loss or illegal block data.

Memory concept
5.2.3 Handling blocks
5.2.3.1 Encryption of blocks
Important information
Note
Supported blocks
S7 Block Privacy can be used to encrypt only function blocks (FBs) and functions (FCs).
Once blocks have been encrypted in STEP 7 they can no longer be edited or monitored. Nor
can any test or commissioning functions, such as status blocks or breakpoints, be
performed.
Requirement
The "S7 Block Privacy" extension package supplied with STEP 7 must be installed. Only by
this means can blocks be hard encrypted.
General procedure
In order to encrypt the blocks, proceed as follows:
1. In the HW config, select the desired block (multiple selection can be made).
2. Right click on the block to be encrypted, and select "Encrypt block...". The "Block
encryption" dialog box opens.
3. Select whether decompilation information should also be encrypted.
Note
If you deactivate the check box, there is no way the block can be decompiled.
4. Enter a code of at least 12 characters in both fields. Make sure the code is securely
stored. Press the "OK" button to start the encryption.
Result: Your block is now encrypted. This is indicated by the following symbols:
Block that can be decompiled
Block that cannot be decompiled

Memory concept
Note
Run time for the command
Typically the run time for the command is extended because the encrypted blocks could not
be executed in a fully optimized manner. The resulting cycle time can be determined only
with encrypted blocks
Note
Extended run times for POWER ON/memory reset/download
The ramp-up time for the CPU, the time required for memory reset and the loading time of
blocks can be extended significantly.
For further information please refer to the STEP 7 online Help under "S7 Block Privacy".
5.2.3.2 Download of new blocks or delta downloads

There are two ways to download additional user blocks or download deltas:
● Download of blocks: You have already created a user program and downloaded it to the
IM 151-8 PN/DP CPU interface module via the SIMATIC Micro Memory Card. You then
want to add new blocks to the user program. In this case you do not need to reload the
entire user program to the MCC. Instead you only need to download the new blocks to
the SIMATIC Micro Memory Card (this reduces the download times for highly complex
programs.)
● Delta download: In this case, you only download the deltas in the blocks of your user
program. In the next step, perform a delta download of the user program, or only of the
changed blocks to the SIMATIC Micro Memory Card, using the programming device/PC.
WARNING
The delta down of block / user programs overwrites all data stored under the same
name on the SIMATIC Micro Memory Card.
The data of dynamic blocks are transferred to RAM and activated after the block is
downloaded.
5.2.3.3 Uploading blocks

In contrast to downloading, uploading involves the transfer of individual blocks or a complete
user program from the IM 151-8 PN/DP CPU interface module to the programming
device / PC. In doing so, the blocks have the content of the last download in the
IM 151-8 PN/DP CPU interface module. Dynamic DBs form the exception, because their
actual values are transferred. Uploading blocks or the user program from the
IM 151-8 PN/DP CPU interface module in STEP 7 does not affect the memory assignment of
the IM 151-8 PN/DP CPU interface module.

Memory concept
5.2.3.4 Deleting blocks

When you delete a block, it is deleted from load memory. In STEP 7, you can also delete
blocks with the user program (DBs also with SFC 23 "DEL_DB"). RAM used by this block is
released.
5.2.3.5 Compressing blocks

When data are compressed, gaps which have developed between memory objects in load
memory/RAM as a result of load/delete operations will be eliminated. This releases free
memory in a continuous block. You can compress both in STOP mode as well as in RUN
mode of the IM 151-8 PN/DP CPU interface module.
5.2.3.6 Promming (RAM to ROM)

When writing the RAM content to ROM, the actual values of the DBs are transferred from
RAM to load memory to form the start values for the DBs.
Note
This function is only permissible if the IM 151-8 PN/DP CPU interface module is in STOP
mode. Load memory is cleared if the function could not be completed due to power loss.
5.2.4 CPU memory reset and restart
Memory reset
After inserting or removing a SIMATIC Micro Memory Card, a complete memory reset
restores the IM 151-8 PN/DP CPU interface module to defined conditions in order to make a
restart (warm start) possible. When resetting the IM 151-8 PN/DP CPU interface module, the
memory management of the IM 151-8 PN/DP CPU interface module is reestablished. Blocks
in load memory are retained. All dynamic runtime blocks are transferred once again from
load memory to RAM, in particular to initialize the data blocks in RAM (restore initial values).
Restart (warm start)

● All retentive DBs retain their current values. Non-retentive DBs are reset to their initial
values.
● The values of all retentive M, C, T are retained.
● All non-retentive user data are initialized:
– M, C, T, I, O with "0"
● All run levels are initialized.
● The process images are deleted.

Memory concept
Reference
Read also section Resetting the IM 151-8 PN/DP CPU interface module using the mode
selector switch.
See also
Reset the IM 151-8 PN/DP CPU interface module using the mode selector switch (Page 151)
5.2.5 Recipes
Introduction
A recipe represents a collection of user data. You can implement a simple recipe concept
using static DBs. In this case, the recipes should have the same structure (length). One DB
should exist per recipe.
Processing sequence
Recipe is written to load memory:
● The individual data records of the recipes are created as static DBs in STEP 7 and then
downloaded to the IM 151-8 PN/DP CPU interface module. Therefore, recipes only use
load memory, rather than RAM.
Working with recipe data:
● SFC83 "READ_DBL" is called in the user program to copy the data record of a current
recipe from the DB in load memory to a static DB that is located in work memory. As a
result, the RAM only has to accommodate the data of one record. The user program can
now access data of the current recipe. The figure below shows how to handle recipe
data:
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5HFLSHQ

Memory concept
Saving a modified recipe:

● The data of new or modified recipe data records generated during program execution can
be written to load memory. To do this, call SFC 84 "WRIT_DBL" in the user program. The
data written to load memory are portable and retentive on Memory reset. You can backup
modified records (recipes) by uploading and saving these in a single block to the
programming device/PC.
Note
Active system functions SFC82 to 84 (active access to the SIMATIC Micro Memory Card)
have a distinct influence on programming device functions (for example, block status,
variable status, download block, upload, open.) This typically reduces performance
(compared to passive system functions) by a factor of 10.
Note
CAUTION
Data on a SIMATIC Micro Memory Card can be corrupted if you remove the card while it
is being accessed by a write operation. In this case, you may have to delete the
SIMATIC Micro Memory Card on your PD, or format the card in the IM151-8 PN/DP
CPU interface module.
Never remove a SIMATIC Micro Memory Card in RUN mode. Always remove it when
power is off, or when the IM151-8 PN/DP CPU interface module is in STOP state, and
when the PD is not writing to the card. If the CPU is in STOP mode and you cannot not
determine whether or not a PD is writing to the card (e.g. load/delete block), disconnect
the communication lines.

Memory concept
5.2.6 Measured value log files
Introduction
Measured values are generated when the IM 151-8 PN/DP CPU interface module executes
the user program. These measured values are to be logged and analyzed.
Processing sequence
Acquisition of measured values:
● The IM 151-8 PN/DP CPU interface module writes all measured values to a DB (for
alternating backup mode in several DBs) which is located in the work memory.
Measured value logging:
● Before the data volume can exceed work memory capacity, you should call
SFC 84 "WRIT_DBL" in the user program to swap measured values from the DB to load
memory. The figure below shows how to handle measured value log files:
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6)&:5,7B'%/

0HDVXUHGYDOXHQ
● You can call SFC 82 "CREA_DBL" in the user program to generate new (additional) static
DBs in load memory which do not require RAM space.

Memory concept
Reference
For additional information on the block SFC 82 can be found in the System and Standard
Functions for S7-300/400 reference manual, or in the STEP 7 Online Help.
Note
SFC 82 is terminated and an error message is generated if a DB already exists under the
same number in load memory and/or work memory.
The data written to load memory are portable and retentive on Memory reset.
Evaluation of measured values:
● Measured value DBs saved to load memory can be uploaded and evaluated by other
communication partners (programming device, PC, for example).
Note
Active system functions SFC82 to 84 (active access to the SIMATIC Micro Memory Card)
have a distinct influence on PG functions (for example, block status, variable status,
download block, upload, open.) This typically reduces performance (compared to passive
system functions) by a factor of 10.
Note
With the IM 151-8 PN/DP CPU interface module you can also generate non-retentive
DBs using SFC 82 (parameter ATTRIB -> NON_RETAIN bit.)
Note

Memory concept
5.2.7 Backup of project data to SIMATIC Micro Memory Card
Function principle
Using the Save project to Memory Card and Fetch project from Memory Card functions, you
can save all project data to a SIMATIC Micro Memory Card, and retrieve these at a later
time. For this operation, the SIMATIC Micro Memory Card can be located in the
IM 151-8 PN/DP CPU interface module or in the programming adapter of a programming
device or PC.
Project data is compressed before it is saved to a SIMATIC Micro Memory Card, and
uncompressed on retrieval.
Note
In addition to project data, you may also have to store your user data on the MMC. You
should therefore first select a SIMATIC Micro Memory Card with sufficient free memory.
A message warns you if the memory capacity on your SIMATIC Micro Memory Card is
insufficient
The volume of project data to be saved corresponds with the size of the project's archive file.
Note
For technical reasons, you can only transfer the entire contents (user program and project
data) using the Save project to memory card action.

6.1 Content
Where can I find what information?

You will find comprehensive information about fitting and connecting an ET 200S in the
relevant sections of the ET 200S Distributed I/O Device Operating Instructions.
The following sections will show you the differences and special features associated with
using an ET 200S with the IM 151-8 PN/DP CPU interface module.
6.2 Installing the IM 151-8 PN/DP CPU interface module
Introduction
The IM 151-8 PN/DP CPU interface module connects the ET 200S with PROFINET.
Requirement
The mounting rail is installed.
Procedure
1. Mount the IM 151-8 PN/DP CPU interface module.
2. Mount the required terminal modules.
Note
Note the installation sequence
If you wish to extend the IM 151-8 PN/DP CPU interface module with an optional DP
master module, you must first of all install the DP master module before you install the
required terminal module.
3. Mount the terminating module.
Reference
The mounting is described in the ET 200S Distributed I/O System
(http://support.automation.siemens.com/WW/view/en/1144348) Operating Instructions.

6.3 Connecting the IM 151-8 PN/DP CPU interface module
Introduction
You connect the supply voltage and PROFINET IO to the IM 151-8 PN/DP CPU interface
module. The IM 151-8 PN/DP CPU interface module is equipped with an internal PROFINET
switch. This allows the PROFINET to be looped through directly, or an additional IO device
(e.g. ET 200S with IM 151-3 PN) to be connected directly.
The structure of a ring topology with media redundancy is performed using the ring ports
P1 R and P2 R. Further IO devices can be connected at port P3; these will however lie
outside the redundancy domain.
35 35 3
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;
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① Connection for PROFINET IO (RJ45 sockets, 3 ports)

P1 R, P2 R: Ring port for creation of ring topology with media redundancy
② Cable holder
③ Connection for supply voltage
CAUTION
PROFINET
Modules with PROFINET interfaces may only be operated in LANs (Local Area Network) in
which all nodes are equipped with SELV / PELV power supplies or protection systems of
equal quality.
A data transfer terminal (modem, for example) is required to access the WAN (Wide Area
Network) in order to ensure compliance with this safety standard.

Requirements
● The IM 151-8 PN/DP CPU interface module is installed on the mounting rail.
● Wire the interface module with the supply voltage switched off.
Required tools
Industrial Ethernet Fast Connect stripping tool (6GK1901-1GA00)
(stripping tool for Industrial Ethernet Fast Connect installation cables)
Power supply
You may only use SELV / PELV-type power supply units with a guaranteed electrically
isolated extra-low voltage (≤ 60 V DC).
Required accessories
● Cable with maximum 2.5 mm2 conductor cross section for the supply voltage
● PROFINET connector (according to the specifications in the PROFINET Installation
Guide)
The following are suitable:
PROFINET RJ45 connector 6GK1901-1BB20-2AA0

with Fast Connect connection system,
90° cable outlet
● Industrial Ethernet Fast Connect installation cables
The following are suitable:
Fast Connect standard cable 6XV1840-2AH10

Fast Connect trailing cable 6XV1840-3AH10
Fast Connect marine cable 6XV1840-4AH10

Installing the PROFINET cable connector

Install the PROFINET cable connector according to the information in the PROFINET
Installation Guide.
The PROFINET Cabling and Interconnection Technology, Version 1.99 guideline can be
found at "PROFINET (http://www.profinet.com)" in the Downloads area.
Pin assignment for the RJ45 cable connector
View of the RJ45 socket Terminal Assignment

1 RD (Receive Data +)
6KLHOG 2 RD_N (Receive Data –)
3 TD (Transmit Data +)

4 Ground
5 Ground
6 TD_N (Transmit Data –)
7 Ground
8 Ground
Connecting PROFINET IO
Connect the PROFINET IO as follows:
1. Insert the PROFINET cable connector onto the PROFINET terminal X1 P1.
2. Clamp the PROFINET cable securely in the cable holder.
The integrated switch enables looping through of PROFINET IO.
If necessary, you can connect the PROFINET connections X1 P2 and X1 P3 to other I/O
devices.

6.4 Installing and connecting the DP master module
Connecting the supply voltages

The voltage supply is over a connecting plug. When it ships, this is connected to the
connection for the supply voltage on the 151-8 PN/DP CPU interface module.
The connecting plug makes it possible to loop the voltage supply uninterrupted.
Pin assignment of the interface:
/ 0 ① 24 VDC (red)

Ground (blue)
②
Ground (blue)
③ 24 VDC (red)
④
0

/

Connect the supply voltage as follows:

1. Strip the wires for the supply voltage to 10 mm.
2. Insert the individual cables into the spring-loaded terminal (round openings) of the cable
connector.
3. Inesrt the wired connector onto the 24 VDC terminal of the 151-8 PN/DP CPU interface
module.
4. Please ensure that there is sufficient strain relief.

If you wish to extend the IM 151-8 PN/DP CPU interface module with an optional DP master
module, you can use the 151-8 PN/DP CPU interface module as a DP master. Connect the
PROFIBUS DP to the DP master module.
Requirements
● The mounting rail has been fitted (see the ET 200S Distributed I/O Device
(http://support.automation.siemens.com/WW/view/en/1144348) Operating Instructions).
● The 151-8 PN/DP CPU interface module is installed on the mounting rail (see Installing
the 151-8 PN/DP CPU interface module (Page 127)).
Note
You should install the required terminal module only having first installed the DP master
module.

Installing the DP master module

1. Suspend the DP master module in the mounting rail to the right of the 151-8 PN/DP CPU
interface module.
2. Rotate the DP master module to the back until it engages.
3. Slide the DP master module to the left until it audibly engages with the 151-8 PN/DP CPU
interface module.
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Figure 6-1 Installing the DP master module
Connecting PROFIBUS DP
Connect the PROFIBUS DP as follows:
● Use a pre-fabricated PROFIBUS cable.
● Insert the bus connector in the X1 connection socket on the DP master module.
● Screw the bus connector into the connection socket.
Pin assignment for the bus connector:
View of the connection socket Terminal Signal Designation

1 – –
2 – –
3 RxD / TxD-P Data line B

4 RTS Request To Send

5 M5V2 Data reference potential (station)

6 P5V2 Supply plus (station)
7 – –
8 RxD / TxD-N Data line A
RS 485 interface
9 – –

Addressing 7
7.1 Addressing the I/O modules
7.1.1 Slot-oriented addressing of the centralized I/O modules
Slot-oriented addressing
A slot-orientated addressing is available only for the centralized I/O of the IM
151-8 PN/DP CPU interface module. If the IM 151-8 PN/DP CPU interface module is started
up without a configuration loaded, then the I/O modules are addressed by slot by default.
This is the digital or analog address set by default according to the type of I/O module (see
table below).
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Figure 7-1 Structure of the default address area

Addressing
Slot assignment
The figure below shows an ET 200S configuration with digital and analog electronic modules
as well as the technology modules and slot assignment.
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Figure 7-2 Slots for the ET 200S
Address assignment
Depending on the slot, 1 byte is reserved in the address areas of the IM151-8 PN/DP CPU
interface module for digital I/Os and motor starters, and 16 bytes is reserved for analog I/Os,
technology modules, 4 IQ-SENSE and High Feature motor starters (up to 63 I/O modules).
The table below indicates the default address assignment for analog and digital modules per
slot for slot-oriented addressing.
Table 7- 1 Default address assignment for centralized I/O modules in an ET 200S with IM
151-8 PN/DP CPU interface module
Reserved Address Area Slot number

1 2 3 4 5 6 7 8 … 66
Digital modules IM 151-8 - 1 2 3 4 … 62
(apart from 8DI, 8DO PN/DP CPU 1
modules)
motor starters
Analog modules, - 272 288 304 320 … 1248
technology modules, to to to to to
4 IQ SENSE, 8DI, 8DO 287 303 319 335 1263
modules,
High Feature motor
starters
Power modules 2 256 272 288 304 320 … 1248
1 with X1 P1 / P2 / P3 as PROFINET interface and X1 as DP interface
2 Diagnostics addresses (no user data)

Addressing
Note
The following digital modules are treated as analog or TF modules for default address
assignment purposes:
 6ES7131-4BF00-0AA0
 6ES7131-4BF50-0AA0
 6ES7132-4BF00-0AA0
 6ES7132-4BF00-0AB0
 6ES7132-4BF50-0AA0
 6ES7131-4RD00-0AB0
 6ES7131-4RD02-0AB0
Example of Slot-Oriented Address Assignment for I/O Modules

The figure below illustrates a sample ET 200S configuration, showing an example of the
address allocation for I/O modules. The addresses for the I/O modules are predefined in
default addressing.
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Figure 7-3 Example of address assignment for I/O modules

Addressing
7.1.2 User-oriented addressing of the I/O Modules
User-oriented addressing
User-oriented module addressing is possible with both centralized and distributed I/Os.
User-oriented addressing means you can freely select
● Input addresses for modules and
● Output addresses for modules
within the range 0 to 2047 with byte-level granularity independently of one another. Assign
the addresses in STEP 7. Specify the module start address that forms the basis for all other
addresses of the module.
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Figure 7-4 Structure of the address area for user-oriented addressing
Note
If you are using PROFIBUS DP or PROFINET IO field devices, then you must always
configure the hardware in STEP 7 HW Config. User-oriented addressing of modules is used
automatically, and there is no fixed slot addressing.
Advantage
Advantages of user-oriented addressing:
● You can make the best possible use of the available address spaces because there are
no "address gaps" between the modules.
● When creating standard software, you can specify addresses that are independent of the
configuration of the ET 200S station.

Addressing
7.2 Addressing on PROFIBUS DP
7.2 Addressing on PROFIBUS DP
Overview
The relevant DP slaves must first be brought into service on the PROFIBUS DP before the
distributed I/Os can be addressed from the user program.
During this commissioning process:
● PROFIBUS addresses are assigned to the slaves
● Address ranges are assigned to the input / output modules or slots so that they can be
addressed from the user program. Slots without user data are given a diagnostics
address.
Additional information on commissioning the IM 151-8 PN/DP CPU interface module as a DP
master module can be found in the Commissioning PROFIBUS DP section.
User-oriented addressing of the distributed PROFIBUS I/Os

You must use user-oriented addressing for the distributed PROFIBUS DP I/Os.
Information can be found in the User-oriented addressing of the I/O modules section.
Addressing consistent user data areas

The table below illustrates the points to consider with respect to communication in a
PROFIBUS DP master system if you want to transfer I/O areas with "Total length"
consistency.
For 1 to 32 byte data consistency on the PROFIBUS DP:

The address area of consistent data in the process image is automatically updated.
To read and write consistent data, you can also use SFC 14 "DPRD_DAT" and SFC 15
"DPWR_DAT". If the address area of consistent data is not in the process image, you must use
SFC 14 and SFC 15 to read and write consistent data.
The length in the SFC must tally with the length of the programmed area when accessing areas with
"Total length" consistency.
Direct access to consistent areas is also possible (e.g. L PEW or T PAW).
In a PROFIBUS DP system you can transfer up to 32 bytes of consistent data.
See also
Commissioning the IM 151-8 PN/DP CPU interface module with DP master module as a DP
master (Page 166)
User-oriented addressing of the I/O Modules (Page 136)

Addressing
7.3 Addressing PROFINET IO
7.3.1 Addressing on PROFINET IO
Overview
The relevant IO devices must first be brought into service on the PROFINET IO before the
distributed I/Os can be addressed from the user program.
During this commissioning process:
● Address ranges are assigned to the input / output modules or slots / subslots so that they
can be addressed from the user program. Slots without user data are given a diagnostics
address.
● The device number and device name are defined for the IO devices.
● The device names are assigned to the IO devices so that the IM 151-8 PN/DP CPU
interface module , as the IO controller, can assign an IP address to and thus address the
IO devices.
Note
Name assignment for I/O devices with "Device replacement without removable medium"
If the functionality "Device replacement without removable medium" is configured in HW
Config, IO devices can also be replaced without the user having to assign a name. To do
so, the IO device must be reset to the factory setting.
Note
IP address parameter / device name in relation to the other path (PN CPU)
 IP address parameters / device names via DCP:
IP address parameters / device names are assigned by DCP (Discovery and
Configuration Protocol). This can be done in two ways:
- by a set-up tool such as PST or STEP 7, e.g. via "Edit Ethernet Nodes"
- by the higher-level controller, if the CPU is operated as an I device.
 IP address parameters / device names via the user program:
The assignment of IP address parameters and/or device names is performed in the
user program of the CPU (via the SFB 104).
Reference
● Other methods of assigning the IP addresses can be found in the section Assignment of
the IP address parameters and the device name (Page 139).
● Additional information on commissioning the IM 151-8 PN/DP CPU interface module as
an IO controller can be found in the Commissioning PROFINET IO (Page 173) section.

Addressing
User-oriented addressing of the distributed PROFINET I/Os

You must use user-oriented addressing for the distributed PROFINET IO I/Os.
Information can be found in the User-oriented addressing of the I/O modules (Page 136)
section.
Addressing consistent user data areas

The table below illustrates the points to consider with respect to communication in a
PROFINET IO system if you want to transfer I/O areas with "Total length" consistency.
For 1 to 1024 byte data consistency on the PROFINET IO:

The address area of consistent data in the process image is automatically updated.
To read and write consistent data, you can also use SFC 14 "DPRD_DAT" and SFC 15
"DPWR_DAT". If the address area of consistent data is not in the process image, you must use SFC
14 and SFC 15 to read and write consistent data.
The length in the SFC must tally with the length of the programmed area when accessing areas with
"Total length" consistency.
Direct access to consistent areas is also possible (e.g. L PEW or T PAW).
In a PROFINET IO system you can transfer up to 1024 bytes of consistent data.
7.3.2 Assignment of the IP address parameters and device name
IP address parametes / device name

Just like any other PROFINET device, the CPU (or its PN interface) requires IP address
parameters and a device name for communication via PROFINET.
The IP address parameters consist of three parts:
● IP address
● Subnet screen
● Address of the router
Retentivity of IP address parameters and device names

The retentivity of IP address parameters and device names depends on how they were
assigned. Non-retentive temporary assignment means:
● IP address parameters and device name remain valid only until the next POWER OFF or
memory reset. After POWER OFF / POWER ON or memory reset, the CPU is only
accessible by means of its MAC address.
● Loading a temporary IP address deletes even retentively stored IP address parameters.

Addressing
Assignment of IP address parameters and device names

The IP address parameters and the device name can be assigned in the following ways:
Assignment of IP address parameters and device names Retentive memory

Standard method: IP address parameters / device name are permanently assigned The data are
Permanent assignment in during the configuration in STEP 7. When the configuration is retentive:
STEP 7 loaded to the CPU, the IP address parameters / device name are  at POWER OFF /
also stored retentively in the CPU. POWER ON
Permanent assignment by IP address parameters / device name are assigned by DCP  after memory reset
setting "IP address (Discovery and Configuration Protocol):  after deletion of
parameters / device name in  By a set-up tool such as PST or in STEP 7, e.g. by "Edit the configuration
relation to the other path" Ethernet Nodes". (SDBs)
 By the higher-level IO controller, if the IM 151-8 PN/DP CPU is  after removal of
operated as an I device with prioritized start-up. the MMC
Temporary assignment in IP address parameter / device name are assigned by DCP The data are not
STEP 7 (Discovery and Configuration Protocol): retentive.
 By automatic IP address assignment via "Accessible Nodes" in
STEP 7, if the CPU does not yet have an IP address.
Temporary assignment by IP address parameter / device name are assigned by DCP
setting "IP address (Discovery and Configuration Protocol):
parameters / device name in  When the IP address parameter device name is assigned to the
relation to the other path" I device by the higher-level IO controller, if the I device is not
operated with prioritized start-up.
Assignment in the user IP address parameters / device name are assigned in the user Retentivity
program program by means of SFB 104. The retentivity of the IP address corresponding to the
parameters / device name can in this case be specified in the specifications in the
respective parameter data record. parameter data record

Addressing
Resetting retentive IP address parameters and device names

Retentive IP address parameters and device names can be reset as follows:
● By "Reset to factory settings"
● By a firmware update
NOTICE
 If a temporary assignment of IP address parameters / device names is performed,
any retentively saved IP address parameters / device names are reset.
 If a permanent assignment of IP address parameters / device names is performed,
any retentively IP address parameters / device names previously saved are
overwritten by the new parameter settings.
NOTICE
Re-use of devices
Perform "Reset to factory settings" before you install a device with retentive IP address
parameters / device names in another subnet / system, or before you place it into
storage.
Reference
Further information on assignment of IP addresses on the I device can be found in the online
Help for STEP 7.

Addressing

Commissioning 8
8.1 Overview
This section contains important notes on commissioning which you should strictly observe in
order to avoid injury or damage to machines.
Note
Your commissioning phase is determined primarily by your application, so we can only offer
you general information, without claiming completeness of this topic.
Reference
Note the information about commissioning provided in the descriptions of your system
components and devices.
8.2 Commissioning procedure
8.2.1 Procedure: Commissioning the hardware
Hardware requirements
● ET 200S is installed
● ET 200S is connected
With a networked ET 200S, the following applies to the interfaces
● PROFINET
– the integrated PROFINET interface of the IM 151-8 PN/DP CPU interface module has
been configured in STEP 7 (IP address and device name set, for instance, in HW
config)
– the IM 151-8 PN/DP CPU interface module is connected to the subnet
● PROFIBUS (on optional DP master module)
– the PROFIBUS address is set
– the terminating resistors on the segments are enabled

Commissioning
Recommended procedure: Hardware

Due to its modular structure and the many different expansion options, an ET 200S can be
very large and complex. It is therefore not a good idea to switch it on for the first time with all
the modules installed. Rather, we recommend a step-by-step commissioning procedure.
We recommend the following initial commissioning procedure for an ET 200S:
Table 8- 1 Recommended commissioning procedure: Hardware
Activity Remarks Information on this can be

found in section
An installation and wiring check - Commissioning check list
according to checklist
Disconnecting drive aggregates This prevents negative effects on your system as a -
and control elements result of program errors.
Tip: By redirecting data from your outputs to a data

block, you can always check the status at the outputs
Preparing the IM Connect a programming device Connecting the programming
151-8 PN/DP CPU device (PG)
Start up the power supply and Commission the power supply and the ET 200S with Initial power on
ET 200S with the IM IM 151-8 PN/DP CPU interface module.
151-8 PN/DP CPU interface Check the LED displays of the IM 151-8 PN/DP CPU Debugging functions,
module and check the LEDs interface module. diagnostics and
troubleshooting
Reset the IM 151-8 PN/DP CPU - Reset the IM 151-8 PN/DP
interface module memory and CPU interface module using
check the LEDs the mode selector switch
Commission the rest of the Plug the modules in according to the configuration ET 200S Operating Instructions
modules and commission them.
DANGER
Proceed step-by-step. Do not go to the next step unless you have completed the previous
one without error / error message.
Reference
Important notes can also be found in the Debugging Functions, Diagnostics and
Troubleshooting section.
See also
Procedure: Software commissioning (Page 145)

Commissioning
8.2.2 Procedure: Software commissioning
Requirements
● You have installed and connected your ET 200S with IM 151-8 PN/DP CPU.
● In order to utilize the full functionality of your IM 151-8 PN/DP CPU interface module, you
require STEP 7 V5.5.
● If the ET 200S is being networked with PROFINET,
– the integrated PROFINET interface of the IM 151-8 PN/DP CPU interface module has
been configured in STEP 7 (IP address and device name set in HW Config)
– the IM 151-8 PN/DP CPU interface module is connected to the subnet.
● If the ET 200S is being networked with PROFIBUS (at the optional DP master module),
– the PROFIBUS address is set
– The terminating resistors on the segment limits are enabled.
Note
Please observe the procedure for commissioning the hardware.
Recommended procedure: Software
Table 8- 2 Recommended commissioning procedure: Software
Activity Remarks Information can be found ...

 Switch on the programming device and run - in the Programming with STEP
SIMATIC Manager 7 Manual
 Transferring the configuration and program to
the IM 151-8 PN/DP CPU interface module:
The IM 151-8 PN/DP CPU interface module
logs on to the SIMATIC Manager with its
MAC address via "Available nodes". If the
Ethernet interface of the PD is set to TCP/IP
(Auto), then during the first establishment of a
communication connection (e.g. double-
clicking this network node that displays only
the MAC address in order to open the online
block container), a temporary IP address is
automatically assigned by the PD to the PN
interface of the IM 151-8 PN/DP CPU
interface module. Now the blocks, especially
also the SDB container with the HW
configuration, can be moved by drag-and-
drop from the offline block container to the
online block container. When loading the
SDB container, the IP address assigned by
STEP 7 in the HW Config are also transferred
by the IM 151-8 PN/DP CPU interface
module.

Commissioning
Activity Remarks Information can be found ...

Debugging the I/Os Helpful functions are here:  in the Programming with
 Monitoring and modifying variables STEP 7 Manual
 Testing with program status  in the Alarm, error and
system messages section
 Forcing
 Controlling the outputs in STOP
mode (PO enable)
Tip: Test the signals at the inputs and
outputs
Commissioning PROFINET IO  in the Commissioning
PROFINET IO section
 in the System Description
PROFINET
Commissioning PROFIBUS DP - in the Commissioning
PROFIBUS DP section
Connect the outputs Commissioning the outputs -
successively.
DANGER
Proceed step-by-step. Do not go to the next step unless you have completed the previous
one without error / error message.
Reaction to errors
React to errors as follows:
● Check the system with the help of the check list in the chapter below.
● Check the LED displays on all modules. The meaning is described in the ET 200S
Distributed I/O Device Operating Instructions.
● If required, remove individual components to trace the error.
Reference
Important notes can also be found in the Debugging Functions, Diagnostics and
Troubleshooting section.
See also
Procedure: Commissioning the hardware (Page 143)

Commissioning
8.3 Commissioning check list
8.3 Commissioning check list
Introduction
Once you have installed and wired up your ET 200S, we advise you to check all the previous
steps once again.
The following tables give you instructions in the form of a checklist for checking your ET
200S. They also provide cross-references to sections containing additional information on
the relevant topic.
Mounting rail
The points to be checked are listed in the ET 200S Operating Instructions ET 200S Operating
Instructions in section
Is the rail mounted firmly to the wall, in the frame or in the cabinet? Installing
Have you maintained the free space required? Installing
Concept of grounding and chassis ground
Have you established a low-impedance connection (large surface, large Wiring and assembly
contact area) to ground potential?
Is the profile rail properly connected to reference potential and ground Wiring and assembly
potential (direct electrical connection or ungrounded operation)?
Are all grounding points of electrically connected measuring instruments Appendix
and of the load power supply units connected to reference potentials?
Module installation and wiring
Are all the terminal modules, including the terminating module, installed Installing
correctly?
Are all the terminal modules wired up correctly? Wiring and assembly
Are all the power modules, electronic modules, ... correctly connected? Wiring and assembly

Commissioning
8.4 Commissioning the modules
8.4.1 Inserting/Replacing a SIMATIC Micro Memory Card
SIMATIC Micro Memory Card (MMC) as memory module

The memory module used in your IM 151-8 PN/DP CPU interface module is a SIMATIC
Micro Memory Card. You can use the SIMATIC Micro Memory Card as a load memory or a
portable data medium.
Note
You must have a connected SIMATIC Micro Memory Card in order to operate the IM 151-8
The SIMATIC Micro Memory Card is not supplied as standard with the IM 151-8 PN/DP
Note
The IM 151-8 PN/DP CPU interface module goes into STOP and requests a memory reset
when you remove the SIMATIC MMC while the IM 151-8 PN/DP CPU interface module is in
RUN state.
CAUTION
Data on a SIMATIC Micro Memory Card can be corrupted if you remove the card while it is
being accessed by a write operation. You may have to delete the SIMATIC Micro Memory
Card using the PD or format it in the IM 151-8 PN/DP CPU interface module if you remove
it from the live system.
DO NOT remove the SIMATIC Micro Memory Card when the system is in RUN state;
always shut down power or set the IM 151-8 PN/DP CPU interface module to STOP in
order to prevent any write access of a programming device. If the CPU is in STOP mode
and you cannot determine whether or not a programming device function is active (e.g. load
/ delete block), disconnect the communication lines.
WARNING
Make sure that the SIMATIC Micro Memory Card to be inserted contains the proper user
program for the IM 151-8 PN/DP CPU interface module (system). The wrong user program
may have fatal processing effects.

Commissioning
Inserting / replacing the SIMATIC Micro Memory Card

1. First of all, switch the IM 151-8 PN/DP CPU interface module to STOP.
2. Is there a SIMATIC Micro Memory Card inserted?
If yes, first of all ensure that no writing PD functions (e.g. downloading blocks) are
running. If you cannot ensure this, interrupt the communication connections of the IM
151-8 PN/DP CPU interface module.
Press the ejector and remove the SIMATIC MMC.
An ejector ① is located on the frame of the module receptacle to enable you to remove
the SIMATIC Micro Memory Card.
Use a small screwdriver or ball-point pen to eject.
3. Insert the ("new") SIMATIC Micro Memory Card into the receptacle so that its beveled
edge points towards the ejector.
4. Gently press the SIMATIC Micro Memory Card into the IM 151-8 PN/DP CPU interface
module until it engages.
5. Perform a reset (refer to section Resetting the IM 151-8 PN/DP CPU interface module
using the mode selector switch (Page 151)).

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Removing and inserting a SIMATIC Micro Memory Card

After you replace a SIMATIC MMC in POWER OFF state, the IM 151-8 PN/DP CPU
interface module detects
● A physically identical SIMATIC Micro Memory Card with a different content
● A new SIMATIC Micro Memory Card with the same content as the old SIMATIC Micro
Memory Card
It automatically performs a Memory reset after POWER ON.

Commissioning
Reference
Additional information about the SIMATIC Micro Memory Card can be found in the S7-300,
CPU 31xC and CPU 31x (http://support.automation.siemens.com/WW/view/en/12996906)
manual, in the Technical Data section.
8.4.2 Initial power on
Requirements
● You have installed and wired up the ET 200S.
● The SIMATIC Micro Memory Card is inserted in the IM 151-8 PN/DP CPU interface
module
● The mode selector of your IM 151-8 PN/DP CPU interface module is set to STOP.
First switch-on of an ET 200S with IM 151-8 PN/DP CPU

Switch on the supply voltage for the ET 200S.
Result:
On the IM 151-8 PN/DP CPU interface module
● The ON LED lights up
● the STOP LED flashes at 2 Hz when the IM 151-8 PN/DP CPU interface module is
carrying out an automatic memory reset
● The STOP LED lights up after the memory reset.

Commissioning
8.4.3 Reset the IM 151-8 PN/DP CPU interface module using the mode selector
switch
When must I perform a memory reset of the IM 151-8 PN/DP CPU interface module?
You must perform a memory reset of the IM 151-8 PN/DP CPU interface module,
● When all retentive memory bits, timers and counters have been cleared and the initial
values of retentive data blocks in the load memory are to be used as actual values in the
work memory.
● if the retentive memory bits, timers and counters could cause unwanted responses after
"Load user program onto memory card" with the user program just downloaded to the IM
Reason: "Load user program onto memory card" does not delete the retentive areas.
● if the IM 151-8 PN/DP CPU interface module requests a memory reset with its STOP LED
flashing at 0.5 Hz intervals. Possible reasons for this request are listed in the table below.
Table 8- 3 Possible causes for a request to memory reset by the IM 151-8 PN/DP CPU interface
module
Causes for a request to memory reset Special features

by the IM 151-8 PN/DP CPU interface
module
The SIMATIC Micro Memory Card has –
been replaced.
RAM error in the IM 151-8 PN/DP CPU –
interface module
Work memory is too small, i.e. not all IM 151-8 PN/DP CPU interface module with SIMATIC Micro
the blocks of the user program on a Memory Card inserted: This causes continuous requests for
SIMATIC Micro Memory Card can be a memory reset.
loaded. This may be prevented by formatting the SIMATIC Micro
Attempts to load faulty blocks; if a Memory Card (see Formatting the SIMATIC Micro Memory
wrong instruction was programmed, for Card (Page 155)).
example. For additional information on the way the SIMATIC Micro
Memory Card responds to a memory reset, see Memory
reset and restart (Page 121).
How to reset memory

There are two ways to reset the IM 151-8 PN/DP CPU interface module memory:
Memory reset using the mode selector Memory reset using the programming device
switch
... is described in this section. ... is only possible when IM 151-8 PN/DP CPU
interface module is in STOP mode
(see STEP 7 Online Help).

Commissioning
Resetting the memory of the IM 151-8 PN/DP CPU using the mode selector switch
The following table contains the steps required to memory reset the IM 151-8 PN/DP CPU
interface module.
Table 8- 4 Steps for performing a memory reset of the IM 151-8 PN/DP CPU interface module
Step Resetting the memory of the IM 151-8 PN/DP CPU

1. Turn the key to STOP position ①
2. Turn the key to MRES position Hold the key in this position until the STOP LED lights up
for the second time and remains on (this takes 3 seconds). ②
Now release the key.
3. You must turn the key to MRES position again within 3 seconds and hold it there until the
STOP LED flashes (at 2 Hz). ③
You can now release the switch. When the IM 151-8 PN/DP CPU interface module has
completed the memory reset, the STOP LED stops flashing and lights up.
The memory reset has been carried out on the IM 151-8 PN/DP CPU interface module.
The procedure described in the table above is only required if you wish to reset the IM 151-8
PN/DP CPU interface module memory without this being requested by the IM 151-8 PN/DP
CPU interface module (STOP LED flashing slowly). If the IM 151-8 PN/DP CPU interface
module prompts you for a memory reset, you only have to turn the mode selector briefly to
the MRES position to initiate the memory reset operation.
The figure below shows how to use the mode selector switch to reset the IM 151-8 PN/DP
CPU interface module memory:
6723
/('
RQ
t
RII
V
PD[V
PLQV
,031'3&38
1 2 3
If the IM 151-8 PN/DP CPU interface module prompts you for another memory reset
following a successful memory reset operation, the SIMATIC Micro Memory Card may need
to be reformatted see section (Formatting the Micro Memory Card (Page 155)).

Commissioning
STOP LED does not flash during the memory reset

What should I do if the STOP LED does not flash during the memory reset or if other LEDs
are lit?
1. You must repeat steps 2 and 3.
2. If the IM 151-8 PN/DP CPU interface module does not perform a memory reset again,
you must evaluate the diagnostics buffer of the IM 151-8 PN/DP CPU interface module.
What happens to the IM 151-8 PN/DP CPU interface module with a memory reset?
Table 8- 5 Internal processes in the IM 151-8 PN/DP CPU during a memory reset
Event Action in the IM 151-8 PN/DP CPU interface module

Process in the IM 1. The IM 151-8 PN/DP CPU interface module deletes the entire user program in the work
151-8 PN/DP CPU memory.
interface module 2. The IM151-8 PN/DP CPU interface module deletes the retentive user data (flags, times,
counters and DB contents).
3. The IM 151-8 PN/DP CPU interface module tests its hardware.
4. The IM 151-8 PN/DP CPU interface module copies the sequence-related content of the
SIMATIC Micro Memory Card (load memory) to the work memory.
Tip: If the IM 151-8 PN/DP CPU interface module is unable to copy the content of the
SIMATIC Micro Memory Card and requests a memory reset, then:
 Remove the SIMATIC Micro Memory Card
 Resetting the memory of the IM 151-8 PN/DP CPU
 Read the diagnostics buffer
If the IP address and device name were not retentive (depending on how they were
assigned): Provide the IM 151-8 PN/DP CPU interface module with a temporary IP
address and then read out the diagnostics buffer
or
in the SIMATIC-Manager under "Available nodes", establish the MAC address of the IM
151-8 PN/DP CPU interface module. When the Ethernet interface of the PD is set to
"TCP/IP (Auto)", you can read out the diagnostics buffer also via this available MAC
address, because then STEP 7 assigns a temporary IP address.
Memory contents The user program is transferred back from the SIMATIC Micro Memory Card to the work memory
after reset and the memory utilization is indicated accordingly.
What's left?  Parameters of the PN interface:
IP address parameters / device name (depending on how they were assigned, see section
Assignment of IP address parameters and device name (Page 139)).
 Data in the diagnostics buffer. (Only the last 100 entries in the diagnostics buffer are retained in
the event of a POWER OFF / POWER ON.)
You can read the diagnostics buffer with the programming device (see STEP 7 Online Help).
 The content of the operating hours counter and the time.

Commissioning
Note
Communication shutdown during memory reset on PROFINET CPUs with integrated switch
Note that the PROFINET interface and the integrated switch are shut down when you reset
memory on this CPU.
During the memory reset on a CPU configured within a line structure, communication via the
CPU's integrated switch to downstream devices is shut down.
A restart of the PROFINET interface is performed after a memory reset, only if the interface
parameters are stored retentively.
The integrated switch is always restarted and can resume communication on completion of
the CPU memory reset.
Special feature: Interface parameters

The table below describes which interface parameters are valid after a CPU memory reset.
Memory reset ... PROFINET interface parameters ... DP parameters with DP master module
inserted
with inserted ... the MPI parameters on the SIMATIC Micro Memory Card or integrated read-only load
SIMATIC Micro Memory Card memory are valid.
If no parameters are stored (SDB), the If no parameters are stored here (SDB),
parameters previously set are valid providing neither are any DP interface parameters
they were retentively stored (depending on present.
how they were assigned, see section:
Assignment of the IP address parameters and
device name (Page 139))
without inserted ... the parameters previously set are valid ... neither are any DP interface
SIMATIC Micro Memory Card providing they were retentively stored parameters present.
(depending on how they were assigned, see
section: Assignment of the IP address
parameters and device name (Page 139))

Commissioning
8.4.4 Formatting the SIMATIC Micro Memory Card
You must format the SIMATIC Micro Memory Card in the following cases
● The SIMATIC Micro Memory Card module type is not a user module.
● The SIMATIC Micro Memory Card has not been formatted.
● The SIMATIC Micro Memory Card is defective.
● The content of the SIMATIC Micro Memory Card is invalid.
The content of the SIMATIC Micro Memory Card has been identified as invalid.
● The "Load user program" operation was interrupted as a result of POWER OFF.
● The "Write RAM to ROM" operation was interrupted as a result of POWER OFF.
● Error when evaluating the module content during Memory reset.
● Formatting error, or formatting failed.
If one of these errors has occurred, the IM 151-8 PN/DP CPU interface module prompts for
yet another memory reset, even after the memory has already been reset. The card's
content is retained until the SIMATIC Micro Memory Card is formatted, unless the "Load user
program" or "Write RAM to ROM" operation was interrupted as a result of POWER OFF.
The SIMATIC Micro Memory Card is only formatted if there is a reason to do so (see above)
and not, for example, when you are prompted for a memory reset after a module is changed.
In this case, a switch to MRES triggers a normal memory reset for which the module content
remains valid.
Use the following steps to format your SIMATIC Micro Memory Card
If the IM 151-8 PN/DP CPU interface module is requesting a memory reset (STOP LED
flashing slowly), you can format the SIMATIC Micro Memory Card as follows:
1. Toggle the switch to the MRES position and hold it there until the STOP LED lights up
and remains on (after approx. 9 seconds).
2. Within the next three seconds, release the switch and toggle it once again to MRES
position. The STOP LED flashes to indicate that formatting is in progress.
Note
Always perform this sequence of operation within the specified time. Otherwise, the
SIMATIC Micro Memory Card will not be formatted, but rather returns to memory reset
status.
See also
Reset the IM 151-8 PN/DP CPU interface module using the mode selector switch (Page 151)

Commissioning
8.4.5 Resetting to the as-delivered state
Setting the IM 151-8 PN/DP CPU interface module back to factory settings
In the factory settings, the properties of the IM 151-8 PN/DP CPU interface module are set to
the following values:
Table 8- 6 Properties of the IM 151-8 PN/DP CPU interface module factory settings
Properties Value
Retentive memory bits, timers, counters All retentive memory bits, timers and counters are
cleared
Set retentive area for memory bits, timers and Default setting
counters (16 memory bytes, no timers, 8 counters)
Contents of the diagnostics buffer cleared
Operating hours counter 0
Time-of-day 1.1.1994 00:00:00
IP address and device name Not available
Procedure
Proceed as follows to reset a IM 151-8 PN/DP CPU interface module to the factory settings
using the mode selector:
1. Switch off the power supply.
2. Remove the SIMATIC Micro Memory Card from the receptacle (see Inserting/replacing a
Micro Memory Card (Page 148))
3. Keep the mode selector switch in the MRES position and switch the power supply on
again.
4. Wait until LED lamp image 1 from the subsequent overview is displayed.
5. Release the mode selector switch, set it back to MRES within 3 seconds and hold it in
this position.
6. The LED lamp image 2 from the subsequent overview is displayed.
This lamp image lights up while the reset operation is running (approximately 5 seconds).
During this period you can cancel the resetting procedure by releasing the mode selector.
7. Wait until LED lamp image 3 from the following overview is displayed and release the
mode selector again.
The IM 151-8 PN/DP CPU interface module is reset to the factory settings. It runs unbuffered
(all the LEDs light up, apart from P1 - LINK, P2 - LINK and P3 - LINK) and changes to STOP
mode.

Commissioning
Lamp images while resetting the IM 151-8 PN/DP CPU interface module
While you are resetting the IM 151-8 PN/DP CPU interface module to the factory settings,
the LEDs light up in succession in the following lamp images:
Table 8- 7 Lamp images
LED Color Lamp image 1 Lamp image 2 Lamp image 3

SF Red ⃞ ⃝ ∆
BF-PN Red ⃞ ⃞ ⃞
MT Yellow ⃞ ⃞ ⃞
ON Green ∆ ∆ ∆
FRCE Yellow ⃝ ⃞ ⃞
RUN Green ⃝ ⃞ ⃞
STOP Yellow ⃝ ⃞ ⃞
P1 - LINK Green ⃞ ⃞ ⃞
Legend:
∆ = LED lit;
⃞ = LED dark;
⃝ = LED flashes at 0.5 Hz
Note
If you remove an (operational) IO device and re-use it in another place or place it in storage,
the IO device should be restored to its as-delivered condition, since the IP address of the
device will generally be stored retentively.

Commissioning
8.4.6 Connecting a programming device / PC to the integrated PROFINET interface

of the IM 151-8 PN/DP CPU interface module
Requirement
● IM 151-8 PN/DP CPU with integrated PROFINET interface
● Programming device / PC with network card
Connecting a programming device / PC to the integrated PROFINET interface of the IM

1. Connect the programming device / PC to the X1 P1 interface of the IM 151-8 PN/DP CPU
interface module using a pre-assembled, uncrossed twisted pair cable ①.
3*3&
A programming device can also be connected and used at the other two ports of the
PROFINET interface.
Result
You have connected your programming device / PC to the integrated PROFINET interface of

Commissioning
Configuring the PROFINET interface of the IM 151-8 PN/DP CPU interface module
If you wish to connect only a programming device and no IO devices to the
IM 151-8 PN/DP CPU interface module, you must also configure the PROFINET interface
accordingly.
Procedure:
Step Activity
Configuring hardware in STEP 7 SIMATIC Manager
1 Select File > New...
Enter a name for your project and click on "OK" to confirm.
2 Select Insert > Station > SIMATIC 300 Station to add an S7-300 station.
3 Double-click "Hardware."
Result: HW Config opens.
4 Insert your IM 151-8 PN/DP CPU interface module using drag-and-drop.
Result: The "Properties – Ethernet Interface PN-IO" window opens. The properties of the
PROFINET interface X1 are shown in the "Parameters" tab.
Assigning the IP address
5 Enter the required IP address in the window.
6 Click "OK" to close the Properties dialog box.
Saving the configuration
7 Save your configuration with Station > Save and compile.
Configuration download
8 Download the configuration to the IM 151-8 PN/DP CPU interface module. There are two
ways of doing this:
 online via the PN interface
To download the configuration, select the MAC address of the target IM
151-8 PN/DP CPU interface module. You can display the list of available nodes in the
"Select node address" window "whilst downloading the HW configuration. Here you can
select the desired target device via the associated IP or MAC address. If the device has
only had a MAC address so far, then this can now be assigned the configured IP
address.
The programming device must be connected to the IM 151-8 PN/DP CPU interface
module in order to do this. The programming device interface must be set to TCP/IP
(Auto). In the IE-PG Access tab of the interface properties you must set: Assign Project-
Specific IP Address.
 offline, by saving the data to a SIMATIC Micro Memory Card in SIMATIC Manager on
your programming device, and then inserting the SIMATIC Micro Memory Card into the
Result
You have assigned a retentive IP address to the PROFINET interface of the IM 151-8 PN/DP

Commissioning
Reference
● Other methods of assigning the IP address can be found in the section Assignment of the
IP address parameters and device name (Page 139).
● Information on PROFINET can be found in the PROFINET
(http://support.automation.siemens.com/WW/view/en/19292127) System Description.
● For information on passive network components such as switches, refer to the SIMATIC
NET manual: Twisted Pair and Fiber-Optic Networks
See also
Configuring and commissioning the PROFINET IO system (Page 173)
8.4.7 Starting SIMATIC Manager
Introduction
SIMATIC Manager is a GUI for online/offline editing of S7 objects (projects, user programs,
blocks, hardware stations and tools).
The SIMATIC Manager lets you
● Manage projects and libraries,
● Call STEP 7 tools,
● Access the PLC (AS) online,
● Editing SIMATIC Micro Memory Cards.
Starting SIMATIC Manager

After installation, the SIMATIC Manager icon appears on the Windows desktop, and the Start
menu contains entry SIMATIC Manager under SIMATIC.
1. Run SIMATIC Manager by double-clicking the icon, or from the Start menu (same as with
all other Windows applications).
User interface
A corresponding editing tool is started up when you open the relevant objects. You start the
program editor by double-clicking the program block you want to edit (object-oriented start).
Online Help
The online help for the active window is always called by pressing F1.

Commissioning
8.4.8 Monitoring and modifying I/Os
The "Monitor and modify variables" tool

The STEP 7 "Monitor and modify variables" tool lets you:
● Monitor program variables in any format
● Editing (modifying) the status or content of variables in the IM 151-8 PN/DP CPU
interface module.
Creating a variable table

You have two options of creating a variable table (VAT):
● In the LAD / FBD / STL editor by selecting the PLC > Monitor/Modify Variables command
This table is also available directly online.
● In the SIMATIC Manager with the Blocks container open via menu item Insert New Object
> Variable table
This table created offline can be saved for future retrieval. You can also test it after
switching to online mode.
VAT structure:
In the VAT, every address to be monitored or modified (e.g. inputs, outputs) occupies one
row.
The meaning of the VAT columns is as follows:
Column text In this field ...

Address contains the absolute address of the variable
Icon contains the symbolic descriptor of the variables
This is identical to the specification in the Symbol Table.
Symbol comment shows the symbol comment of the Symbol Table
Status format contains the default format setting, e.g. HEX.
You can change the format as follows:
 right-click in the format field. The Format List opens.
or
 left-click in the format field until the relevant format appears
Status value shows the content of the variable at the time of update
Modify value is used to enter the new variable value (modify value)
Monitor variable
You have two options for monitoring variables:
● Updating the status values once via menu item Variable > Update Status Values
or
● Continuous update of status values via menu item Variable > Monitor

Commissioning
Modifying variables
To modify variables, proceed as follows:
1. Left-click the field Modify value of the relevant variable.
2. Enter the modify value according to the data type.
3. To update modify values once, select the menu item Variable > Activate Modify Value.
or
Enable modify values permanently via menu item Variable > Modify.
4. In the Monitor test function, verify the modify value entry in the variable.
Is the modify value valid?
You can disable the modify value entered in the table. An invalid value is displayed same as
a comment. You can re-enable the modify value.
Only valid modify values can be enabled.
Setting the trigger points

Trigger points:
● The "Trigger point for monitoring" determines the time of update for values of variables to
be monitored.
● The "Trigger point for modifying" determines the time for assigning the modify values to
the variables to be modified.
Trigger condition:
● The "Trigger condition for monitoring" determines whether to update values once when
the trigger point is reached or continuously every time the trigger point is reached.
● The "Trigger condition for modifying" determines whether to assign modify values once or
permanently to the variable to be modified.
You can customize the trigger points using the tool "Monitoring and Modifying Variables" in
the menu item Variable > Set Trigger... .
Special features
● If "Trigger condition for monitoring" is set to once , the menu items Variable > Update
Status Values or Variable > Monitor have the same effect, namely a single update.
● If "Trigger condition for modifying" is set to once , the menu items Variable > Update
Status Values or Variable > Modify have the same effect, namely a single assignment.
● If trigger conditions are set to permanent , the said menu items have different effects as
described above.
● If monitoring and modifying is set to the same trigger point, monitoring is executed first.
● If Process mode is set under Debug > Mode, values are not cyclically updated when
permanent modifying is set.
To correct or avoid error: Use the Force test function.

Commissioning
Saving/opening the variable table

Saving the VAT
1. After aborting or completing a test phase, you can save the variable table to memory. The
name of a variable table starts with the letters VAT, followed by a number from 0 to
65535; e.g. VAT5.
Opening VAT
1. Select the menu item Table > Open.
2. Select the project name in the Open dialog.
3. In the project window below, select the relevant program and mark the Blocks container.
4. In the block window, select the desired table.
5. Confirm with OK.
Creating a connection to the IM 151-8 PN/DP CPU interface module

The variables of a VAT represent dynamic quantities of a user program. To monitor or
modify variables, you will need to establish a connection with the relevant IM 151-8 PN/DP
CPU interface module. Every variable table can be linked to another IM 151-8 PN/DP CPU
interface module.
Use the PLC > Connect to ... menu item to establish a connection to one of the following IM
151-8 PN/DP CPU interface modules:
● configured IM 151-8 PN/DP CPU interface module
● directly connected IM 151-8 PN/DP CPU interface module
● available IM 151-8 PN/DP CPU interface module
The table below lists the display of variables.
Interface modules The variables of the IM 151-8 PN/DP CPU interface module are
displayed, ...
configured IM 151-8 PN/DP in S7 program (hardware station) of which the variable table is
CPU interface module stored.
directly connected IM 151-8 that is connected directly to the programming device.
available IM 151-8 PN/DP that is selected in the dialog window.
CPU interface module Use the PLC > Connect to ... > Available CPU ... menu item to
connect to an available IM 151-8 PN/DP CPU interface module. With
this you can create a connection to any IM 151-8 PN/DP CPU
interface module in the network.

Commissioning
Controlling outputs in STOP of the IM 151-8 PN/DP CPU interface module

The function Enable PO resets the output disable signal for the peripheral outputs (PO),
This enables you to control the PO when the IM 151-8 PN/DP CPU interface module is in
STOP mode.
In order to enable the POs, proceed as follows:
1. Select Table > Open the variable table (VAT) to open the variable table containing the
POs you want to modify, or activate the window containing the corresponding VAT.
2. To control the POs of the active VAT, select the required IM 151-8 PN/DP CPU interface
module connection using the PLC > Connect to ... menu item.
3. Use the PLC > Operating Mode menu item to open the Operating Mode dialog and
switch the IM 151-8 PN/DP CPU interface module to STOP mode.
4. Enter your values in the "Modify value" column for the PO you want to modify.
Examples:
PO: POB 7 modify value: 2#0100 0011
POW 2 W#16#0027
POD 4 DW#16#0001
5. Select Variable > Enable PO to set "Enable PO" mode.
6. Modify the PO by selecting Variable > Activate Modify Values. "Enable PO" mode
remains active until reset by selecting Variable > Enable PO once mode.
"Enable PO" is also terminated when the connection to the programming device is
dropped.
7. Return to step 4 if you want to set new values.
Note
If the IM 151-8 PN/DP CPU interface module changes its mode, for example, from STOP
to RUN or STARTUP, a message is shown.
A message is also shown if the IM 151-8 PN/DP CPU interface module is set to "Enable
PO" function while the IM 151-8 PN/DP CPU interface module is in RUN mode.
Note
I/O output modules that were configured for use of the IM as an I device in the I/O transfer
area, cannot be controlled after PA disconnection.

Commissioning
8.5 Commissioning PROFIBUS DP
8.5.1 Commissioning the PROFIBUS DP network
Requirements
Requirements for commissioning a PROFIBUS DP network:
● The IM 151-8 PN/DP CPU interface module can be expanded by one DP master module.
● A PROFIBUS DP network is installed.
● You have configured the PROFIBUS DP network using STEP 7 and have assigned a
PROFIBUS DP address and the address space to all the nodes.
● Note that you must also set address switches for some of the DP slaves (see the
description of the relevant DP slave).
● The software as shown in the following table is required for the IM 151-8 PN/DP CPU
interface module:
Table 8- 8 Software requirements for the IM 151-8 PN/DP CPU interface module
Interface module Order number Software required

IM 151-8 PN/DP CPU 6ES7151-8AB01-0AB0 STEP 7 V5.5 and higher
DP address areas of the IM 151-8 PN/DP CPU interface module
Table 8- 9 DP address areas of the IM 151-8 PN/DP CPU interface module
Address area IM 151-8 PN/DP CPU

Entire address range of 2048 bytes
inputs and outputs
Number of those in process image Bytes 0 to 2047 (can be set)
for I/Os Bytes 0 to 127 (preset)

Commissioning
DP diagnostics addresses
DP diagnostic addresses occupy 1 byte per DP master and DP slave in the input address
range. For example, at these addresses DP standard diagnostics can be called for the
relevant node (LADDR parameter of SFC 13). The DP diagnostics addresses are specified
in your configuration. If you do not specify any DP diagnostic addresses, STEP 7 assigns
these DP diagnostics addresses in descending order, starting at the highest byte address.
If there is an IM 151-8 PN/DP CPU interface module with DP master module as the master,
assign two different diagnostics addresses for S7 slaves:
● Diagnostics address of the slave (address for slot 0)
At this address all slave events are reported in the DP master (node proxy), e.g. node
failure.
● Diagnostics address of the module (address for slot 2)
All module (STOP / RUN transition of an IM 151-7 CPU as an intelligent DP slave, for
example) events are reported in the master (OB 82) at this address.
8.5.2 Commissioning the IM 151-8 PN/DP CPU interface module with DP master
module as a DP master
Requirements for commissioning

● A DP master module is connected to the IM 151-8 PN/DP CPU interface module.
● The PROFIBUS subnet has been configured.
● The DP slaves are ready for operation (see relevant DP slave manuals).
● Before commissioning, you must configure the IM 151-8 PN/DP CPU interface module as
a DP master. That means that, in STEP 7 you must
– configure the IM 151-8 PN/DP CPU interface module as a DP master,
Note
You must suspend the DP master module separately as a submodule (X2) in the
station window in HW Config.
– assign a PROFIBUS address to the DP interface on the DP master module,

– assign a master diagnostics address to the DP interface on the DP master module,
– Integrate the DP slaves into the DP master system
Is the DP CPU a DP slave?
If so, this DP slave will appear in the PROFIBUS DP catalog as an already configured
station. In the DP master, assign a slave diagnostics address to this DP slave CPU.
You must interconnect the DP master with the DP slave CPU and specify the address
areas for data exchange with the DP slave CPU.

Commissioning
Commissioning
Commission the IM 151-8 PN/DP CPU interface module with DP master module as a DP
master in the PROFIBUS subnet as follows:
1. Download the PROFIBUS subnet configuration created with STEP 7 (preset
configuration) from the programming device to the IM 151-8 PN/DP CPU interface
module.
2. Switch on all the DP slaves.
3. Switch the IM 151-8 PN/DP CPU interface module from STOP to RUN.
Behavior of the IM 151-8 PN/DP CPU interface module during commissioning

● The DP master module is installed and IM 151-8 PN/DP CPU interface module is
configured as a DP master
⇒ the IM 151-8 PN/DP CPU interface module switches to RUN with master functionality
● The DP master module is installed and the IM 151-8 PN/DP CPU interface module is not
configured as a DP master
⇒ the IM 151-8 PN/DP CPU interface module switches to RUN without master
functionality
Starting up the IM 151-8 PN/DP CPU interface module as a DP master

During startup, the IM 151-8 PN/DP CPU interface module checks the configured preset
configuration of its DP master system against the actual configuration.
If the preset configuration = the actual configuration, the IM 151-8 PN/DP CPU interface
module goes to RUN.
If the preset configuration ≠ the actual configuration, the configuration of parameter Startup if
preset configuration ≠ actual configuration determines the startup behavior of the IM 151-8
Startup when the preset configuration ≠ actual Startup when the preset configuration ≠ actual
configuration = Yes (default setting) configuration = no
IM 151-8 PN/DP CPU in RUN The IM 151-8 PN/DP CPU interface module
(BF LED flashes if any of the DP slaves cannot remains in STOP mode, and the BF LED flashes
be addressed). after the set Monitoring time for transfer of
parameters to modules.
The flashing BF LED indicates that at least one
DP slave cannot be addressed. In this case,
check that all the DP slaves are switched on and
correspond with your configuration, or read out
the diagnostics buffer with STEP 7.

Commissioning
Recognizing the operating state of DP slaves (Event recognition)

The table below shows how the IM 151-8 PN/DP CPU interface module with DP master
module acting as a DP master recognizes operating mode transitions of a CPU acting as a
DP slave or any interruption of the data exchange.
Table 8- 10 Event recognition of the IM 151-8 PN/DP CPU interface module as a DP master
Event What happens in the DP master?

Bus interruption  Call of OB86 with the message Station failure
(short circuit,
(incoming event; diagnostics address of the DP slave assigned to the DP
connector removed) master)
 With I/O access: Call of OB 122
(I/O access error)
DP slave:  Call of OB 82 with the message Module error
RUN → STOP (incoming event; diagnostics address of the DP slave assigned to the DP
master; Variable OB82_MDL_STOP=1)
DP slave:  Call of OB82 with the message Module OK
STOP → RUN (outgoing event; diagnostics address of the DP slave assigned to the DP
master; variable OB82_MDL_STOP=0)
Tip:
When commissioning the IM 151-8 PN/DP CPU interface module as the DP master, always
program OB 82 and OB 86. This helps you to recognize and evaluate data exchange errors
or interruptions.
Constant Bus Cycle Time

This is a property of PROFIBUS DP that ensures bus cycles of exactly the same length. The
"Constant bus cycle time" function ensures that the DP master always starts the DP bus
cycle after a constant interval. From the perspective of the slaves, this means that they
receive their data from the master at constant time intervals.
In Step 7 HW config, you can configure constant bus cycle times for PROFIBUS subnets.
A detailed description of the constant bus cycle time can be found in the STEP 7 Online
Help.
Time synchronization
Information about time synchronization via PROFIBUS DP can be found under Interfaces >
PROFIBUS DP.

Commissioning
SYNC/FREEZE
The SYNC control command is used to set the DP slaves of a group to sync mode. In other
words, the DP master transfers the current output data and instructs the relevant DP slaves
to freeze their outputs. The DP slaves writes the output data of the next output frames to an
internal buffer; the state of the outputs remains unchanged.
After each SYNC control command, the DP slaves of the selected groups transfer the output
data stored in their internal buffer to the process outputs.
The outputs are only updated cyclically again after you transfer the UNSYNC control
command using SFC11 "DPSYC_FR".
The FREEZE control command is used to set the relevant DP slaves to Freeze mode. In
other words, the DP master instructs the DP slaves to freeze the current state of the inputs.
It then transfers the frozen data to the input area of the IM 151-8 PN/DP CPU interface
module.
Following each FREEZE control command, the DP slaves freeze the state of their inputs
again.
The DP master does not receive the current state of the inputs cyclically once more until you
have sent the UNFREEZE control command with SFC11 "DPSYC_FR".
SFC 11 is described in the STEP 7 online help and in the System and Standard Functions
for S7-300/400 reference manual.
Powering up the DP master system
IM 151-8 PN/DP CPU as a DP master

Set the power-up monitoring time for DP slaves using the Monitoring time for parameter transfer to
modules parameter.
This means that the DP slaves must power up within the set time and must be set by the IM 151-8
PN/DP CPU interface module (as DP master).
PROFIBUS address of the DP master

For the IM 151-8 PN/DP CPU interface module you must not set "126" as a PROFIBUS
address.
See also
PROFIBUS DP (Page 32)

Commissioning
8.5.3 Direct data exchange
Requirement
In Step 7 HW config, you can configure "Direct Data Exchange" for PROFIBUS nodes. The
IM 151-8 PN/DP CPU interface module with DP master module participate in a direct data
exchange as a receiver.
Definition
"Direct data exchange" is a special communication relationship between PROFIBUS DP
nodes.
Direct data exchange is characterized by the fact that the PROFIBUS DP nodes "listen" on
the bus for data that a DP slave returns to its DP master. This mechanism allows the
"listening node" (recipient) direct access to deltas of input data of remote DP slaves.
Address Areas
During configuration in STEP 7, use the I/O input addresses to specify the address area of
the recipient at which the sender's data should be read.
The IM 151-8 PN/DP CPU interface module with DP master module can be a receiver:
● as a DP master
● as a CPU that is not integrated in a master system

Commissioning
Example: Direct data exchange via DP CPUs

The example in the figure below shows the relationships you can configure for direct data
exchange. All the DP masters and DP slaves (apart from slave 3 and slave 5) are in each
case a DP-CPU, whereby the IM 151-8 PN/DP CPU interface module can be just a DP
master. Note that other DP slaves (ET 200M, ET 200S, ET 200pro) can only operate as
transmitters.
'3PDVWHU '3PDVWHU
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Commissioning
8.6 Commissioning PROFINET IO
8.6.1 Requirements for commissioning PROFINET
Requirements
Requirements to be satisfied before you can start to commission your PROFINET IO system:
ET 200S with ... Software required PROFINET IO system installed

IM 151-8 PN/DP CPU STEP 7 V5.5 and higher X
PROFINET IO address areas of the IM 151-8 PN/DP CPU interface module
Table 8- 11 PROFINET IO address areas of the IM 151-8 PN/DP CPU interface module
Address area IM 151-8 PN/DP CPU

Entire address range of 2048 bytes
inputs and of outputs
Number of those in process image Bytes 0 to 2047 (can be set)
for I/Os Byte 0 to 127 (preset)
In the input address area, diagnostics addresses each take up 1 byte for
● The IO controller
● the PROFINET interface and its ports and each IO device (header module at slot 0),
● each module / submodule without user data within the device (e.g. ET 200S power
module or ports of the PROFINET interface).
You can use these addresses, for example, to read module-specific diagnostics data records
by calling SFB 52. The diagnostics addresses are specified in your configuration. If you do
not specify any diagnostics addresses, STEP 7 assigns these addresses in descending
order, starting from the highest byte address.

Commissioning
8.6.2 Configuring and commissioning the PROFINET IO system
Overview
There are several ways to start commissioning the PROFINET IO interface of the IM 151-8
PN/DP CPU interface module, and then the PROFINET IO system:
● online via the PN interface
● offline, by saving the data to a SIMATIC Micro Memory Card in SIMATIC Manager on
your programming device, and then inserting the SIMATIC Micro Memory Card into the
Commissioning a PROFINET IO system directly via PN interface
(76
2
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Num Meaning
ber
① Connect the programming device / PC to the X1 P1 interface of the IM 151-8 PN/DP CPU
interface module using a pre-assembled, uncrossed twisted pair cable.
② Use a pre-assembled, uncrossed twisted pair cable to connect the IO device (e.g. ET 200S) to
the integrated PROFINET interface X1 P2 of your IM 151-8 PN/DP CPU interface module.
The IO device can also be connected to X1 P3. It is also possible to interpose a switch.
Commissioning requirements:
● The IM 151-8 PN/DP CPU interface module is in STOP mode.
● The IO devices are switched on.
● The PROFINET subnet is installed, and the communication partners (programming
device, IO controller, IO devices, for example) are connected to the PROFINET subnet.

Commissioning
Configuring the PROFINET IO system
Step Activity
Configuring hardware in STEP 7 SIMATIC Manager
1 Select File > New...
Enter a name for your project and click on OK to confirm.
2 Select Insert > Station > SIMATIC 300 Station to add an S7-300 station.
3 Double-click "Hardware."
Result: HW Config opens.
4 Insert your IM 151-8 PN/DP CPU interface module using drag-and-drop.
Result: The "Properties – Ethernet Interface PN-IO" window opens. The properties of the PROFINET
interface X1 are shown in the "Parameters" tab.
Assigning the IP address (example: Assignment of a retentive IP address)
5 Click "New" on the "Properties – Ethernet Interface PN-IO" dialog box to create a new subnet.
Result: The "Properties – New Industrial Ethernet Subnet" dialog box opens.
6 Assign a name and confirm with "OK."
Result: You are back to the "Properties – Ethernet Interface PN-IO" dialog box.
7 Enter the IP address and the subnet mask in the dialog box. This information is available from your network
administrator.
8 If you setup a connection via router, you must also enter the address of the router. This information is also
available from your network administrator.
9 Click "OK" to close the Properties dialog box.
Configuring the PROFINET IO system
10 Insert the IO devices at the PROFINET IO system, for example, an IM 151-3 PN (ET 200S under
PROFINET IO), then configure the slots and set their parameters using drag-and-drop with reference to the
physical layout.
11 Select Edit > Object properties to assign device names and numbers to the IO devices.

Commissioning
Step Activity
12 If you are running PROFINET IO and PROFINET CBA in parallel, open the Properties dialog for the
PROFINET IO system,
 activating the "Use this module for PROFINET CBA communication" check box
 Modify the "Communication portion (PROFINET IO)" parameter (e.g. change the communication portion
of PROFINET IO to 87.5 %).
13 If you wish diagnostic events at the PN interface to trigger a diagnostic interrupt OB (OB 82), then activate
the check box "OB 82 / I/O fault task - call in the event of communication interrupt" in the properties of the
PROFINET IO system.
Tip: The information on the events is also available in the diagnostics buffer of the IM 151-8 PN/DP CPU
14 Save your configuration with Station > Save and compile.
Configuration Download
15 Download the configuration to the IM 151-8 PN/DP CPU interface module. There are two ways of doing this:
 Online via the PN interface. When you download the configuration in a system containing several nodes,
select the appropriate IP address for the IM 151-8 PN/DP CPU interface module. Select the MAC
address of the target interface module if the IM 151-8 PN/DP CPU interface module does not yet have an
IP address. You can display the list of available nodes in the "Select node address" window whilst
downloading the HW configuration. Here you can select the desired target device via the associated IP
or MAC address. If the device has only had a MAC address so far, then it can now be assigned the
configured IP address.
The programming device must be connected to the subnet. The programming device interface must be
set to TCP/IP (Auto). In the IE-PG Access tab of the interface properties you must set: Assign Project-
Specific IP Address.
 offline, by saving the data to a SIMATIC Micro Memory Card in SIMATIC Manager on your programming
device, and then inserting the SIMATIC Micro Memory Card into the IM 151-8 PN/DP CPU interface
module

Commissioning
Step Activity
Assigning IO Device Names
16 Requirement: The programming device must be connected to the subnet. The programming device interface
must be set to TCP/IP (Auto) mode. Setting in the IE-PG Access tab of the interface properties dialog box:
Assign Project-Specific IP Address.
Procedure: In online mode, select the various IO devices in HW Config, then select PLC > Ethernet > Assign
Device Name to assign the corresponding device names.
Note: When you have configured "Device replacement without removable medium" and specified the set
topology of the PROFINET IO system with the topology editor, you don´t always have to assign the device
name. For this to be the case, the actual topology must correspond with the set topology and the devices
must be reset to the factory settings.
Note: The IM 151-8 PN/DP CPU interface module can only assign the IP address automatically, and thus
communicate correctly with the IO device, if you have assigned a device name to the IO device.
If the configuration of the IO devices you downloaded to the IM 151-8 PN/DP CPU interface module actually
corresponds to their physical configuration on the subnet, then the IO devices will be addressed by the IM
151-8 PN/DP CPU interface module, and the BF LED will stop flashing on both the IM 151-8 PN/DP CPU
interface module and the IO device.
You can then switch the IM 151-8 PN/DP CPU interface module to RUN, provided there are no other
conditions preventing startup, and the IM 151-8 PN/DP CPU interface module and IO devices will exchange
data (read inputs, write outputs, for example).
Result
You have used STEP 7 to configure the PROFINET interface of your IM 151-8 PN/DP CPU
interface module and the PROFINET IO system. The IM 151-8 PN/DP CPU interface module
can now be reached by other nodes on your Industrial Ethernet subnet.
Reference
● Other methods of assigning the IP addresses can be found in the section Assignment of
the IP address parameter and the device name (Page 139).
● Detailed information on address assignment for the PROFINET IO interface and for
setting the properties of the PROFINET IO interface and the individual ports can be found
in the online Help for STEP 7 and in the PROFINET System Description

Commissioning
Starting up the IM 151-8 PN/DP CPU interface module as an IO controller

During start-up, the IM 151-8 PN/DP CPU checks the preset configuration against the actual
configuration
● Of the local I/O,
● the PROFINET IO system and
● (the distributed I/O on the PROFIBUS DP system).
The start-up of the IM 151-8 PN/DP CPU depends on the configuration settings made under
the "Start-up" tab:
Table 8- 12 Starting up the IM151-8 PN/DP CPU interface module as an IO controller
Preset = Actual Preset ≠ Actual configuration

configuration Startup permitted if Preset configuration is not the same as the Startup not permitted if
Actual configuration Preset configuration is not
the same as the Actual
configuration
IM 151-8 PN/DP CPU in IM 151-8 PN/DP CPU in RUN IM 151-8 PN/DP CPU does
RUN After POWER ON, and after the parameter monitoring time has not start up.
elapsed, the IM 151-8 PN/DP CPU interface module switches to
RUN.
The flashing BF-PN LED indicates that at least one IO device
cannot be addressed. In this case, check that all IO devices are
switched on and correspond to the set configuration. For
additional information, read the diagnostics buffer in STEP 7.

Commissioning
Starting up the IM151-8 PN/DP CPU interface module as an I device

During start-up, the IM 151-8 PN/DP CPU checks the preset configuration against the actual
configuration
● of the centralized I/O,
● of the distributed I/O on the PROFIBUS DP system, and
● the PROFINET IO system.
The start-up of the IM 151-8 PN/DP CPU depends on the configuration settings made under
the "Start-up" tab:
Table 8- 13 Starting up the IM151-8 PN/DP CPU as an I device
Preset = Actual Preset ≠ Actual configuration

configuration Startup permitted if Preset configuration is not the same as the Startup not permitted if
Actual configuration Preset configuration is not
the same as the Actual
configuration
IM 151-8 PN/DP CPU in IM 151-8 PN/DP CPU in RUN IM 151-8 PN/DP CPU does
RUN. After POWER ON, and after the parameter monitoring time has not start up.
elapsed, the IM 151-8 PN/DP CPU switches to RUN.
If the LED BF-PN flashes, this means that:
 When configured as an I device with no lower-level IO
system: None of the higher-level controllers can
accommodate the I device (due for instance to a loss of
connection or to a mismatch of the transfer areas between the
IO controller and I device). In this case, check the
configuration and the wiring of the PROFINET IO system.
 When configured as an I device with a lower-level IO system:
The higher-level controller cannot accommodate the I device
(due for instance to a loss of connection or to a mismatch of
the transfer areas between the IO controller and I device). Or:
At least one IO device cannot be assigned an address. In this
case, check that all IO devices are switched on and
correspond to the set configuration.
For further information, read the diagnostics buffer in STEP 7.

Commissioning
Detecting interruptions in the data transfer to the IO device

The following table shows how the IM 151-8 PN/DP CPU interface module recognizes
interruptions in the data transfer:
Table 8- 14 Event recognition of the IM 151-8 PN/DP CPU interface module as an IO controller
Event What happens in the IO controller?

IM 151-8 PN/DP CPU in RUN IM 151-8 PN/DP CPU in
STOP
Bus interruption (short  Call to OB 86 with the message Station failure The event is written to the
circuit, connector (incoming event; diagnostics address of the IO device) diagnostics buffer
removed)  With I/O access: call of OB 122 (I/O access error)
Further information on this and the behavior during status transitions in the IO controller or in
the I device can be found in the section "I device" of the PROFINET System Description
Note
When commissioning the IM151-8 PN/DP CPU for the operation of I devices, both in the IO
controller and in the I device, always program the OB 83 (because of the Return-of-
Submodule-Alarms which are generated during status transition of the respective
communications partner in the RUN mode).
Always program OB86 when you commission the CPU. This allows you to detect and
analyze interruptions in the data transfer.
If "OB85 call during I/O Access Error" was also configured in the HW config, the OB 85 must
also be programmed so as to detect access errors during the process image transfer.
Reference
A detailed description of the user data transfer can be found in the PROFINET System
Status/control, programming via PROFINET

You can use the PROFINET interface to program the IM 151-8 PN/DP CPU interface module
or execute the status and control programming device functions.
If you have not yet commissioned the PROFINET interface of the IM 151-8 PN/DP CPU
interface module, you can connect to the IM 151-8 PN/DP CPU interface module using its
MAC address (see also Configuring the PROFINET IO System in the table above).
Therefore, always download the configuration data from the HW Config to the IM
151-8 PN/DP CPU interface module. You select the IM 151-8 PN/DP CPU interface module
from the MAC address. After you have downloaded the configuration, the IM 151-8 PN/DP
CPU interface module is also assigned the configured IP address. With that you can then
use all programming device functions, such as download program, status/control etc., on the
interface.

Commissioning

Service and maintenance 9
9.1 Overview
For the ET 200S with IM 151-8 PN/DP CPU, service and maintenance are
● Backing up the firmware to the SIMATIC Micro Memory Card
● Updating the firmware via the SIMATIC Micro Memory Card
● Updating of the firmware online
● Backing up of project data on a SIMATIC Micro Memory Card
● Replacing an IM 151-8 PN/DP CPU interface module
● replacing a DP master module
9.2 Backing up firmware on a SIMATIC Micro Memory Card
In which situations should I back up the firmware?

In some cases, we recommend that you back up the firmware on your IM 151-8 PN/DP CPU
interface module.
For example, you might want to replace the IM 151-8 PN/DP CPU interface module in your
system with an IM 151-8 PN/DP CPU interface module from your inventory. In this case, you
should make sure that the IM 151-8 PN/DP CPU interface module from your inventory has
the same firmware that is used in the system.
We also recommend that you create a back-up copy of the firmware for emergency
situations.
On which IM 151-8 PN/DP CPU can you backup the firmware?

You can backup firmware as of the following versions of the IM 151-8 PN/DP CPU interface
module:
Interface module Order number SIMATIC Micro Memory Card required

≥ in MB
IM 151-8 PN/DP CPU 6ES7151-8AB00-0AB0 4
IM151-8 PN/DP CPU 6ES7151-8AB01-0AB0 8

Service and maintenance
9.3 Updating the firmware
Backing up the firmware on your IM 151-8 PN/DP CPU interface module to the SIMATIC Micro
Memory Card
Table 9- 1 Backing up the firmware to the SIMATIC micro memory card
Step Action required: This takes place in the IM 151-8 PN/DP CPU
interface module:
1. Insert the new SIMATIC Micro Memory The IM 151-8 PN/DP CPU requests a memory
Card in the IM 151-8 PN/DP CPU interface reset.
module.
2. Turn the mode selector switch to MRES -
position and hold it there.
3. Switch supply voltage off and then on ... the STOP, RUN and FRCE LEDs start
again and hold the mode selector switch in flashing.
the MRES position until ...
4. Mode selector switch to STOP. -
5. Mode selector switch briefly to MRES  The IM 151-8 PN/DP CPU interface module
position, then let it return to STOP. starts to back up the firmware on the
SIMATIC Micro Memory Card.
 All LEDs are lit during the backup
operation.
 The STOP LED flashes when the backup is
complete, to indicate that the IM
requires a memory reset.
6. Remove the SIMATIC Micro Memory Card -
with the backed up firmware.
9.3.1 When should you update the IM 151-8 PN/DP CPU interface module?
After (compatible) functional expansions, or after an enhancement of operating system
performance, the firmware of the IM 151-8 PN/DP CPU interface module should be
upgraded (updated) to the latest version.
Update of an IM 151-8 PN/DP CPU

The IM151-8 PN/DP CPU with the order number 6ES7151-8AB00-0AB0 cannot currently be
upgraded to a firmware version >= V3.2.
An IM151-8 PN/DP CPU with the order number 6ES7151-8AB01-0AB0 can be configured as
IM151-6ES7151-8AB00-0AB0 using STEP 7 V5.4. The new functionalities of the
IM151-8 PN/DP CPU V3.2 are, however, not available.

Where do I get the latest version of the firmware?

You can order the latest firmware (as *.UPD files) from your Siemens partner, or download it
from the Internet (http://www.siemens.com/automation/service&support).
9.3.2 Firmware update using a SIMATIC Micro Memory Card
Table 9- 2 Firmware update using a SIMATIC Micro Memory Card
Step Action required: This takes place in the IM 151-8 PN/DP CPU
interface module:
1 Recommendation
Before you update the IM 151-8 PN/DP CPU interface module firmware, create a backup
copy of the "old" firmware on an empty SIMATIC Micro Memory Card. If problems occur
during the update, you can reload your old firmware from the SIMATIC Micro Memory Card.
2 Transfer the update files to a blank -
SIMATIC Micro Memory Card using
STEP 7 and your programming device.
To do this, click "Update PLC / operating
system" in the SIMATIC Manager.
Note: You will need a SIMATIC Micro
Memory Card with at least 8 MB of
memory.
3 Switch off the IM 151-8 PN/DP CPU -
power and insert a SIMATIC Micro
Memory Card containing the firmware
update.
4 Switch on power.  The IM 151-8 PN/DP CPU interface module
automatically detects the SIMATIC Micro
Memory Card with the firmware update and
runs the update.
 All LEDs are lit during firmware update.
 The STOP LED flashes when the backup is
complete, to indicate that the IM
requires a memory reset.
5 Switch off the IM 151-8 PN/DP CPU -
power and insert a SIMATIC Micro
Memory Card containing the firmware
update.

Result
● You have updated your IM 151-8 PN/DP CPU interface module online with a new
firmware version.
● All the parameters within the module have been reset during the firmware update.
NOTICE
Aborting the firmware update by POWER ON / POWER OFF or by removal of the Micro
Memory Card can lead to loss of the firmware on the CPU. In this condition only the
SF-LED continues to flash at 2 Hz (all other LEDs are off). However since the boot block
remains, you can regenerate the valid firmware by repeating the firmware update as
described.

9.3.3 Updating the firmware online (via networks)

To update the IM 151-8 PN/DP CPU interface module firmware, you require the (*.UPD) files
containing the latest FW version.
Requirements
● The firmware can be updated online in STEP 7 V5.4 + SP 4 or later.
● The interface module of the station pending a firmware update must be accessible online.
● The files containing the current firmware versions must be available in the file system of
your programming device or PC. A folder may contain only the files of one firmware
version.
Performing a firmware update

1. Run STEP 7 and change to HW Config.
2. Open the station with the IM 151-8 PN/DP CPU interface module that is to be updated.
3. Select the IM 151-8 PN/DP CPU interface module.
4. Select PLC > Update Firmware.
5. In the Update Firmware dialog, select the path to the firmware update files (*.UPD) using
the Browse button.
6. After you selected a file, the information in the lower fields of the Update Firmware dialog
box shows you the firmware file and version for the corresponding modules.
7. Click on the Run button. STEP 7 checks to determine whether the selected file can be
interpreted by the IM 151-8 PN/DP CPU interface module and, if so, then downloads the
file to the interface module. If this requires changing the operating state of the IM
151-8 PN/DP CPU interface module, you will be asked to perform these tasks in the
relevant dialog boxes. The IM 151-8 PN/DP CPU interface module then performs the
firmware update independently.
8. Use STEP 7 (read out the CPU diagnostics buffer) to verify that the IM 151-8 PN/DP CPU
interface module can start with the new firmware.
As an alternative you can also trigger the firmware update in SIMATIC Manager:
● Select the respective IM 151-8 PN/DP CPU interface module as the target CPU and then
select "Update PLC / Firmware".
● Via "Available nodes", select the target CPU and then select "Update PLC / Firmware".
You can use both paths to read step 5 described above. Then continue with the remaining
steps.
Result
● You have updated your IM 151-8 PN/DP CPU interface module online with a new
firmware version.

9.4 Backing up project data on a SIMATIC Micro Memory Card
Function principle
Using the Save project to Memory Card and Fetch project from Memory Card functions, you
can save all project data to a SIMATIC Micro Memory Card, and retrieve these at a later
time. For this operation, the SIMATIC Micro Memory Card can be located in an IM
151-8 PN/DP CPU interface module or in the SIMATIC Micro Memory Card adapter of a
programming device or PC.
Project data is compressed before it is saved to a SIMATIC Micro Memory Card, and
uncompressed on retrieval.
Note
In addition to project data, you may also have to store your user data on the SIMATIC Micro
Memory Card. You should therefore first select a SIMATIC Micro Memory Card with
sufficient free memory.
A message warns you if the memory capacity on your SIMATIC Micro Memory Card is
insufficient
The volume of project data to be saved corresponds with the size of the project's archive file.
Note
For technical reasons, you can only transfer the entire contents (user program and project
data) using the Save project to memory card action.

Handling the functions

How you use the Save project to memory card / Retrieve project from memory card functions
depends on the location of the SIMATIC micro memory card:
● When the SIMATIC MMC is inserted in the MMC slot, select a project level (for example,
CPU, programs, sources or blocks) which is uniquely assigned to the IM
151-8 PN/DP CPU interface module from the project window in SIMATIC Manager.
Select the Target system > Save project to memory card or Target system > Retrieve
project from memory card menu command. All the complete project data is then written to
/ retrieved from the SIMATIC Micro Memory Card.
● If project data are not available on the currently used programming device (PG/PC), you
can select the source CPU via "Available nodes" window. Select PLC > Show available
nodes to open the "Available nodes" window. Then select the connection / IM
151-8 PN/DP CPU that contains your project data on the SIMATIC Micro Memory Card.
Now select menu command Fetch project from Memory Card.
● If the SIMATIC MMC is located in the MMC programming unit of a PD or PC, open the
"S7 memory card window" using the File > S7 Memory Card > Open command. Select
the Target system > Save project to memory card or Target system > Retrieve project
from memory card menu command. to open a dialog in which you can select the source
or target project.
Note
Project data can generate high data traffic. Especially in RUN mode with read/write
access to the IM 151-8 PN/DP CPU interface module, this can lead to waiting periods of
several minutes.
Sample application
When you assign more than one member of your service and maintenance department to
perform maintenance tasks on a SIMATIC PLC, it may prove difficult to provide quick access
to current configuration data to each staff member.
However, IM 151-8 PN/DP CPU interface module configuration data available locally on any
IM 151-8 PN/DP CPU that is to be serviced can be accessed by any member of the service
department. They can edit this data and then release the updated version to all other
personnel.

9.5 Replacing the IM 151-8 PN/DP CPU interface module
Introduction
Note
If you remove an (operational) device and re-use it in another place or place it in storage, the
device should be restored to its as-delivered condition, since the IP address of the device will
generally be stored retentively.
You can replace the IM 151-8 PN/DP CPU interface module if it is faulty.
Requirements
To replace the IM 151-8 PN/DP CPU interface module you must switch off the supply
voltage on the faulty IM 151-8 PN/DP CPU interface module .
Result: Failure of the ET 200S station and all components connected to it (DP slaves, IO
devices)
CAUTION
PROFINET IO
If you switch off the supply voltage at an ET 200S, the integrated switch will also fail. This
will interrupt communication with all connected peers (e.g. IO devices or other PROFINET
devices) that communicate with one another via this switch.
NOTICE
PROFIBUS DP
The bus terminator function may fail if you shut down supply voltage at the first or last bus
node of a bus segment.
Required tools
Screwdriver with 3 mm blade

Replacing the IM 151-8 PN/DP CPU interface module

The IM 151-8 PN/DP CPU interface module is wired, and the terminal modules are on the
right:
1. Switch off the supply voltage for the faulty IM 151-8 PN/DP CPU interface module.
2. Remove the SIMATIC Micro Memory Card from the receptacle (see Inserting/replacing a
Micro Memory Card (Page 148))
3. Release the connector for the supply voltage and the RJ45 connector(s) on the IM
4. Use a screwdriver to slide the slider on the IM 151-8 PN/DP CPU interface module
downwards until it stops. Now move the IM 151-8 PN/DP CPU interface module to the
left.
Note: The slider is located in the centre beneath the IM 151-8 PN/DP CPU interface
module.
5. Press down on the slider while swiveling the IM 151-8 PN/DP CPU interface module off
the rail.
6. Suspend the new IM 151-8 PN/DP CPU interface module in the rail.
7. Press down on the slider while swiveling the IM 151-8 PN/DP CPU interface module
downwards until the slider audibly engages.
8. Now move the IM 151-8 PN/DP CPU interface module to the right until the first terminal
module.
If a DP master module is connected:
Move the IM 151-8 PN/DP CPU interface module to the right until it audibly engages on
the DP master module.
9. Insert the SIMATIC Micro Memory Card removed from the defective IM
151-8 PN/DP CPU interface module into the slot on the new IM 151-8 PN/DP CPU
interface module.
10.Switch on the power supply.
Behavior of the IM 151-8 PN/DP CPU interface module after replacement

As the SIMATIC Micro Memory Card has been changed, after the IM 151-8 PN/DP CPU
interface module has been replaced it always automatically resets the memory and remains
in STOP mode, regardless of the position of the mode selector. The IM 151-8 PN/DP CPU
interface module can then be switched to RUN once more using the mode selector.
If the IM 151-8 PN/DP CPU interface module stays in STOP, you can view the cause of error
in STEP 7 (see the STEP 7 User Manual).

9.6 Replacing the DP master module
Introduction
You may replace a defective DP master module.
Requirements
To replace the DP master module you must switch off the supply voltage on the associated
IM 151-8 PN/DP CPU interface module .
Result: Failure of the ET 200S station and all components connected to it (DP slaves, IO
devices)
CAUTION
PROFINET IO
If you switch off the supply voltage at an ET 200S, the integrated switch will also fail. This
will interrupt communication with all connected partners (e.g. IO devices or other
PROFINET devices) that communicate with one another via this switch.
NOTICE
PROFIBUS DP
The bus terminator function may fail if you shut down supply voltage at the first or last bus
node of a bus segment.
Required tools
3 mm screwdriver

Replacing the DP master module

The DP master module and the IM 151-8 PN/DP CPU interface module are wired, and the
terminal modules are on the right:
1. Switch off the supply voltage for the respective ET 200S station (IM 151-8 PN/DP CPU).
2. Release the connector for the supply voltage and the RJ45 connector(s) on the IM
3. Use a screwdriver to slide the slider on the IM 151-8 PN/DP CPU interface module
downwards until it stops. Now move the IM 151-8 PN/DP CPU interface module about 40
mm to the left.
Note: The slider is located in the centre beneath the IM 151-8 PN/DP CPU interface
module.
4. Use the screwdriver to slide the slider on the DP master module downwards to the stop.
Slide the faulty DP master module to the left until the connector for the backplane bus is
free.
Note: The slider is located underneath the DP master module.
5. Keeping the slider pressed down, swivel the DP master module out of the mounting rail.
6. Suspend the new DP master module in the rail and swing it downwards.
7. Slide the DP master module to the right until the first terminal module.
8. Move the IM 151-8 PN/DP CPU interface module to the right until it audibly engages with
the DP master module.
9. If required, connect the connector for the supply voltage and the RJ45 connector(s) with
10.Switch on the power supply.


Functions 10
10.1 Assigning parameters of the reference junction for the connection of
thermocouples
Introduction
If you want to use the IM 151-8 PN/DP CPU interface module in an ET 200S system with
thermocouples and a reference junction, set the parameters in the "Properties" section of the
hardware configuration.
Parameter assignment of the reference junction
Table 10- 1 Setting parameters for the reference junction
Parameters Value range Explanation

Activation of the reference activated / You can enable the reference junction with
junction not activated this parameter. Only then can you continue
(Example, see figure to parameterize the reference junction.
below)
Slot none / 5 to 66 You can use this parameter to assign the
(Example, see figure RTD module slot to the reference junction.
below)
Channel number RTD on channel 0 This parameter can be used to set the
RTD on channel 1 channel (0 / 1) for measuring the reference
temperature (calculation of the
(Example, see figure
compensation value) for the assigned slot of
below)
the RTD module.
RTD module parameter Value range Explanation

Measurement Resistance / If you use a channel of the RTD module for
type/measurement range temperature reference junction configuration, you must
measurement, e.g. configure the measurement type /
 RTD-4L Pt100 measurement range for this channel as
standard range RTD-4L Pt 100 climatic range.
TC module parameter Value range Explanation

Reference junction number 1 This parameter allows you to assign the
reference junction (1) that contains the
reference temperature (compensation value).
Reference junction channel None, RTD This parameter allows you to enable the use
0 and reference junction of the reference junction.
channel 1

Functions
10.1 Assigning parameters of the reference junction for the connection of thermocouples
Example of a parameterization dialog box
Figure 10-1 Example for a parameterization dialog box of the IM 151-8 PN/DP CPU module
parameters in STEP 7
Reference
You can find detailed information on the procedure, the connection system and an example
of configuration in the section entitled Analog Electronic Modules in the ET 200S Distributed
I/O System Manual.

Functions
10.2 Removal and insertion of modules during operation
10.2.1 Overview
The ET 200S with IM 151-8 PN/DP CPU supports the removal and insertion of in each case
one module of the ET 200S I/O system during operation and in an energized state.
Exceptions
The IM 151-8 PN/DP CPU interface module itself must not be removed during operation and
in an energized state.
Removal and insertion of modules in an energized state and during operation

When removing and inserting modules in an energized state and during operation, refer both
to the specifications given here and the restrictions in the ET 200S Distributed I/O System
(http://support.automation.siemens.com/WW/view/en/1144348) Operating Instructions,
section Wiring and equipping.
WARNING
When an output module is inserted, the outputs set by the user program become active
immediately. We therefore advise you to set the outputs to "0" in the user program before
removing the module.
If modules are removed or inserted incorrectly (see ET 200S Distributed I/O System
(http://support.automation.siemens.com/WW/view/en/1144348) Operating Instructions,
section Wiring and equipping), this can cause uncontrolled system states. Adjacent
modules could be affected.

are configured in the I/O transfer area of an I device, can be found in the PROFINET System
Description (http://support.automation.siemens.com/WW/view/en/19292127), section
Diagnostics and interrupt behavior and Conditions for use of I devices.

Functions
10.2.2 What happens when modules are removed during operation

● When you remove a module from the ET 200S I/O system during operation, OB 83 is
called and a corresponding diagnostics buffer entry is generated (event ID 3961H). This
takes place regardless of whether the associated power module is switched on or off.
If the OB 83 is available on the IM 151-8 PN/DP CPU interface module, this remains in
RUN.
The absence of the module is noted in the system status list.
● If the module that has been removed is accessed from the user program, an I/O access
error occurs with a corresponding entry in the diagnostics buffer and the OB 122 is called
up.
If the OB 122 is available on the IM 151-8 PN/DP CPU interface module, this remains in
RUN.
10.2.3 Procedure when modules are inserted during operation
Overview
If you insert a module in the ET 200S I/O system during operation, the IM 151-8 PN/DP CPU
interface module initially carries out a set / actual comparison with regard to the inserted
module. In doing so, the configured module is compared with the one that is actually
inserted. The activities described below take place dependent on the result of the set / actual
comparison.
Non-configurable modules
The following actions will take place regardless of whether the power module of the inserted
module is switched on or off.
Table 10- 2 Result of the set / actual comparison in the case of non-configurable modules
Inserted module = configured module Inserted module ≠ configured module

OB 83 is called with the corresponding OB 83 is called with the corresponding
diagnostics buffer entry (event -ID 3861H). diagnostics buffer entry (event -ID 3863H).
The module remains entered in the system status The module remains entered in the system status
list as unavailable. list as unavailable.
Direct access is again possible. Direct access is not possible.

Functions
Modules that can be parameterized

The following actions only take place when the power module of the inserted module is
switched on.
Table 10- 3 Result of the preset/actual comparison in the case of parameterizable modules with the
power module switched on

OB 83 is called with the corresponding OB 83 is called with the corresponding
diagnostics buffer entry (event -ID 3861H). diagnostics buffer entry (event ID 3863H).
The IM 151-8 PN/DP CPU interface module The IM 151-8 PN/DP CPU interface module does
reconfigures the module. not configure the module.
If parameter assignment is successful, the The module remains entered in the system status
module is entered in the system status list as list as unavailable.
available. The SF LED on the module remains lit.
The following actions only take place when the power module of the inserted module is
switched off.
Table 10- 4 Result of the preset/actual comparison in the case of parameterizable modules with the
power module switched off

OB 83 is called with the corresponding diagnostics buffer entry (event -ID 3861H).
When the power module is switched on, the IM When the power module is switched on, the IM
151-8 PN/DP CPU interface module reconfigures 151-8 PN/DP CPU interface module does not
the module. reconfigure the module.
If parameter assignment is successful, the The module remains entered in the system status
module is entered in the system status list as list as unavailable.
available. The SF LED on the module remains lit.

Functions
10.3 Switching power modules off and on during operation
10.3 Switching power modules off and on during operation
What happens when power modules are switched off during operation
If the load power voltage to a power module is switched off during operation, the following
activities take place:
● If you enable diagnostics when assigning parameters for the power module, the
diagnostics interrupt OB 82 (diagnostics address of the power module) is called with the
corresponding diagnostics buffer entry (event ID 3942H).
● The power module is entered as present but faulty in the system status list.
Switching off the load power supply has the following effects on the modules supplied by the
power module:
● The SF LED on the modules lights up.
● The modules can continue to be accessed without an I/O access error occurring.
● The outputs of the modules are deenergized and inactive for the process.
● The inputs of digital modules and FM modules return 0; the inputs of analog modules
return 7FFFH.
What happens when power modules are switched on during operation

If the load power supply to a power module is switched on during operation, the following
activities take place:
● If you enable diagnostics when assigning parameters for the power module, the
diagnostics interrupt OB 82 (diagnostics address of the power module) is called with the
corresponding diagnostics buffer entry (event ID 3842H).
● The power module is entered as present and o.k. in the system status list.
Switching on the load power supply has the following effects on modules supplied by the
power module:
● The SF LED on the modules goes out.
● The modules regain their full functionality.
Removal and insertion of power modules during operation

If, during operation, you remove or insert a power module, the activities listed in section
Removing and inserting modules during operation take place.
Removal and insertion has the same effects as switching the load power supply off and on
for the modules that are supplied by the power module.

are configured in the I/O transfer area of an I device can be found in the PROFINET System
Description (http://support.automation.siemens.com/WW/view/en/19292127), section
Diagnostics and interrupt behavior and Conditions for use of I devices.

Functions
10.4 Power module with status byte
Diagnostic status of the power module

The diagnostic status of the power module can be evaluated as the input byte in the status
byte.
To do this, set a check in the "Status byte" check box in the "Addresses" tab in the properties
dialog of the power module.
The current status of the power module is held in a freely selectable input byte of the status
byte. This is updated irrespective of whether the "No Load Voltage" diagnosis has been
enabled.
Example: Cross circuit detection

An external power supply can cause a cross circuit in a power module, even when it is
switched off. The status byte allows detection of the cross circuit.
Information on the meaning of bits in the status byte can be found in the documentation for
the respective power module.

Functions

Debugging functions, diagnostics and
troubleshooting 11
11.1 Overview
This chapter helps you to get acquainted with tools you can use to carry out the following
tasks:
● Hardware/software error diagnostics.
● Elimination of hardware/software errors.
● Testing the hardware/software – for example, during commissioning.
Note
It would go beyond the scope of this manual to provide detailed descriptions of all the
tools you can use for diagnostics, testing and troubleshooting functions. Further notes are
found in the relevant hardware/software manuals.
11.2 Reading/saving service data
Application
In the case of a service, for example, if the IM151-8 PN/DP CPU signals the state
"DEFECTIVE" (all LEDs flashing), you have the option of saving special information for
analyzing the CPU state.
This information is stored in the diagnostic buffer and in the actual service data.
Select the “Target system -> Save service data” command to read and this information and
save the data to a file to forward to Customer Support.
Procedure
1. If the IM151-8 PN/DP CPU is in the state "DEFECTIVE" (all LEDs flashing), switch the
power supply off and on (power off/on).
Result: The IM 151-8 PN/DP CPU is in "STOP" mode.
2. As soon as possible after the IM151-8 PN/DP CPU has switched to "STOP" mode, select
the respective IM151-8 PN/DP CPU with the "Target system > Available nodes" menu
command in the SIMATIC Manager.
3. Use the SIMATIC Manager menu command "Target system > Save service data" to save
the service data.
Result: A dialog box opens in which you specify the storage location and name of the two
files.
4. Save the files.
5. Forward these files to Customer Support on request.

Debugging functions, diagnostics and troubleshooting
11.3 Identification and maintenance data of the IM 151-8 PN/DP CPU interface module
11.3 Identification and maintenance data of the IM 151-8 PN/DP CPU

interface module
Definition and properties

Identification and maintenance data (I&M) are data that are stored in a module for assisting
you in:
● Checking the system configuration
● Locating hardware changes in a system
● Correcting errors in a system
Identification data (I data) is information regarding the module, like for example, order
number and serial number, which are partly also printed on the housing of the module. I data
is manufacturer´s information about the module. It is fixed and can only be read.
Maintenance data (M data) is system-specific information, such as the installation location. M
data is created during the configuration and written to the module.
I&M data enable modules to be uniquely identified online.
Reading and writing the I&M data of the IM 151-8 PN/DP CPU interface module with STEP 7
Read:
● In STEP 7 the I&M data is displayed under "Module state – IM 151-8 PN/DP CPU"
("General" and "Identification" tabs) and via "Available nodes" (detailed view) (see
STEP 7 online help).
● In the user program, the I&M data can be read via SFC 51. Specify the required SSL
sublist number and the index in the input parameters of the SFC 51 (see table below).
● You can read the I&M data on the "Start" and "Identification" pages using the web server.
Write:
You will always need STEP 7 HW Config to write the M data for modules.
For example, you can enter the following data during configuration:
● Name of the automation system (device name)
The device name is assigned when you create the station in SIMATIC Manager. In this
case a "SIMATIC 300(1) station is created by default. This name can be changed at any
time.
● You can enter the following data in STEP 7 HW Config on the "General" tab under "IM
151-8 PN/DP CPU Properties":
– Name of the module
In this case, HW Config assigns a default name, e.g. IM 151-8 PN/DP CPU interface
module (this can be changed).
– Higher level designation of the module
No default setting
– Location designation of a module
No default setting

11.3 Identification and maintenance data of the IM 151-8 PN/DP CPU interface module
Reading the I&M data from the IM 151-8 PN/DP CPU interface module with the user program
If you want to read the I&M data from the IM 151-8 PN/DP CPU interface module in the user
program, you must read the associated system state list, specifying the relevant SSL ID and
the index using SFC 51. The SSL IDs and the associated indexes are listed in the following
table.
SSL sublists with I&M data

The I&M data can be found in the following SSL sublists under the specified indexes.
Table 11- 1 SSL sublists with I&M data
SSL ID Index Meaning

W#16#… W#16#…
Module identification
0111 an identification data record
0001 Identification of the module
This contains the module's order number and the product version.
0006 Identification of the basic software
Provides information on the software version of the module.
(The IM 151-8 PN/DP CPU interface module has no basic software so, in this case,
the identification data are the same as index 0001.)
0007 Identification of the basic firmware
Provides information on the firmware version of the module.
Identification of a component
011C Identification of a component
0001 Name of the automation system
The name of the automation system (device name) is saved to this parameter.
0002 Name of the module
The name of the module is saved to this parameter.
0003 Higher level designation of the module
This is a system-wide unique identifier for the module.
000B Location designation of a module
This is the module's installation location.
For detailed information on the structure and content of the system state lists, see the
System and Standard Functions for S7-300/400 reference manual.
Additional information about reading the SSL with SFC 51 can be found in Reference
Manual System and Standard Functions for S7-300/400 or in the Online Help for STEP 7.
I&M data for the connected I/O devices

Information about the I&M data for the I/O devices connected to the IM 151-8 PN/DP CPU
interface module can be found in the relevant I/O module manuals.

11.4 Debugging functions
11.4.1 Overview: Debugging functions
Determining addressed nodes with "Node flashing test"

To identify the addressed node, select PLC > Diagnostics/Setting > Node/Flashing Test in
STEP 7.
A dialog appears in which you can set the flashing time and start the flashing test. The
directly connected node can be identified by a flashing FRCE LED. The flashing test cannot
be performed if the FORCE function is active.
Debugging functions of the software: Monitoring and modifying variables, stepping mode
STEP 7 offers you the following testing functions that you can also use for diagnostics:
● Monitoring and modifying variables
Can be used to monitor the current values of individual variables of a user program or an
IM 151-8 PN/DP CPU interface module on the programming device / PC. You can also
assign constant values to the variables.
● Testing with program status
You can test your program by viewing the program status of each function (result of
logical links, status bit) or the data of specific registers in real-time mode.
If you have selected the LAD programming language to be represented in STEP 7, the
color of the symbol will indicate a closed switch or an active circuit, for example.
● Stepping mode
When testing in single-step mode, you can process your program instructions in
sequence (= single-step) and set break points. This is only possible in testing mode and
not in process mode.
Note
Number of blocks and breakpoints that can be monitored with status block
In the case of IM151-8 PN/DP CPU ≥ V3.2, you can monitor two blocks at the same time
and can set up to four breakpoints in single-step mode.

Debugging functions of the software: Forcing variables

The Force function can be used to assign the variables of a user program or IM
151-8 PN/DP CPU interface module (also: inputs and outputs) constant values which can not
be overwritten by the user program.
For example, you can use it to jumper sensors or switch outputs permanently, irrespective of
the user program.
DANGER
This could result in severe injury or even death, and damage to property.
Incorrect use of the Force function could result in death or severe injury, and damage to
machinery or even the entire plant. Always follow the safety instructions in the STEP 7
manuals.
DANGER
Forcing with the IM 151-8 PN/DP CPU interface module
The force values in the process image of the inputs can be overwritten by write commands
(such as T IB x, = I x.y, Copy with SFC, etc.) and by read I/O commands (such as L PIW x)
in the user program, or by write PG/OP functions! Outputs initialized with forced values only
return the forced value if not accessed by the user program via I/O write instructions (TPQB
x, for example) or by programming device / OP write functions!
Always ensure that forced values in the I/O process image cannot be overwritten by the
user program or programming device / OP functions!
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Note
Forcing process image partitions
Inputs and outputs within the process image partition cannot be forced.
The differences between forcing and modifying variables
Table 11- 2 The differences between forcing and modifying variables
Characteristics/function Forcing Modifying Variables

Memory bit (M) - Yes
Timers and counters (T, C) - Yes
Data blocks (DB) - Yes
Inputs and outputs (I, O) Yes Yes
Peripheral inputs (PI) - -
Peripheral outputs (PO) - Yes
User program can overwrite modify/force values Yes Yes
Maximum number of force values 10 -
POWER OFF retentive Yes No
Reference
Details on debugging functions of the software are available in the STEP 7 Online Help and
in the Programming with STEP 7
(http://support.automation.siemens.com/WW/view/en/18652056) manual.
For additional information on the cycle times, please refer to the "Cycle time (Page 247)"
chapter.

11.4.2 Overview: Diagnostics
Introduction
System errors can occur especially in the commissioning phase. Tracking these errors might
be a time-consuming effort, since they can occur both on the hardware and software side.
The many different testing functions ensure that commissioning runs smoothly.
Note
Errors during operation are almost always a result of faults or damage to the hardware.
Type of error
Errors that the IM 151-8 PN/DP CPU interface module can recognize and to which you can
respond with organization blocks (OBs) can be split into the following categories:
● Synchronous error: Errors you can relate to a specific point in the user program (error
when accessing an I/O module, for example).
● Asynchronous error: Errors you can not relate to a specific point in the user program
(cycle time exceeded, module error, for example).
Troubleshooting
Programming with foresight and, above all, knowledge and proper handling of diagnostic
tools puts you into an advantageous position in error situations:
● You can reduce the effects of errors.
● It makes it easier for you to locate errors (by programming error OBs, for example).
● You can limit downtimes.

Diagnostics with LED display

The SIMATIC hardware of the distributed I/Os offers diagnostics with LEDs.
These LEDs are implemented in three colors:
LED color Status of the IM 151-8 PN/DP CPU interface module

Green Regular operation.
Example: Power is on.
Yellow Non-regular operating status.
Example: Forcing is active.
Red Fault.
Example: Bus error
LED flashing Special event
Example: Memory reset
The LEDs for the PROFINET interface ports are of the following colors:
LED color State Meaning

Green Off No other device is connected to the corresponding port of the integrated
PROFINET interface of the IM 151-8 PN/DP CPU interface module .
On Another PROFINET device (such as a switch) is connected at the
corresponding port of the integrated PROFINET interface of the IM
151-8 PN/DP CPU interface module and the physical connection has been
established.
Reference
Notes on diagnosing suitable I/O modules can be found in the ET 200S Operating
Instructions.
Diagnostics buffer
If an error occurs, the IM 151-8 PN/DP CPU interface module writes the cause of error to the
diagnostics buffer. In STEP 7 you use the programming device to read the diagnostics
buffer. This location holds error information in plain text.
Modules with diagnostics capability that do not have their own diagnostics buffer write their
error information to the IM 151-8 PN/DP CPU interface module´s diagnostics buffer.
When an error or an interrupt event occurs, (e.g. diagnostic interrupt for an I/O module), the
IM 151-8 PN/DP CPU interface module switches to STOP mode, or you can respond in the
user program via error / interrupt OBs. This would be OB82 in the above example.
Diagnostics of field devices on PROFINET

For additional information, refer to the PROFINET
(http://support.automation.siemens.com/WW/view/en/19292127) System Description and to
the From PROFIBUS DP to PROFINET IO
(http://support.automation.siemens.com/WW/view/en/19289930) Programming Manual.

Diagnostics with system functions

On the IM 151-8 PN/DP CPU interface module, we recommend that you use the more user-
friendly SFB 54 "RALRM" (called in diagnostic OB 82) to evaluate the diagnostics from I/O
modules or DP slaves.
Further options for diagnostics with system functions are listed below:
● Using SFC 51 "RDSYSST" to read an SSL sublist or an extract thereof.
● Reading the diagnostic data (slave diagnostics) of a DP slave, using SFC 13
"DPNRM_DG"
Every DP slave provides slave diagnostic data according to EN 50170 Volume 2,
PROFIBUS. You can use SFC 13 "DPNRM_DG" to read this diagnostic data. Error
information is stored in hex code. Refer to the relevant module manual for information on
the meaning of the read code.
For example, the entry of the value 50H (= dual 0101 0000) in byte 7 of the slave
diagnostics for the distributed I/O module ET 200B indicates a faulty fuse or missing load
voltage in channel group 2 and 3.
● Reading a data record with SFB 52 "RDREC"
You can use SFB 52 "RDREC" (read record) to read a specific data record from the
addressed module. Data records 0 and 1 are especially suitable for reading diagnostic
information from a diagnosable module.
Data record 0 contains 4 bytes of diagnostic data that indicates the current state of a
module. Data record 1 contains the 4 bytes of diagnostic data also stored in data
record 0, plus module-specific diagnostic data.
● Reading the start information of the current OB using SFC 6 "RD_SINFO"
Information about the error can also be found in the start information of the relevant error
OB.
You can use SFC 6 "RD_SINFO" (read start information) to read the start information of
the OB that was last called and not yet processed completely, and of the startup OB that
was last called.
● Triggering detection of the bus topology in a DP master system with SFC 103
"DP_TOPOL"
The diagnostic repeater makes it easier to identify faulty modules or an interruption on
the DP cable when a fault occurs during operation. The repeater acts as a slave and is
able to determine the topology of a DP segment and log faults on the basis of this
topology.
You can use SFC103 "DP_TOPOL" to trigger the identification of the bus topology of a
DP master system by the diagnostic repeater. SFC 103 is described in the STEP 7 online
help and in the System and Standard Functions for S7-300/400
(http://support.automation.siemens.com/WW/view/en/1214574) reference manual. The
diagnostic repeater is described in the Diagnostic Repeater for PROFIBUS DP
(http://support.automation.siemens.com/WW/view/en/7915183) Manual.

11.4.3 Diagnostic functions available in STEP 7
Diagnosing with the "Diagnosing hardware" function"

Locate the cause of a module error by viewing the online information on the module. You
can locate the cause of an error in the user program cycle with the help of the diagnostics
buffer and of the stack content. In addition to this, you can check whether a user program is
capable of running on the IM 151-8 PN/DP CPU interface module.
Hardware diagnostics give you an overview of the PLC status. In an overview
representation, a symbol can display the error status of every module. A double-click on the
faulty module opens detailed error information. The scope of this information depends on the
specific module. You can view the following information:
● General information about the module (e.g. order number, version, designation) and state
of the module (e.g. faulty).
● Module errors (channel errors, for example) in centralized I/O modules and
PROFIBUS DP slaves or PROFINET IO devices.
● Maintenance information: Maintenance requirement and maintenance demanded
● Display of messages from the diagnostics buffer.
● Diagnostic data about the PROFINET interface and its ports is also available (e.g.
network connection, communication diagnostics and statistics).
For the IM 151-8 PN/DP CPU interface module, you can also view the following information
about the module states:
● Cause of an error in the user program cycle.
● Indication of the cycle time (longest, shortest and last cycle).
● Performance data (number of possible inputs and outputs, memory bits, counters, timers
and blocks).
For complete and current details of diagnostic functions in STEP 7 and specific procedures,
refer to the Programming with STEP 7 manual and the STEP 7 Online Help.

11.4.4 Network infrastructure diagnostics (SNMP)
Availability
As an open standard, you can use any systems or software solutions for diagnostics based
on SNMP in PROFINET.
Network Diagnostics
SNMP (Simple Network Management Protocol) makes use of the wireless UDP transport
protocol. It consists of two network components, similar to the client/server model. The
SNMP manager monitors the network nodes and the SNMP agents collect the various
network-specific information in the individual network nodes and stores it in a structured form
in the MIB (Management Information Base). This information allows a network management
system to run detailed network diagnostics.
MIB
An MIB (Management Information Base) is a database of a device. SNMP clients access this
database in the device. The S7 device family supports, among others, the following standard
MIBs:
● MIB II, standardized in the RFC 1213
● LLDP-MIB, standardized in the international standard IEE 802.1AB
● LLDP PNIO-MIB, standardized in the international standard IEE 61158-6-10
Detecting the network topology

LLDP (Link Layer Discovery Protocol) is a protocol that is used to detect the closest
neighbors. It enables a device to send information about itself and to save information
received from neighboring devices in the LLDP MIB. This information can be looked up via
the SNMP. This information allows a network management system to determine the network
topology.
Integrating HMI devices via the SNMP OPC server

Configuration of the OPC server is integrated into STEP 7 HW Config. The communication
with the OPC server is carried out without an S7 connection. You therefore do not need to
configure S7 connections.
Stations that have already been configured in the STEP 7 project can be transferred directly.
As an alternative to STEP 7, the configuration can also be run with the NCM PC (included on
the SIMATIC NET CD) or can be determined automatically and transferred to the project
configuration.
Use of SNMP in the SIMATIC NET environment

SNMP-compliant devices from the SIMATIC NET family can be monitored and operated via
a conventional standard Internet browser. The management system known as web-based
management offers a range of device-specific information (network statistics, status of
redundant supply, for example).

Diagnostics with the SIMATIC NET SNMP OPC server

The SNMP OPC server software enables the diagnostics and parameter assignment of any
SNMP devices, even via, for example, HMI devices that cannot read SNMP variables from
other devices.
The OPC server uses the SNMP protocol to exchange data with these devices.
All information can be integrated into OPC-compatible systems, into the WinCC HMI system,
for example. This enables process and network diagnostics to be combined in the HMI
system.
Uses of SNMP
SNMP can be used as follows:
● By users to integrate network diagnostics into a central HMI/SCADA system using the
SNMP OPC server.
● By the IT administrators of machine and system operators to monitor their Industrial
Ethernet network using standard network management systems.
● By the IT administrators to primarily monitor the office network, but often also the
automation network using standard network management systems (for example, HP
Openview).
● Information relating to SNMP from the network management standardization group can
be found on the Internet (http://www.profibus.com).
● Additional information on SNMP can be found on the Internet (http://www.snmp.org).
● Additional information on SNMP OPC servers can be found on the Internet
(http://www.siemens.com/snmp-opc-server).
● The PROFINET system description
(http://support.automation.siemens.com/WW/view/en/19292127) contains additional
information about the SNMP communication service and diagnostics with SNMP.

11.5 Diagnostics using status and error LEDs
11.5.1 Introduction
Diagnostics with LEDs is an initial tool for error localization. Usually, you evaluate the
diagnostics buffer for further error localization.
The buffer contains plain text information on the error that has occurred. For example, you
will find the number of the appropriate error OB here. If you generate this error OB, you can
prevent the IM 151-8 PN/DP CPU interface module switching to STOP mode.
11.5.2 Status and error displays of the IM 151-8 PN/DP CPU interface module
Table 11- 3 Status and error displays of the IM 151-8 PN/DP CPU interface module
LED Meaning
SF MT ON FRCE RUN STOP
Off Off Off Off Off Off The IM 151-8 PN/DP CPU has no power supply.
Remedy:
Check whether the supply voltage is connected to mains and
switched on.
Off X On X Off On The IM 151-8 PN/DP CPU is in STOP mode.
To correct or avoid error: Start the IM 151-8 PN/DP CPU
interface module.
On X On X Off On The IM 151-8 PN/DP CPU is in STOP mode as a result of an
error.
To correct or avoid error: refer to the tables below, evaluation
of the SF LED
X X On X Off Flashes The IM 151-8 PN/DP CPU requests a memory reset.
(0.5 Hz)
X X On X Off Flashes The IM 151-8 PN/DP CPU carries out a memory reset.
(2 Hz)
X X On X Flashes On The IM 151-8 PN/DP CPU is in start-up mode.
(2 Hz)
X X On X Flashes On The IM 151-8 PN/DP CPU was paused by a programmed
(0.5 Hz) break point.
For further information, refer to the Programming with STEP 7
(http://support.automation.siemens.com/WW/view/en/1865205
6) Manual.
On X On X X X Hardware or software error
To correct or avoid error: refer to the tables below, evaluation
of the SF LED

LED Meaning
SF MT ON FRCE RUN STOP
X On X X X X  During IRT operation of a PROFINET IO system:
– Failure of the Sync Master in a Sync Domain
– Loss of synchronization with its own CPU (e. g. due to
failure of the Sync Master)
– Loss of synchronization with a connected PROFINET
IO device
 Other PROFINET IO maintenance demand (e.g. excessive
attenuation in fiber-optic cables)
 In the case of media redundancy (MRP):
– Connection between ring ports is missing or interrupted
– An MRP client in the ring has failed
– If several redundancy managers are present
X X X On X X You enabled the Force function
For further information, refer to the Programming with STEP
(http://support.automation.siemens.com/WW/view/en/1865205
6)7 manual.
X X X Flashe X X Node flashing test was activated.
s
(2 Hz)
Flashe X Flashe Flashe Flashes Flashes There is an internal system error in your IM 151-8 PN/DP
s s s CPU. The procedure is as follows:
1. Set the mode selector switch to STOP.
2. Switch the supply voltage 1L+ off and on again.
3. Read the diagnostics buffer with STEP 7.
4. Read the service data (see section "Reading/saving
service data (Page 201)" )
5. Contact your local SIEMENS partner.
Flashe Off Off Off Off Off The IM151-8 PN/DP CPU has no valid firmware;
s To correct or avoid error: Perform a firmware update with a
(2 Hz) Micro Memory Card (see section Firmware update with a
Micro Memory Card (Page 183)).
X = This state is irrelevant for the current IM 151-8 PN/DP CPU function.
Maintenance information MT
The LED MT lights up yellow as soon as a maintenance demand is received from the
PROFINET IO.
In addition to the LED display, an alarm message is generated if these interrupts have been
enabled by the configuration of the PN interface.

Reference
● A detailed description of the OBs and SFCs required for their evaluation can be found in
the STEP 7 Online Help and in the S7-300/400 System and Standard Functions
(http://support.automation.siemens.com/WW/view/en/1214574) Reference Manual.
● For detailed information on maintenance, refer to the PROFINET System Description
11.5.3 Evaluating the SF LED in case of software errors
Table 11- 4 Evaluation of the SF LED (software error)
Possible error Response of the IM 151-8 Possible Remedies

PN/DP CPU interface
module
TOD interrupt is enabled and Call of OB 85. The IM 151-8 Load OB 10 (OB number can be
triggered. However, a matching PN/DP CPU interface seen from the diagnostics buffer).
block is not loaded. module STOPs if OB 85 is
(Software/configuration error) not loaded.
Start time of the enabled TOD Call of OB 80. The IM 151-8 Disable the TOD interrupt before
interrupt was jumped, e.g. by PN/DP CPU interface you set the time-of-day with SFC 29.
advancing the internal clock. module STOPs if OB 80 is
not loaded.
Delay interrupt triggered by Call of OB 85. The IM 151-8 Load OB 20 (OB number can be
SFC 32. However, a matching PN/DP CPU interface seen from the diagnostics buffer).
Process interrupt is enabled and Call of OB 85. The IM 151-8 Load OB 40 (OB number can be
triggered. However, a matching PN/DP CPU interface seen from the diagnostics buffer).
Status alarm is generated, but Call of OB 85. The IM 151-8 Load OB55
the appropriate OB55 is not PN/DP CPU interface
loaded. module STOPs if OB 85 is
not loaded.
Update alarm is generated, but Call of OB 85. The IM 151-8 Load OB56
the appropriate OB 56 is not PN/DP CPU interface
loaded. module STOPs if OB 85 is
not loaded.
Vendor-specific alarm is Call of OB 85. The IM 151-8 Load OB57
generated, but the appropriate PN/DP CPU interface
OB57 is not loaded. module STOPs if OB 85 is
not loaded.
Access to missing or defective Call OB 85 (depending on Load OB 85. The start information of
I/O module when the process the parameter settings in the OB contains the address of the
image is updated (software or HW Config). The IM 151-8 relevant I/O module. Replace the
hardware error) PN/DP CPU interface affected I/O module or eliminate the
module STOPs if OB 85 is program error.
not loaded.

Possible error Response of the IM 151-8 Possible Remedies

PN/DP CPU interface
module
The cycle time was exceeded. Call of OB 80. The IM 151-8 Extending the cycle time (STEP 7 –
Probably too many interrupt PN/DP CPU interface Hardware configuration), changing
OBs called simultaneously. module STOPs if OB 80 is the program structure.
not loaded. The IM 151-8 To correct or avoid error:
PN/DP CPU interface If necessary, retrigger cycle time
module switches to STOP monitoring by calling SFC 43
even though OB 80 is
loaded if twice the cycle
time was exceeded without
the cycle time being
triggered again.
Programming error Call of OB 121. The IM 151- Eliminate the programming error.
 Block not loaded 8 PN/DP CPU interface The STEP 7 testing function helps
module STOPs if OB 121 is you to locate the error.
 Wrong block number
not loaded.
 Wrong timer/counter number
 Read/write access to wrong
area
 etc.
I/O access errors Call of OB 122. The IM 151- Check the I/O module address
An error has occurred when I/O 8 PN/DP CPU interface assignment in HW Config and
module data was accessed module STOPs if OB 122 is identify whether an I/O module / DP
not loaded. slave / PROFINET IO device has
failed.
Tip:
● You can use SFC 39 to disable all interrupts and asynchronous error events.
Note
The shorter the selected cyclic interrupt period, the more likely it is that cyclic interrupt
errors will occur. You must take into account the operating system times of the IM 151-8
PN/DP CPU interface module, the user program runtime and extension of the cycle time
by active programming device functions, for example.
Reference
A detailed description of the OBs and on SFCs required for their evaluation can be found in
the STEP 7 Online Help and in the S7-300/400 System and Standard Functions reference
manual.

11.5.4 Evaluating the SF LED in case of hardware errors
Table 11- 5 Evaluating the SF LED (hardware error)
Possible error Response of the IM 151-8 PN/DP CPU Possible Remedies

interface module
A centralized I/O module was Call of OB 83. The IM 151-8 PN/DP CPU Load OB 83.
removed or inserted while the interface module STOPs if OB 83 is not loaded.
system was in RUN mode. If more than one module is removed, the IM
151-8 PN/DP CPU interface module always
switches to STOP.
A distributed module was removed Call of OB 83. The IM 151-8 PN/DP CPU Load OB 83 and OB 86.
or inserted on PROFINET IO while interface module STOPs if OB 83 is not loaded.
the system was in RUN. OB 86 is also called when one or more modules
of an ET 200S (IO device) are removed or
inserted while the system is in RUN. The IM
151-8 PN/DP CPU interface module STOPs if
OB 86 is not loaded.
A distributed module was removed Call of OB 86. The IM 151-8 PN/DP CPU Load OB86 or OB82.
from or inserted on the interface module STOPs if OB 86 is not loaded.
PROFIBUS DP while the system If the module was integrated using a GSD file:
was in RUN mode. Call of OB 82. The IM 151-8 PN/DP CPU
interface module STOPs if OB 82 is not loaded.
An I/O module with diagnostic Call of OB 82. The IM 151-8 PN/DP CPU Response to the diagnostic event,
capability reports a diagnostic interface module STOPs if OB 82 is not loaded. which depends on the parameter
interrupt. assignments for the I/O module.
Attempt to access a missing or faulty Call of OB 85, if access was attempted during Load OB 85 or OB 122. The start
I/O module. Loose connector update of the process image (OB 85 call must information of the OB contains the
(software or hardware error). be enabled accordingly in the parameters). Call address of the relevant I/O
OB 122 for direct I/O access. The IM 151-8 module. Replace the relevant I/O
PN/DP CPU interface module STOPs if an OB module, fix the connector or
is not loaded. eliminate the program error.
SIMATIC Micro Memory Card is The IM 151-8 PN/DP CPU switches to STOP Replace the SIMATIC Micro
faulty. and requests a memory reset. Memory Card, reset the IM 151-8
memory, transfer the program
again, then set the IM 151-8
PN/DP CPU interface module to
RUN mode.

Possible error Response of the IM 151-8 PN/DP CPU Possible Remedies

interface module
A port interconnection was If no partner device is present or an incorrect Create a connection to the correct
configured but either no partner or partner device is connected, this leads to a partner.
an incorrect partner was detected at respective diagnostics buffer entry and a
the port. display in the communication diagnostics of the
port at the PN interface.
If the call of an OB 82 for communication
interrupts at the PN interface is enabled in the
HW config, then when the IM is in RUN mode
and the corresponding event occurs, the OB 82
is called here also.
The IM151-8 PN/DP CPU is The IO controller is in RUN mode and the I Load OB85 or OB122.
operated as an I device at an IO device is in STOP mode:
controller (can also be a CPU) in a Direct I/O access to inputs / outputs in the
PN IO subnet. application transfer areas / I/O transfer
One of the two communication areas to the I devices lead to access errors
partners switches to STOP mode (or in the IO controller (call OB 122).
is in STOP mode).  If the application transfer areas / I/O transfer
areas are within the process image and the
call of the OB 85 is assigned parameters in
the case of process image transfer errors,
then in this case the OB 85 is called.
The IO controller is in STOP mode and the I
device is in RUN mode:
 Access errors in the I device (call OB 122).
 If the application transfer areas are within
the process image and the call of the OB 85
is assigned parameters in the case of
process image transfer errors, then in this
case the OB 85 is called.
Reference
manual.

11.5.5 Status and error displays for the PN interface
Status and Error Indicators: PROFINET devices
Table 11- 6 LED displays for PROFINET
LED LED status Description of the status

P1 - LINK, Lit There is an Ethernet connection between the allocated port of the PROFINET interface of
P2 - LINK, your PROFINET device and a communication peer on the Ethernet (a switch, for
P3 - LINK example).
Flashes Only for IO devices does the "Flashing node test" by the SIMATIC Manager result in the
LINK LED flashing.
The LINK LED can also be induced to flash for CPUs, for instance, by calling up "Search
the Network" from the HW config (Target system > Ethernet > Edit Ethernet Nodes >
Search).
Comments: For CPUs, the usual "Flashing node test" results in the FORCE LED flashing.
If it does not light The Ethernet connection between the PROFINET interface of the PROFINET device and
up the communication partner is down.
BF-PN lit1 Error on the PROFINET interface, communication no longer possible (for example, with a
CPU as IO controller, when the connection to the switch is down)
To correct or avoid error: See the table below
Flashes The BF LED always flashes if, from the point of view of the PROFINET IO controller, the
communication cannot be correctly established to any device (due, for instance, to a CPU
failure of one or more IO devices).
Communication via a PROFINET interface port can in principle be performed.
For a CPU that is operated as an I device, the BF LED flashes until one controller has
correctly established communication to this device.
To correct or avoid error: See the table below
If it does not light No error at the PROFINET interface
up
1 The BF-PN LED only lights up if a PROFINET IO system is configured. If the BF-PN
LEDs do not light up because the PROFINET IO system is not to be used, for example,
then the PROFINET IO system must be separated or deleted from the configuration in
HW Config.

Remedy for errors at the PROFINET interface - BF-PN LED lights up
Table 11- 7 BF-PN LED lights up
Possible error Example response of the IM Possible remedies

151-8 PN/DP CPU interface
module
 Bus fault (no cable connection to a Call OB 86 (if the IM 151-8  Check the bus cable for a short-circuit or
subnet/switch) PN/DP CPU interface break.
 Wrong transmission speed module is in RUN mode and  Check whether the IM 151-8 PN/DP CPU
 Full duplex mode is not activated. has previously run IO interface module is connected to a switch and
devices that have now not to a hub.
failed).  Check that data are being transmitted at 100
The IM 151-8 PN/DP CPU Mbps and in full duplex mode.
interface module STOPs if  Evaluate the diagnostics. Edit the
OB 86 is not loaded. configuration.
 If a DP master module is connected to your IM
151-8 PN/DP CPU interface module, then you
can read out the diagnostics via the DP master
interface. Edit the configuration.
Remedy for errors at the PROFINET interface of an IO controller - BF-PN LED flashes
Table 11- 8 BF-PN LED flashes with a PROFINET IO controller
Possible error Example response of the IM Possible remedies

151-8 PN/DP CPU interface
module
 Failure of a connected IO device Call OB 86 (if the IM 151-8  Check whether the Ethernet cable is
 If at least one of the assigned IO PN/DP CPU interface connected to the IM 151-8 PN/DP CPU
devices cannot be assigned an module is in RUN mode and interface module and that the bus is not
address. before occurrence of the interrupted.
 Bad engineering configuration error had previously run  Wait until the IM 151-8 PN/DP CPU interface
PROFINET IO devices that module has started up. If the LED does not
have now failed). stop flashing, check the IO devices or evaluate
their diagnostic information.
The IM 151-8 PN/DP CPU
interface module STOPs if  Check whether the configured device name
matches its actually assigned name.
OB 86 is not loaded.
 Check whether the connected IO devices have
different device names and IP addresses.

Remedy with errors on the PROFINET interface of an I device - BF2/ BF3 LED flashes
Table 11- 9 BF2/ BF3 LED flashes on an I device
Possible error Reaction based on the Possible remedies

example of a CPU
When configured as an I device with no lower-level IO system:
 Wrong IP address Call OB 86 if the IM 151-8  Check that the Ethernet cable is correctly
 Bad engineering configuration PN/DP CPU interface connected.
 Wrong parameter assignment module is in RUN mode and  Check whether the Ethernet cable to the
the user data controller is interrupted.
 IO controller not found / switched
communication to the  Check the configuration and parameter
off, but there is an Ethernet
higher-level IO controller(s) assignment, especially the IP addresses and
connection.
has failed. device names.
 In Shared I device mode: If all
configured IO controllers are The IM 151-8 PN/DP CPU  Switch on the IO controller.
unavailable or are switched off, but interface module STOPs if  Check whether the expected configuration
the Ethernet connection is up (link OB 86 is not loaded. matches the actual configuration.
to a neighboring device is active). When the  Check the physical communication connection
 Bad or no device name IM151-8 PN/DP CPU is for interruptions.
 The response monitoring time has being used as a shared I  Wait until the IM 151-8 PN/DP CPU has
expired. device, the BF does not started up. If the LED still persists in flashing,
flash unless the check the IO controller(s) and evaluate the
communication to both the diagnostics buffer of the IO controller(s) and
higher-level controllers has the I device.
failed.
In addition, when configured as an I device with a lower-level IO system:
 Failure of a connected IO device Call OB 86 (if the IM 151-8  Check that the Ethernet cable is connected to
 At least one of the assigned IO PN/DP CPU interface the module or whether the bus is interrupted.
devices cannot be addressed module is in RUN mode and  Wait until the CPU has completed its startup. If
 Bad engineering configuration before occurrence of the the LED persists in flashing, check the IO
error had previously run devices or evaluate their diagnostic
PNIO devices that have now information.
failed).  Check whether the configured device name
The IM 151-8 PN/DP CPU matches its actually assigned name.
interface module STOPs if  Check whether the connected IO devices have
OB 86 is not loaded. different device names and IP addresses.

11.5.6 Status and Error Indicators: PROFINET IO Devices
Troubleshooting errors on the PROFINET interface of an IO device and in mixed mode with IO
controller/I device - BF LED flashes
Table 11- 10 BF LED flashes on a PROFINET IO device
Possible problem Possible remedies

 The IP address is incorrect  Check that the Ethernet cable is correctly connected.
 Bad engineering configuration  Check whether the Ethernet cable to the controller is
 Bad parameter assignment interrupted.
 IO controller not found / switched off, but there is an  Check the configuration data and parameters.
Ethernet connection.  On the IO device: Switch on the IO controller.
 In Shared I-Device mode: All configured IO controllers  Check whether the expected configuration matches the
are not available or are switched off, but the Ethernet actual configuration.
connection is up (link to a neighboring device is active)  Check the physical communication connection for
 Incorrect or missing device name interruptions.
 The response monitoring time has expired.
 In IRT mode with "high performance": Connection to the
sync master is down
Tip: Identification of the PROFINET device in the cubicle

When they are first commissioned, PROFINET IO devices must be assigned a device name.
In STEP 7/HW Config, you can make the LINK LED of a named PROFINET IO device flash
using Target system > Ethernet > Assign Device Name . This allows you, for example, to
clearly identify a PROFINET IO device among several identical devices in a control cabinet.
Maintenance LED
This LED indicates that a maintenance request is pending, e.g., loss of synchronization of
the own station.
For additional information, refer to the STEP 7 online help.

11.5.7 Status and error displays of the DP master module
Explanation of the BF LED
Table 11- 11 BF LED
Meaning
IM 151-8 PN/DP CPU DP master
module
SF ON BF
On On On/flashes PROFIBUS DP interface error.
To correct or avoid error: See the tables below
Table 11- 12 BF LED on the DP master module lights up
Possible error Response of the IM 151-8 PN/DP Possible remedies

CPU interface module
 Bus fault (hardware fault). Call of OB 86 (if the IM 151-8 PN/DP  Check to see if the connector for
 Slave not available or switched off CPU interface module is in RUN and PROFIBUS DP is inserted
has previously run DP slaves that are properly.
 Short-circuit on the bus
now failing).  Check the bus cable for a short-
The IM 151-8 PN/DP CPU interface circuit or break.
module STOPs if OB 86 is not  Analyze the diagnostic data. Edit
loaded. the configuration.
Table 11- 13 BF LED on the DP master module flashes
Possible error Response of the IM 151-8 PN/DP Possible remedies

CPU interface module
The IM 151-8 PN/DP CPU interface Call of OB 86 (if the IM 151-8 PN/DP  Check whether the bus cable on the
module is the DP master: CPU interface module is in RUN and DP master module is connected to
connected DP slaves have since the IM 151-8 PN/DP CPU interface
 Failure of a connected station
failed). module and that the bus is not
 At least one of the configured slaves interrupted.
cannot be accessed. The IM 151-8 PN/DP CPU interface
module STOPs if OB 86 is not  Wait until the IM 151-8 PN/DP CPU
 Incorrect configuration interface module has started up. If
(configured address areas of the loaded.
the LED does not stop flashing,
actual structure do not correspond check the DP slaves or evaluate the
with the set structure.) diagnostic data for the DP slaves.
 Check the settings for the
configured address areas for the
DP master.
Reference
manual.

11.6 Diagnostics on the PROFIBUS DP
11.6.1 Diagnostics of the IM 151-8 PN/DP CPU interface module as a DP master
Evaluate diagnostics in the user program

The figure below illustrates the procedure for evaluating diagnostics data in the user
program.
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Diagnostics addresses for DP masters and DP slaves

With IM 151-8 PN/DP CPU interface module you assign diagnostics addresses for the
PROFIBUS DP. Verify in your configuration that the DP diagnostics addresses are assigned
once to the DP master and once to the DP slave.
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Explanation of the DP master configuration Explanation of the DP slave configuration

When you configure the DP master, assign two When you configure the DP slave, you also
different diagnostics addresses for an intelligent assign it a diagnostics address (in the associated
DP slave, that is, one diagnostics address for slot DP slave project).
0, and one for slot 2. These two addresses This diagnostics address is referred to as
perform the following functions: assigned to the DP slave below.
 The diagnostics address for slot 0 reports in This diagnostics addresses is used by the DP
the master all events relating to the entire slave to obtain information about the state of the
slave (station representative), for example,
DP master, or bus interruptions.
node failure.
 The diagnostics address for slot 2 is used to
report events concerning this slot. For
example, if the IM 151-7 CPU is acting as an
intelligent slave, it returns the diagnostic
interrupts for operating state transitions.
These diagnostics addresses are referred to as
assigned to the DP master below.
These diagnostics addresses are used by the DP
master to obtain information about the state of
the DP slave, or about bus interruptions.

Event detection
The table below shows how the IM 151-8 PN/DP CPU interface module acting as a DP
master recognizes operating mode transitions of a CPU acting as a DP slave or any
interruption of the data exchange.
Table 11- 14 Event recognition of the IM 151-8 PN/DP CPU interface module as a DP master
Event What happens in the DP master?

Bus interruption (short  Call of OB 86 with the message Station failure (incoming event;
circuit, connector diagnostics address of Slot 0 of the DP slave that is assigned to the
removed) DP master)
 With I/O access: call of OB 122 (I/O access error)
DP slave: RUN → STOP  Call of OB 82 with the message Module error
(incoming event; diagnostics address of Slot 2 of the DP slave that is
assigned to the DP master; Variable OB82_MDL_STOP=1)
DP slave: STOP → RUN  Call of OB 82 with the message Module OK.
(outgoing event; diagnostics address of Slot 2 of the DP slave that is
assigned to the DP master; Variable OB82_MDL_STOP=0)
Evaluation in the user program

The table below shows how you can, for example, evaluate RUN to STOP transitions of the
DP slave in the DP master.
Table 11- 15 Evaluating RUN to STOP transitions of the DP slave in the DP master
In the DP master In the DP slave (e.g. CPU 31x-2 DP)

Diagnostics addresses: (Example) Diagnostics addresses: (Example)
Master diagnostics address =1023 Slave diagnostics address =422
Slave diagnostics address =1022 Master diagnostics address = irrelevant
(Slot 0 of slave)
(Diagnostic) address for "Slot 2"=1021
(Slot 2 of slave)
The IM 151-8 PN/DP CPU interface module calls CPU: RUN -> STOP
OB 82 with the following information: The CPU generates a DP slave diagnostic
 OB82_MDL_ADDR:=1021 message frame
 OB82_EV_CLASS:=B#16#39 (incoming event)
 OB82_MDL_DEFECT:=module fault
Tip: This information is also available in the
diagnostics buffer of the IM 151-8 PN/DP CPU
interface module.
In the user program you should also include
SFC 13 "DPNRM_DG" for reading DP slave
diagnostic data.

11.7 Defective configuration statuses of the ET 200S
11.7 Defective configuration statuses of the ET 200S
Fault indications in the diagnostics buffer

Defective configuration statuses of the ET 200S distributed I/O system are entered in the
diagnostics buffer.
Error type Error location Cause of error Remedy

1 04 to 66 (slot) Communication interruption Check the configuration
If necessary 67 Displays the first slot at which no I/O of the ET 200S.
(bus terminator module is recognized.
module)  Missing I/O module during POWER
ON or several I/O modules are missing
during operation.
 Interruptions at the rear panel bus
 Short-circuit at the rear panel bus ("04"
is output as the slot).
 Termination module missing.
If the termination module is missing,
the number of the inserted I/O
modules + 1 are output.
11.8 Failure of the load voltage from the power module
Load voltage failure

Should the load voltage of the power module fail, the electronic modules will behave as
follows:
● No output for output modules.
● Substitute values are generated for input modules.
Note
Electronic modules that are re-parameterized during operation must be parameterized yet
again once the load voltage has been restored to the power module.

11.9 Basics of diagnostics in PROFINET IO
11.9 Basics of diagnostics in PROFINET IO
Totally Integrated Diagnostics Concept

PROFINET IO supports you with an integrated diagnostics concept. The diagnostics concept
with PROFINET IO is similar to that of PROFIBUS DP.
Below, we will explain the basics of the concept.
Basic concept
Each individual or several errors occurring simultaneously are transferred from the IO device
to the IO controller.
If you require the full status of the IO device including any pending errors, you can also read
the status directly from the IO device.
Extended maintenance concept

PROFINET devices support the comprehensive diagnostics and maintenance concept
described in the IEC 61158-6-10 standard.
The aim of the maintenance concept is the early detection and elimination of potential faults -
before they cause a production failure.
The PROFINET devices / modules / submodules can therefore also display information for
preventive maintenance, in addition to the status information "OK" and "Faulty".
Maintenance information
Maintenance information describes the urgency with which maintenance is needed. The
concept distinguishes between two levels of maintenance information:
Maintenance information Symbol in STEP 7 MT LED status Example

Maintenance requirement green wrench Off The attenuation on a fiber-optic conductor
(maintenance required): is becoming too high. Although operation is
Maintenance is still possible, the transmission link may fail
recommended completely in the near future.
Maintenance request yellow wrench Yellow Failure of the synchronization master in a
(maintenance demanded): synchronization domain for the IRT
Maintenance alarm operation of a PNIO system
The times at which maintenance information is generated are defined individually for each
wear parameter (e.g. attenuation on a fiber optic cable).
Information on Diagnostics in PROFINET IO

For additional information, refer to the STEP 7 Online Help, the From PROFIBUS DP to
PROFINET IO programming manual and the PROFINET System Description.
The system status lists and data records for PROFINET diagnostics are described in the
programming manual.

Technical data 12
12.1 General technical data
Reference
The IM 151-8 PN/DP CPU interface module conforms to the standards and test values that
apply to the ET 200S distributed I/O device. Detailed information on the general technical
specifications can be found in the ET 200S Distributed I/O Device Operating Instructions.
12.2 IM 151-8 PN/DP CPU interface module
12.2.1 IM 151-8 PN/DP CPU with DP master module block diagram

The following figure shows the block diagram for the IM 151-8 PN/DP CPU interface module
with the optional DP master module.
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Figure 12-1 IM 151-8 PN/DP CPU interface module with DP master module block diagram

Technical data
12.2.2 IM 151-8 PN/DP CPU technical specifications
Table 12- 1 Technical specifications of the IM 151-8 PN/DP CPU interface module
IM 151-8 PN/DP CPU and product version
Order number 6ES7151-8AB01-0AB0
 Hardware version 01
 Firmware version V 3.2.0
 Associated programming package STEP 7 V5.5 and higher
Memory
Work memory
 Work memory 192 kB
 Expandable No
 Capacity of the retentive memory for retentive 64 KB
data blocks
Load memory
 Pluggable (MMC) Yes
 Pluggable (MMC), max. 8 MB
Buffering Guaranteed by SIMATIC MMC (maintenance-
free)
Data retention on the SIMATIC Micro Memory At least 10 years
Card (after final programming)
Execution times
Processing times of
 Bit operations 0.06 µs
 Word instructions 0.12 µs
 Fixed-point arithmetic 0.16 µs
 Floating-point arithmetic 0.59 µs
Timers / counters and their retentivity
S7 counters 256
 Retentive memory Configurable
 Default From C0 to C7
 Counting range 0 to 999
IEC Counters Yes
 Type SFB
 Number Unlimited
(limited only by work memory)
S7 timers 256
 Retentive memory Configurable
 Default Not retentive
 Timer range 10 ms to 9990 s

Technical data
IEC timers Yes
 Type SFB
 Number Unlimited
(limited only by work memory)
Data areas and their retentive address areas
Bit memory
 Number, max. 256 Byte
 Retentivity, configurable Yes, from MB0 to MB255
 Retentivity, preset From MB0 to MB15
Number of clock memories 8 (1 memory byte)
Local data per priority class, max. 32 kB per runtime level / 2 kB per block
Blocks
Total number of blocks 1024 (DBs, FCs, FBs)
The maximum number of blocks that can be
loaded may be reduced if you are using another
SIMATIC Micro Memory Card.
OBs See instruction list
 Size, max. 64 KB
 Number of free-cycle OBs 1 (OB 1)
 Number of time-of-day interrupt OBs 1 (OB 10)
 Number of time-delay interrupt OBs 2 (OB 20, 21)
 Number of cyclic interrupt OBs 4 (OB 32, OB 33, OB 34, OB 35)
 Number of hardware interrupt OBs 1 (OB 40)
 Number of DPV1 interrupt OBs 3 (OB 55, 56, 57)
 Number of isochronous interrupt OBs 1 (OB 61); only for PROFINET IO
 Number of asynchronous error OBs 6 (OB 80, 82, 83, 85, 86, 87)
(OB 83 only for centralized I/O and PN IO)
 Number of startup OBs 1 (OB 100)
 Number of synchronous error interrupt OBs 2 (OB 121, 122)
Nesting depth
 Per priority class 16
 Additional within an error OB 4
FBs See instruction list
 Number, max. 1024
(in the number range 0 to 7999)
 Size 64 kB
FCs See instruction list
 Number, max. 1024
(in the number range 0 to 7999)
 Size 64 kB
Data blocks

Technical data
 Number, max. 1024 (in the number range 1 to 16000)
 Size, max. 64 kB
 Non-retain support (configurable retentive Yes
address areas)
Address areas (I/O)
Total I/O address area
 Inputs, freely adressable 2048 bytes
 Outputs, freely adressable 2048 bytes
 Of which distributed
– Inputs, freely adressable 2048 bytes
– Outputs, freely adressable 2048 bytes
Process I/O image

 Inputs, adjustable 2048
 Outputs, adjustable 2048
 Inputs, preset 128
 Outputs, preset 128
Process image partitions
 Number of process image partitions 1
 Volume of user data in the process image 1600 bytes
partition with an isochronous PROFINET IO,
max.
Digital channels
 Inputs 16336
 Outputs 16336
 Inputs, central 496
 Outputs, central 496
Analog channels
 Inputs 1021
 Outputs 1021
 Inputs, central 124
 Outputs, central 124
Removal
Mounting rail 1
I/O module for each ET 200S Max. 63
Station width ≤ 1 m or < 2 m
Current carrying capacity per load group (power Max. 10 A
module)
Time-of-day
Clock
 Hardware clock (real-time clock) Yes

Technical data
 Factory setting DT#1994-01-01-00:00:00
 Buffered, can be synchronized Yes
 Buffered period Typically 6 weeks
(at an ambient temperature of 40 °C)
 Behavior of the clock on expiration of the The clock keeps running, continuing at the time-
buffered period of-day it had when power was switched off.
 Behavior of the real-time clock after POWER The clock continues running after POWER OFF.
ON
 Deviation per day typ. 2 s, max. 10 s
Operating hours counter
 Number 1
 Number 0
 Value range 0 to 2 31 hours
(using the SFC 101)
 Granularity 1 hour
 Retentive Yes; must be manually restarted after every
restart
Time synchronization
 Supported Yes
 on PROFINET Via NTP (only as time-of-day client)
 on PROFIBUS DP Time-of-day master / time-of-day slave (with DP
master module)
S7 message functions
Number of stations that can be logged on for 12 (depends on the number of connections
signaling functions configured for programming device / OP
communication)
Process diagnostics messages
 Supported Yes
 Simultaneously enabled interrupt S blocks, 300
max.
Test and startup functions
Status/control
 Monitor/modify variable Yes
 Variables Inputs, outputs, memory bits, DBs, timers,
counters
 Maximum number of variables 30
 Number of variables, of those status variables, 30
max.
 Number of variables, of those modify variables, 14
max.
Force
 Force Yes
 Forcing, variables Inputs/Outputs

Technical data
 Maximum number of variables 10
Block status Yes; (max. 2 blocks simultaneously)
Single-step Yes
Number of breakpoints 4
Diagnostics buffer
 Yes Yes
 Maximum number of entries 500
 Adjustable No
 of which are power-failure-proof The last 100 entries are retained.
 Maximum number of entries that can be read in 499
RUN Yes (from 10 to 499)
– Adjustable 10
– Default
Service data can be read Yes
Monitoring functions
Status LEDs Yes
Communication functions
PD/OP communication Yes
Prioritized OCM communication
 Supported No
Routing Yes (with DP master module)
 Connections, max. 4
Data set routing Yes (with DP master module)
S7 basic communication
 Supported Yes (I blocks only)
 User data per job, max. 76 Byte
 User data per job (consistent), max. 76 bytes
S7 communication
 As server Yes
 As client Yes (via integrated PN interface and loadable
FBs)
 User data per job, max. See STEP 7 Online Help, common parameters
 User data per job (consistent), max. of SFBs/FBs and SFCs/FCs for S7
communication)
 Maximum number of configurable connections 10
 Maximum total number of instances 32
Web server
 Supported Yes
 User-defined pages Yes
 Number of web clients 5
Open IE communication

Technical data
Open IE communication, supported Yes
Local port numbers used by the system 0, 20, 21, 23, 25, 80, 102, 135, 161, 8080,
34962, 34963, 34964, 65532, 65533, 65534,
65535
Number of connections / access points, total 8
TCP/IP Yes (via integrated PROFINET interface and
loadable FBs)
 Maximum number of connections 8
 Data length for connection type 01H, max. 1460 bytes
 Data length for connection type 11H, max. 32768 bytes
 Several passive connections per port, Yes
supported (multi-port)
ISO on TCP (RFC1006) Yes (via integrated PROFINET interface and
loadable FBs)
 Data length, max. 32768 bytes
UDP Yes (via integrated PROFINET interface and
loadable FBs)
 Data length, max. 1472 bytes
iPAR server
iPAR server, supported Yes
Number of connections
 Total 12
Suitable for PD communication 11
 PD communication, reserved 1
 PD communication, configurable, min. 1
 PD communication, configurable, max. 11
Suitable for OP communication 11
 OP communication, reserved 1
 OP communication, configurable, min. 1
 OP communication, configurable, max. 11
Suitable for S7 basic communication 10
 S7 basic communication, reserved (default) 0
 S7 basic communication, configurable, min. 0
 S7 basic communication, configurable, max. 10
PROFINET CBA
Acyclic transmission Yes
Cyclic transmission Yes
PROFINET CBA (with reference setting for communication load)
Reference setting for CPU communication 50%

Technical data
Number of remote interconnecting partners 32
Number of master/slave functions 30
Total of all master/slave connections 1000
Data length of all incoming 4000 bytes
master/slave connections, max.
Data length of all outgoing 4000 bytes
master/slave connections, max.
Number of device-internal and PROFIBUS 500
interconnections
Data length of the device-internal and PROFIBUS 4000 bytes
interconnections, max.
Data length per connection, max. 1400 bytes
Remote interconnections with acyclical
transmission
 Scan rate: Scan interval, min. 500 ms
 Number of incoming interconnections 100
 Number of outgoing interconnections 100
 Data length of all incoming interconnections, 2000 bytes
max.
 Data length of all outgoing interconnections, 2000 bytes
max.
 Data length per connection, (acyclic 1400 bytes
interconnections), max.
Remote interconnections with cyclical transmission
 Transmission frequency: Minimum transmission 1 ms
interval
 Number of incoming interconnections 200
 Number of outgoing interconnections 200
 Data length of all incoming interconnections, 2000 bytes
max.
 Data length of all outgoing interconnections, 2000 bytes
max.
 Data length per connection, (acyclic 450 bytes
interconnections), max.
HMI variables via PROFINET (acyclic)
 Update HMI variables 500 ms
 Number of stations that can be logged on for 2x PN OPC / 1x iMAP
HMI variables (PN OPC/iMAP)
 Number of HMI variables 200
 Data length of all HMI variables, max. 2000 bytes
PROFIBUS proxy functionality
 supported Yes
 Number of coupled PROFIBUS devices 16

Technical data
 Data length per connection, max. 240 bytes (slave dependent)
1st interface
Port designation X1
Type of interface PROFINET
Physics RJ45 Ethernet
Isolated Yes
Integrated switch Yes
Number of ports 3
Automatic determination of transmission rate Yes (10/100 Mbps)
Transmission rate, max. 100 Mbps full duplex
Autonegotiation Yes
Autocrossing Yes
Media redundancy Yes
 Switch-over time in the case of cable breakage, 200 ms (PROFINET MRP)
typ.
 Number of nodes in the ring, max. 50
Change of the IP address to runtime, supported Yes
Keep Alive function, supported Yes
Functionality
MPI No
PROFIBUS DP master No
PROFIBUS DP slave No
PROFINET IO Controller Yes; even in combination with IO device
functionality
PROFINET IO device Yes; even in combination with IO controller
functionality
PROFINET CBA Yes
Open IE communication Yes; via TCP/IP, ISO on TCP, UDP
Web server Yes
Point-to-point communication No
PROFINET IO controller
Services
Routing Yes
 S7 routing Yes (with inserted DP master module)
 Data set routing Yes (with DP master module inserted, for field
devices on the PROFIBUS DP)
S7 communication Yes; with loadable FBs, max. configurable
connections: 10, max. number of instances: 32
Number of integrated PROFINET IO controllers 1
RT, supported Yes
IRT supported Yes

Technical data
Maximum number of connectable I/O devices 128
Maximum number of connectable I/O devices for 128
RT
 of which in line, max. 128
Number of IO devices with IRT and the "High 128
Flexibility" option
Maximum number of IO devices with IRT and the 64
"High Performance" option
Shared device, supported Yes
Isochronous mode Yes (OB 61); only for PROFINET IO
Prioritized start-up, supported Yes
 Maximum number of I/O devices 32
Activating/deactivating PROFINET IO devices Yes
 Max. number of I/O devices that can be 8
enabled / disabled simultaneously
Hot-swapping of I/O devices (partner ports), Yes
supported
 Maximum number of I/O devices per tool 8
Device replacement without removable medium Yes
Address area
Inputs, max. 2048 bytes
Outputs, max. 2048 bytes
Max. user data consistency with PROFINET IO 1024 bytes
Send cycles 250 μs, 500 μs, 1 ms;
2 ms, 4 ms (not for IRT with the "High Flexibility"
option)
Update Time
Update times The minimum update time is also determined by
the communication set for PROFINET IO, by the
number of IO Devices used, and by the volume
configured for user data.
For RT
 for send clock of 250 μs  250 µs to 128 ms
 for send clock of 1 ms  1 ms to 512 ms
For IRT with the "high flexibility" option

Technical data
For IRT with the "high performance" option
For IRT with the "high performance" option and Update time = set "non-whole number" send
parameter assignment of "non-whole number" clock (in multiples of 125 µs: 375 μs, 625 μs …
send clocks 3.875 ms)
PROFINET I device
Services
S7 routing Yes
S7 communication Yes; with loadable FBs, max. configurable
connections: 10, max. number of instances 32
RT, supported Yes
IRT supported Yes
Shared Device Yes
 Max. number of IO controllers for a Shared 2
Device
Isochronous mode No
PROFIenergy, supported With SFB 73 / 74 prepared for loadable
PROFIenergy standard FB for I device
Application transfer areas Yes
I/O transfer areas Yes
Transfer memory
Inputs, max. 1440 bytes; per controller for a Shared Device
Outputs, max. 1440 bytes; per controller for a Shared Device
Submodules
 Number, max. 64
 User data per submodule, max. 1024 bytes
2nd interface
Port designation X2;on the DP master module
Type of interface RS 485, integrated interface on the DP master
module
Physics RS 485
Isolated Yes
Max. interface power supply No
(15 V DC to 30 V)
Connection 9-pin sub-D socket
Functionality
MPI No
DP master Yes

Technical data
DP slave No
PROFINET IO controller No
PROFINET IO device No
PROFINET CBA No
Open IE communication No
Web server No
Point-to-point link No
DP master
Services
Routing Yes
Data set routing Yes; (to field devices on the PROFIBUS DP)
Global data communication
 Supported No
S7 communication
As server Yes (one-sided configured connection)
As client No
Transmission rate, max. Up to 12 Mbaud
Support for constant bus cycle time Yes
Isochronous mode No
Enable/disable DP slaves Yes
 Max. number of DP slaves that can be enabled 8
/ disabled simultaneously
SYNC/FREEZE Yes
Direct data exchange Yes
DPV1 Yes
Number of DP slaves, max. 32
Address area
 Inputs, max. 2048 bytes
 Outputs, max. 2048 bytes
User data per DP slave
 Inputs, max. 244 bytes
 Outputs, max. 244 bytes
Programming
Programming language STEP 7 V5.5 and higher
 LAD Yes
 FBD Yes
 STL Yes
 SCL Yes
 CFC Yes
 GRAPH Yes

Technical data
 HiGraph Yes
Instruction set See instruction list
Nesting levels 8
System functions (SFC) See instruction list
System function blocks (SFB) See instruction list
User program protection / password protection Yes
Encryption of blocks Yes; with S7 Block Privacy
Mounting dimensions W x H x D (mm) 120 x 119.5 x 75
Weight ca. 320 g
Voltages, currents, electrical potentials
Rated supply voltage for the electronic 24 VDC
components 1L+
 Permissible range 20.4 V to 28.8 V
 Reverse polarity protection Yes; against destruction
 Short-circuit protection Yes
 Power failure buffering 5 ms
Current consumption from rated supply voltage
1L+
 IM 151-8 PN/DP CPU Typ. 352 mA at 20 V; 294 mA at 24 V; 246 mA at
29 V
 IM151-8 PN/DP CPU + DP master module Typ. 426 mA at 20 V; 355 mA at 24 V; 296 mA at
29 V
 Power supply for the ET 200S backplane bus Max. 700 mA
Inrush current Typically 1.8 A
I2 t Typically 0.13 A2s
External fusing of power supply lines
(recommended)
 Electronic / encoder supply 1L+ 24 VDC / 16 A circuit-breaker with type B or C
tripping characteristic
Note:
A 24 VDC/16A circuit-breaker with type B
tripping characteristic trips before the equipment
fuse is tripped.
A 24 VDC/16A circuit-breaker with type C
tripping characteristic trips after the equipment
fuse is tripped.
Power loss Typically 5.5 W
Insulation tested with 500 VDC
Galvanic isolation
 between the backplane bus and supply No
voltages 1L+
 between PROFIBUS / PROFINET and power Yes
supplies 1L+

Technical data
12.3 DP master module
 between the electronics and supply voltage No
1L+
Maximum potential difference 75 VDC, 60 VAC
Status, interrupts, diagnostics
Interrupts Yes
Diagnostics function Yes
Group errors Red "SF" LED
Bus monitoring PROFINET Red "BF-PN" LED
Maintenance information Yellow "MT" LED
Monitoring of the supply voltage for the electronic Green LED "ON"
components 1L+
Existing connection to PROFINET Green LED "P1 - LINK", "P2 - LINK" and
"P3 - LINK"
12.3 DP master module
12.3.1 Technical specifications - DP master module
Table 12- 2 Technical specifications of the DP master module
Removal
DP master module
 Position At the right alongside IM 151-8 PN/DP CPU
 Number for each IM 151-8 PN/DP CPU 1
Dimensions
Mounting dimensions W x H x D (mm) 35 x 119.5 x 75
Weight approx. 100 g
Status, interrupts, diagnostics
PROFIBUS DP bus monitoring Red "BF" LED

Appendix A
A.1 Order numbers
A.1.1 Module order numbers
Table A- 1 IM 151-8 PN/DP CPU order numbers
Designation Order number

IM 151-8 PN/DP CPU interface module with terminating module, 6ES7151-8AB01-0AB0
1 unit
* The SIMATIC Micro Memory Card is not supplied as standard.
DP master module
Table A- 2 DP master module order numbers

DP master module, 1 unit 6ES7138-4HA00-0AB0

Appendix
A.1 Order numbers
A.1.2 Order numbers of accessories
IM 151-8 PN/DP CPU interface module accessories
Table A- 3 IM 151-8 PN/DP CPU accessories order numbers

SIMATIC Micro Memory Card 64k 6ES7953-8LF30-0AA0
SIMATIC Micro Memory Card 128k 6ES7953-8LG30-0AA0
SIMATIC Micro Memory Card 512k 6ES7953-8LJ30-0AA0
SIMATIC Micro Memory Card 2M 6ES7953-8LL30-0AA0
SIMATIC Micro Memory Card 4M 6ES7953-8LM30-0AA0
SIMATIC Micro Memory Card 8M (suitable for an FW update) 6ES7953-8LP30-0AA0
Label sheets DIN A4, 10 units
 beige 6ES7193-4BA00-0AA0
 Yellow 6ES7193-4BB00-0AA0
 red 6ES7193-4BD00-0AA0
 petrol 6ES7193-4BH00-0AA0
Connectors and cables
Table A- 4 Connectors and cables order numbers

PROFINET
PROFINET RJ45 connector with FastConnect connection system,
90° cable outlet
 1 per pack, 1 pack 6GK1901-1BB20-2AA0
 10 per pack, 1 pack 6GK1901-1BB20-2AB0
PROFINET FC cable
Sold by meter, min. quantity 20 m
Delivery unit max. 1000 m, 1 m
 FC TP standard cable 6XV1840-2AH10
 FC TP trailing cable (for cable carriers) 6XV1840-3AH10
 FC TP marine cable 6XV1840-4AH10
PROFINET FastConnect stripping tool 6GK1901-1GA00
PROFIBUS
PROFINET bus connector (12 Mbit/s)
with FastConnect connection system, 90° cable outlet
 without PD connection socket 6ES7972-0BA50-0XA0
 with PD connection socket 6ES7972-0BB50-0XA0

Appendix
A.2 Dimension drawings

PROFIBUS FC cable
Sold by meter, min. ordering quantity 20 m
Delivery unit max. 1000 m, 1 m
 FC Standard Cable 6XV1830-0EH10
 FC Trailing Cable (for cable carriers) 6XV1830-3EH10
 FC Food Cable (PE sheath) 6XV1830-0GH10
 FC Food Cable (PUR sheath) 6XV1830-0JH10
PROFIBUS FastConnect stripping tool 6GK1905-6AA00
A.2 Dimension drawings
A.2.1 IM 151-8 PN/DP CPU interface module

5DLOVXSSRUW
Figure A-1 IM 151-8 PN/DP CPU interface module dimensional diagram

Appendix
A.3 Cycle and response times
A.2.2 DP master module
DP master module
5DLOVXSSRUW
Figure A-2 DP master module dimensional diagram
A.3.1 Overview
Overview
This section contains detailed information about the following topics:
● Cycle time
● Response time
● Interrupt response time
Reference: Cycle time

You can view the cycle time of your user program on the programming device. For additional
information, refer to the STEP 7 Online Help or to the Configuring Hardware and
Connections in STEP 7 manual.

Appendix
Reference: Execution time

Execution times can be found in the S7-300 Instruction List. The instruction list contains the
execution times in table form for all
● STEP 7 instructions that can be processed by the IM 151-8 PN/DP CPU interface module
● SFCs / SFBs integrated in the IM 151-8 PN/DP CPU interface module,
● The IEC functions that can be called in STEP 7.
A.3.2 Cycle time
A.3.2.1 Overview: Cycle time
Introduction
This section explains what we mean by the term "cycle time", what it consists of, and how
you can calculate it.
Meaning of the term cycle time

The cycle time represents the time that an operating system needs for one program pass,
i.e. one OB 1 cycle, including all program sections and system activities interrupting this
cycle. This time is monitored.
Time slice model

Cyclic program processing, and therefore user program execution, is based on time shares.
To clarify these processes, let us assume that every time share has a length of precisely
1 ms.
Process image
During cyclic program processing, the IM 151-8 PN/DP CPU interface module requires a
consistent image of the process signal. To ensure this, the process signals are read / written
prior to program execution. The IM 151-8 PN/DP CPU interface module then does not
address input (I) and output (Q) operand areas directly at the I/O modules, but rather
accesses the system memory area containing the I/O process image.

Appendix
Sequence of cyclic program processing

The table and figure below show the phases in cyclic program processing.
Table A- 5 Cyclic program processing
Step Sequence
1 The operating system initiates cycle time monitoring.
2 The IM 151-8 PN/DP CPU interface module writes the values from the process output
image to the output modules.
3 The IM 151-8 PN/DP CPU interface module reads the status at the inputs of the input
modules and then updates the process input image.
4 The IM 151-8 PN/DP CPU interface module processes the user program in time slices
and executes the operations specified in the program.
5 At the end of a cycle, the operating system executes queued tasks, for example, loading
and deleting blocks.
6 The IM 151-8 PN/DP CPU interface module then returns to the start of the cycle, and
restarts cycle time monitoring.

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In contrast to S7-400 CPUs, the IM 151-8 PN/DP CPU interface module only accesses data
with an OP / TP (monitor and modify functions) at the cycle control point (for data
consistency, see Technical specifications). Processing of the user program is not interrupted
by the monitor and modify functions.

Appendix
Extending the cycle time

Always make allowances for the extension of the cycle time of a user program due to:
● Time-based interrupt processing
● Process interrupt processing
● Diagnostics and error processing
● Processing isochronic interrupts
● Communication with programming devices (PGs), operator panels (OPs) and via
connected CPs (e.g. Ethernet or PROFIBUS DP)
● Testing and commissioning such as, e.g. status/controlling of variables or block status
functions.
● Transfer and deletion of blocks, compressing user program memory
● Write/read access to the SIMATIC Micro Memory Card using SFC 82 to 84 in the user
program
● S7 communication via the PROFINET interface.
● PROFINET CBA communication via the PROFINET interface (system load, SFC call,
updating at the cycle control point)
● PROFINET IO communication via PROFINET interface (system load)

Appendix
A.3.2.2 Calculating the cycle time
Introduction
The cycle time is derived from the sum of the following influencing factors.
Process image update

The table below shows the times that an IM 151-8 PN/DP CPU interface module needs to
update the process image (process image transfer time). The specified times may be
extended as a result of interrupts or IM 151-8 PN/DP CPU interface module communication.
The process image transfer time is calculated as follows:
Table A- 6 Formula for calculating the typical transfer time for the process image (PI)
The transfer time of the process image is calculated as follows:

Base load K + Number of bytes in the PI for ET 200S I/Os (A)
+ Number of words in the PI via PROFINET (P)
+ Number of words in the PI via PROFIBUS DP (D)
= Transfer time for the process image
Table A- 7 Data for calculating the process image (PI) transfer time
Constant Components IM 151-8 PN/DP CPU

C Base load 140 µs
A per byte in the PO for centralized ET 200S I/Os 60 µs
P per WORD in the PROFINET area for the 0.5 µs
(PROFINET only) integrated PROFINET interface
D per word in the DP area for the DP interface 0.5 µs
(PROFIBUS DP only) integrated in the DP master
Extending the user program processing time

In addition to actually working through the user program, your IM 151-8 PN/DP CPU
interface module´s operating system also runs a number of processes in parallel, such as
timer management for the core operating system. These processes extend the processing
time of the user program by up to 10%.

Appendix
Operating system processing time at the scan cycle check point

The table below shows the operating system processing time at the cycle control point of the
IM 151-8 PN/DP CPU interface module. This time applies without:
● Testing and commissioning routines, e.g. status/controlling of variables or block status
functions
● Transfer and deletion of blocks, compressing user program memory
● Communication
● Writing, reading of the SIMATIC Micro Memory Card with SFC 82 to 84
Table A- 8 Typical operating system processing time at the scan cycle check point
Interface module Cycle control at the scan cycle check point (CCP)
IM 151-8 PN/DP CPU 150 μs
Extension of the cycle time as a result of nested interrupts

Enabled interrupts also extend cycle time. Details are found in the table below.
Table A- 9 Typical extended cycle time due to nested interrupts
Interrupt type Process Diagnostic Time-of- Delay interrupt Cyclic

interrupt interrupt day interrupt
interrupt
IM 151-8 PN/DP CPU 200 µs 250 µs 300 μs 180 µs 160 µs
The program runtime at interrupt level must be added to this time extension.
Extension of the cycle time due to error
Table A- 10 Typical cycle time extension as a result of errors
Type of error Programming errors I/O access errors

IM 151-8 PN/DP CPU 120 µs 130 µs
You have to add the program execution time of the interrupt OB to this increase. The times
required for multiple nested interrupt/error OBs are added accordingly.

Appendix
A.3.2.3 Communication load
Configured communication load for PG/OP communication, S7 communication and PROFINET CBA
The CPU operating system continuously provides a specified percentage of total CPU
processing performance (time slice technology) for communication tasks. Processing
performance not required for communication is made available to other processes.
In the hardware configuration you can specify a communication load value between 5% and
50%. The default value is 20%.
The extension of the cycle time is dependent on the communication loading and can
fluctuate.
You can use the following formula for calculating the maximum cycle time extension factor:
100 / (100 – configured communication load in %)
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Example: 20% communication load

In your hardware configuration, you have specified a communication load of 20%. The
calculated cycle time is 10 ms. Using the above formula, the cycle time is extended by the
factor 1.25.
Example: 50% communication load

In your hardware configuration, you have specified a communication load of 50%. The
calculated cycle time is 10 ms. Using the above formula, the cycle time is extended by the
factor 2.

Appendix
Dependency of actual cycle time on the communication load

The figure below describes the non-linear dependency of the actual cycle time on the
communication load. In our example we have chosen a cycle time of 10 ms.
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Influence on the actual cycle time

From the statistical viewpoint, asynchronous events such as interrupts occur more frequently
within the OB1 cycle when the cycle time is extended as a result of communication load.
This further extends the OB1 cycle. This extension depends on the number of events that
occur per OB1 cycle and the time required to process these events.
Note
Change the value of the "communication load" parameter to check the effects on the cycle
time during system runtime. You must consider the communication load when setting the
maximum cycle time, otherwise time errors may occur.
Tips
● Use the default setting whenever possible.
● Increase this value only if the CPU is used primarily for communication and if the user
program is not time critical.
● In all other situations you should only reduce this value.

Appendix
A.3.2.4 Cycle time extension as a result of testing and commissioning functions
Runtimes
The runtimes of the testing and commissioning functions are operating system runtimes, so
they are the same for every CPU. How the cycle time is extended as a result of active testing
and commissioning functions is shown in the table below.
Table A- 11 Cycle time extension as a result of test and commissioning functions
Function IM 151-8 PN/DP CPU

Status variable Negligible
Control variable Negligible
Status block Typ. 3 µs for each monitored line
+ 3 x runtime of monitored block
The monitoring of large blocks and the monitoring of loops can lead to a
significant increase in the cycle time.
Setting process and test mode in the LAD/FBD/STL editor

Switching between process and test mode is carried out directly in the LAD/FBD/STL editor
in the "Test/Mode" menu.
Loops in the test and process mode are handled differently in the Status block.
● Process mode: First loop iteration is displayed
● Test mode: Last loop iteration is displayed. Leads to a significant cycle time increase for
many loop iterations.
In terms of function, there is also no difference between process mode and test mode.
Note
It is also possible to set breakpoints in test mode.
Reference
Information on the cycle extension due to Component Based Automation (CBA) can be
found in the respective section of the S7-300, CPU 31xC and CPU 31x, Technical Data
(http://support.automation.siemens.com/WW/view/en/12996906) manual.

Appendix
A.3.3 Response time
A.3.3.1 Overview: Response time
Definition of response time

The response time is the time between the detection of an input signal and the change of a
linked output signal.
Fluctuation width
The physical response time lies between the shortest and the longest response time. You
must always reckon with the longest response time when configuring your system.
The shortest and longest response times are shown below, to give you an idea of the
fluctuation width of the response time.
Factors
The response time depends on the cycle time and following factors:
● Delay in the I/O module inputs and outputs
● Additional send cycles for PROFINET IO
● Additional DP cycle times on PROFIBUS DP
● Execution in the user program
Reference
The delay times are described in the technical data for the I/O modules in the ET 200S
Distributed I/O Device
(http://support.automation.siemens.com/WW/view/en/10805258/133300) manual.
Update Time for PROFINET IO

If you configured your PROFINET IO system in STEP 7, STEP 7 calculates the send cycle
for PROFINET IO. You can then view the PROFINET IO send cycles on your PG.

Appendix
DP cycle times in the PROFIBUS DP network

If you configured your PROFIBUS DP master system with STEP 7, then STEP 7 will
calculate the typical DP cycle time that must be expected. You can then view the DP cycle
time of your configuration on the programming device.
The figure below gives you an overview of the DP cycle time. In this example, let us assume
that the data of each DP slave has an average length of 4 bytes.
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With multi-master operation on a PROFIBUS-DP network, you must make allowances for the
DP cycle time at each master. That is, you will have to calculate the times for each master
separately and then add up the results.

Appendix
A.3.3.2 Shortest response time
Conditions for the shortest response time

The figure below shows the conditions under which the shortest response time is reached.
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The (shortest) response time is the sum of:
Table A- 12 Formula: Shortest response time
1 x process image transfer time for the inputs

+ 1 x process image transfer time for the outputs
+ 1 x program processing time
+ 1 × operating system processing time at the SCC
+ Delay in the inputs and outputs
= Shortest response time
The result is equivalent to the sum of the cycle time plus the I/O delay times.
See also
Overview: Response time (Page 255)

Appendix
A.3.3.3 Longest response time
Conditions for the longest response time

The figure below shows the conditions under which the longest response time is reached.
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Appendix
Calculation
The (longest) response time is the sum of:
Table A- 13 Formula: Longest response time
2 x process image transfer time for the inputs

+ 2 x process image transfer time for the outputs
+ 2 x program processing time
+ 2 × operating system processing time
+ 2 x PROFINET IO update time (only if PROFINET IO is used)
+ 2 x DP cycle time on PROFIBUS DP (only if PROFIBUS DP is used)
+ Delay in the inputs and outputs
= Longest response time
Equivalent to the sum of 2 x the cycle time + I/O delay time + 2 x the PROFINET IO scan
cycle or 2 x the DP cycle time on PROFIBUS DP.
See also
Overview: Response time (Page 255)
A.3.4 Interrupt response time
A.3.4.1 Overview: Interrupt response time
Definition of interrupt response time

The interrupt response time is the time that elapses between the first occurrence of an
interrupt signal and the call of the first interrupt OB instruction. Generally valid: Higher-
priority interrupts take priority. This means that the interrupt response time is increased by
the program processing time of the higher-priority interrupt OBs and the interrupt OBs of
equal priority which have not yet been executed (queued).
Process interrupt and diagnostic interrupt response times of the IM 151-8 PN/DP CPU interface
module
Table A- 14 Process interrupt and diagnostic interrupt response times of the IM 151-8 PN/DP CPU
interface module
Interrupt response times (without communication) for ... Duration

Process alarm / diagnostic alarm less than 10 ms

Appendix
Process interrupt processing

Process interrupt processing begins after process interrupt OB 40 is called. Higher-priority
interrupts stop process interrupt processing. Direct I/O access is executed during runtime of
the instruction. After process interrupt processing has terminated, cyclic program execution
continues or further interrupt OBs of equal or lower priority are called and processed.
See also
Overview (Page 246)
A.3.4.2 Reproducibility of Time-Delay and Watchdog Interrupts
Definition of "reproducibility"
Time-delay interrupt:
The period that expires between the call of the first operation in the interrupt OB and the
programmed time of interrupt.
Watchdog interrupt:
The fluctuation range of the interval between two successive calls, measured between the
respective initial operations of the interrupt OB.
Reproducibility
The following times apply for the IM151-8 PN/DP CPU:
● Time-delay interrupt: +/- 100 μs
● Watchdog interrupt: +/- 100 μs
These times only apply if the interrupt can actually be executed at this time and if it is not
delayed, for example, by higher-priority interrupts or queued interrupts of equal priority.

Appendix
A.4 Additional documentation

The following documentation contains detailed information on specific topics. The
appropriate areas of these operating instructions refer to this documentation.
You can find the documents together with the associated entry ID on the Internet.
Name of manual Description

Operating Instructions Application planning; assembling; wiring and
ET 200S Distributed I/O System assembly; commissioning; functions; alarm, error,
and system messages; interface modules,
Entry ID: 1144348
COMPACT modules
(http://support.automation.siemens.com/WW/vie
w/en/1144348)
Manuals Description of functions and technical
(http://support.automation.siemens.com/WW/vie specifications of the terminal modules, power
w/en/10805258/133300) for the modules, and digital and analog electronic
ET 200S Distributed I/O System modules
System Manual Basic description of PROFINET:

PROFINET system description  Network components
Entry ID: 19292127  Data exchange and communication
(http://support.automation.siemens.com/WW/vie  PROFINET IO
w/en/19292127)  Component-based automation
 Application example of PROFINET IO and
Component Based Automation
Programming Manual Guideline for the migration from PROFIBUS DP to
From PROFIBUS DP to PROFINET IO PROFINET I/O.
Entry ID: 19289930
w/en/19289930)
Instructions List  List of the instruction set of the CPUs and their
CPU 312, CPU 314, CPU 315-2 DP, execution times.
CPU 315-2 PN/DP, CPU 317-2 PN/DP,  List of the executable blocks
CPU 319-3 PN/DP, IM 151-8 PN/DP CPU, (OBs/SFCs/SFBs) and their execution times.
IM 154-8 PN/DP CPU
Entry ID:31977679
w/en/31977679)
Reference Manual Overview of objects included in the operating
System software for S7-300/400 system and systems for S7-300 and S7-400 CPUs:
standard functions, Volume 1/2 OBs
Entry ID: 1214574 SFCs
(http://support.automation.siemens.com/WW/vie SFBs
w/en/1214574) IEC functions
diagnostics data
system status list (SSL)
events
This manual is part of the STEP 7 reference
information. You can also find the description in
the Online Help for STEP 7.

Appendix
Name of manual Description

Manual This manual provides an overview of programming
Programming with STEP 7 with STEP 7.
Entry ID: 18652056 This manual is part of the STEP 7 basic
(http://support.automation.siemens.com/WW/vie information. You can also find the description in
w/en/18652056) the Online Help for STEP 7.
Manual basics, configuration, saving, importing, exporting,
Configuring Hardware and Communication networking, configuring connections, downloading
Connections with STEP 7
Entry ID: 18652631
w/en/18652631)
Manual Description of:
CPU 31xC and CPU 31x, Technical  Operating and display elements
specifications  Communication
Entry ID: 12996906  Memory concept
(http://support.automation.siemens.com/WW/vie  Cycle and response times
w/en/12996906)
 Technical data
SIMATIC NET: Twisted Pair and Fiber-Optic Industrial Ethernet networks
Networks network configuration,
Entry ID: 8763736 components,
(http://support.automation.siemens.com/WW/vie  Guidelines for setting up networked
w/en/8763736) automation systems in buildings, etc.
Tutorial Creating PROFINET components, commissioning
Component Based Automation, Commissioning systems
Systems
Entry ID: 18403908
w/en/18403908)
Communication with SIMATIC Basics, services, networks,
Entry ID: 1254686 communication functions,
(http://support.automation.siemens.com/WW/vie connecting PDs/OPs,
w/en/1254686) project design and configuration in STEP 7
Manual Starting SIMATIC PDM, configuring networks and
The Process Device Manager devices, working with SIMATIC PDM,
communication, diagnostics
Entry ID: 21407212
w/en/21407212)
Manual product overview, functions, configuration
Diagnostic repeater for PROFIBUS DP possibilities, installation, wiring, commissioning,
diagnostics
Entry ID: 7915183
w/en/7915183)

Glossary
Accumulator
Accumulators represent CPU register and are used as buffer memory for download, transfer,
comparison, calculation and conversion operations.
See also CPU
Address
An address is the identifier of a specific operand or operand area.
Examples: Input I 12.1; Memory Word MW 25; Data Block DB 3.
Analog modules
Analog modules convert analog process values (for example, temperature) into digital values
that can be processed by the IM 151-8 PN/DP CPU interface module or convert digital
values into analog manipulated variables.
Application
→ User program
Application
An application is a program that runs directly on the MS-DOS / Windows operating system.
Applications on the programming device include, for example, the STEP 7 basic package,
S7-GRAPH and others.
ASIC
ASIC is the acronym for Application Specific Integrated Circuits.
PROFINET ASICs are components with a wide range of functions for the development of
your own devices. They implement the requirements of the PROFINET standard in a circuit
and allow extremely high packing densities and performance.
Because PROFINET is an open standard, SIMATIC NET offers PROFINET ASICs for the
development of your old devices under the name ERTEC .
Automation system
An automation system is a programmable logic controller in the context of SIMATIC S7.
See also Programmable Logic Controller

Glossary
Autonegotiation
Configuration protocol in the Fast Ethernet. Before the actual data transfer the devices on
the network agree a transfer mode that each participating device can master (100 Mbps or
10 Mbps, full-duplex or half-duplex)
Backplane bus
Serial data bus used by the interface module to communicate with electronic modules and to
supply power to these. The individual modules are interconnected by means of terminal
modules.
Backup memory
Backup memory ensures buffering of the memory areas of a CPU without backup battery. It
backs up a configurable number of timers, counters, bit memory, data bytes and retentive
timers, counters, bit memory and data bytes).
See also CPU
Baud rate
Data transfer rate (in bps)
Bit memory
Bit memory are part of the CPU's system memory. They store intermediate results of
calculations. They can be accessed in bit, word or dword operations.
See System memory
Bus
A bus is a communication medium connecting several nodes. Data can be transferred via
serial or parallel circuits, that is, via electrical or fiber optic conductors .
Bus connector
Physical connection between the bus node and the bus cable.
Bus node
This is a device that can send, receive or amplify data via the bus. It can be a DP master, DP
slave, RS 485 repeater, active star coupler etc.
Bus segment
A bus segment is a self-contained section of a serial bus system. Bus segments are linked to
one another using repeaters in PROFIBUS DP, for example.

Glossary
Changing IO devices during operation (changing partner ports)

Functionality of a PROFINET device.
A PROFINET device that supports this function can communicate during operation with
changing communication partners at the same port.
Chassis ground
Chassis ground includes all the interconnected inactive parts of equipment that must not
carry a hazardous voltage even in the event of a fault.
Clock memory
Memory bit which can be used to generate clock pulses in the user program (1 memory
byte).
Note
Make sure that the clock memory byte is not overwritten in the user program.
Code block
A SIMATIC S7 logic block contains elements of the STEP 7 user program. (in contrast to a
DB: this contains only data.)
See also Data block
Component-based automation
→ PROFINET CBA
Compression
The programming device online function "Compress" is used to rearrange all valid blocks in
CPU RAM in one continuous area of user memory, starting at the lowest address. This
eliminates fragmentation which occurs when blocks are deleted or edited.
Configuration
Assignment of modules to slots and (for example with electronic modules) addresses.
Consistent data
Data which are related in their contents and not to be separated are referred to as consistent
data.
For example, the values of analog modules must always be handled as a whole, that is, the
value of an analog module must not be corrupted as a result of read access at two different
points of time.

Glossary
Counters
Counters are part of CPU system memory. The content of "Counter cells" can be modified by
STEP 7 instructions (for example, up/down count.)
See also System memory
CPU
Central processing unit = CPU of the S7 automation system with a control and arithmetic
unit, memory, operating system, and interface for programming device.
Cycle time
The cycle time represents the time a CPU requires for one execution of the user program.
See also User program
See also CPU
Cyclic interrupt
→ Interrupt, cyclic interrupt
Data block
Data blocks (DB) are data areas in the user program which contain user data. There are
shared data blocks which can be accessed by all code blocks, and instance data blocks
which are assigned to a specific FB call.
Data exchange broadcast

→ Direct data exchange
Data exchange traffic

Data set routing

Functionality of a module with several network connections.
Modules that support this function are able to pass on data of an engineering system (for
example parameter data generated by SIMATIC PDM) from a subnetwork such as Ethernet
to a field device at the PROFIBUS DP.
Data, static
Static data can only be used within a function block. These data are saved in an instance
data block that belongs to a function block. Data stored in an instance data block are
retained until the next function block call.

Glossary
Data, temporary
Temporary data is the local data of a block. It is stored in the L-stack when the block is
executed. After the block has been processed, this data is no longer available.
DCP
DCP (Discovery and Basic Configuration Protocol). Enables the assignment of device
parameters (such as IP addresses) using manufacturer-specific configuration
tools/programming tools.
Default router
The default router is the router that is used when data must be forwarded to a partner
located within the same subnet.
In STEP 7, the default router is called Router. STEP 7 assigns a local IP address to the
default router by default.
Determinism
→ Real Time
Device
Within the context of PROFINET, "device" is the generic term for:
● Automation systems
● Field devices (PLC, PC, for example)
● Active network components (for example, distributed I/O, valve terminals, drives)
● Hydraulic devices
● Pneumatic devices
The main characteristic of a device is its integration in PROFINET communication over
Ethernet or PROFIBUS.
The following device types are distinguished based on their attachment to the bus:
● PROFINET devices
● PROFIBUS devices
Device
→ PROFIBUS device
Device
→ PROFINET device

Glossary
Device name
Because a fixed IP address is assigned to the device name, an IO device must have a
device name in order to be addressed by an IO controller. With PROFINET, this procedure is
used because names are easier to handle than complex IP addresses.
The assignment of a device name for a specific IO device can be compared with the setting
of the PROFIBUS address for a DP slave.
In the state of delivery a IO device has no device name. The IO device can only be
addressed by a IO controller after the device has been assigned a device name, for the
transfer of configuration data (IP address and other data) in the startup phase or for the
exchange of user data in cyclic operation, for example.
Alternatively the device name can be written directly to the SIMATIC Micro Memory Card
(e.g. for the ET 200S IO device) in the programming device.
Device replacement without removable media / PD

IO devices having this function can be replaced simply:
● A removable medium (such as Micro Memory Card) with stored device name is not
required.
● The device name does not have to be assigned with the PD.
● If a replacement is necessary, an IO device already in operation has to be reset to the
factory settings by using "Reset to factory setting".
The replaced IO device obtains the device name from the IO controller, not from the
removable medium or from the programming device. For this purpose, the IO controller uses
the configured topology and the neighbor relationships determined by the IO devices. The
configured setpoint topology must agree with the actual topology.
Diagnostic interrupt
Modules capable of diagnostics operations report detected system errors to the CPU by
means of diagnostic interrupts.
See also CPU
Diagnostics
→ System diagnostics
Diagnostics buffer
The diagnostics buffer represents a buffered memory area in the CPU. It stores diagnostic
events in the order of their occurrence.
Direct data exchange

Direct data exchange is a special communication relationship between PROFIBUS DP
nodes. The direct data exchange is characterized by PROFIBUS DP nodes which "listen" on
the bus and know which data a DP slave returns to its DP master.

Glossary
Distributed I/O systems

I/O systems that are not integrated into the central controller, but rather at distributed
locations a long distance from the CPU, such as:
● ET 200M, ET 200L, ET 200S, ET 200pro
● DP/AS-I Link
● S5-95U with PROFIBUS DP slave interface
● Further DP slaves supplied by Siemens or other vendors.
The distributed I/O systems are connected to the DP master via PROFIBUS DP.
DP master
→ Master
DP master
A master that complies with the IEC 61784-1:2002 Ed1 CP 3/1 standard is known as a DP
master.
DP slave
→ Slave
DP slave
A slave running on the PROFIBUS using the PROFIBUS DP protocol in compliance with IEC
61784-1:2002 Ed1 CP 3/1 is known as a DP slave.
DP Standard
Bus protocol of the ET 200 distributed I/O system to IEC 61784-1:2002 Ed1 CP 3/1.
DPV1
The designation DPV1 means extension of the functionality of the acyclical services (to
include new interrupts, for example) provided by the DP protocol. The DPV1 functionality is
an integral part of the IEC 61784-1:2002 Ed1 CP 3/1 standard.
Electrically isolated
Electrically isolated I/O modules are isolated from the reference potentials of the control and
load circuits by means of an optocoupler, relay contact or transformer circuit, for example.
I/O circuits may be connected to the same potential.

Glossary
Electronic modules
Electronic modules form the interface between the process and the automation system.
There are
● digital input and output modules
● analog input and output modules
● Technology modules
Equipotential bonding
Electrical connection (equipotential bonding conductor) that keeps electrical equipment and
extraneous conductive objects to the same or almost the same potential in order to prevent
disturbing or dangerous voltages between those objects.
Error display
One of the possible reactions of the operating system to a runtime error is to output an error
message. Further reactions: Error reaction in the user program, CPU in STOP.
See also Runtime error
See also Error reaction
Error handling via OB

After the operating system has detected a specific error (e.g. an access error with STEP 7),
it calls a dedicated organization block (error OB) in which the subsequent behavior of the
CPU can be defined.
Error response
Reaction to a runtime error. Reactions of the operating system: It sets the automation
system to STOP, indicates the error, or calls an OB in which the user can program a
reaction.
See also Runtime error
ERTEC
→ ASIC

Glossary
ET 200
The ET 200 distributed I/O system with PROFIBUS DP or PROFINET IO allows the
connection of distributed I/Os to a CPU via a DP master or IO controller. ET 200 is
characterized by high-speed reaction times, because of a minimum data transfer volume
(bytes.)
The ET 200 is based on IEC 61784-1:2002 Ed1 CP 3/1.d standard.
The ET 200 works on the master / slave principle or controller / device principle.
The DP masters are, for example, the IM 308-C master connection or the IM 151-8 PN/DP
CPU interface module with DP master module. An IO controller could be, for example, the IM
DP slaves / IO devices could be the distributed I/Os ET 200M, ET 200L, ET 200S,
ET 200pro or DP slaves / IO devices from Siemens or other vendors.
External lightning protection

External plant components at which galvanic coupling of lightning surges is excluded.
Corresponds with lightning protection zone 0A and 0B.
Fast Ethernet
Fast Ethernet describes the standard for transferring data with 100 Mbits. Fast Ethernet uses
the 100 Base-T standard.
FB
→ Function block
FC
→ Function
Flash EPROM
FEPROMs can retain data in the event of power loss, same as electrically erasable
EEPROMs. However, they can be erased within a considerably shorter time (FEPROM =
Flash Erasable Programmable Read Only Memory). They are used on SIMATIC Micro
memory cards.
FORCE
The Force function can be used to assign the variables of a user program or CPU (also:
inputs and outputs) constant values.
Note in this connection also the restrictions in section Overview: Debugging functions in
section Debugging functions, diagnostics and troubleshooting.

Glossary
FREEZE
Control command a DP master may broadcast to a group of DP slaves.
When it receives a FREEZE command, the slave freezes its current input status and outputs
its data cyclically to the DP master.
The DP slave freezes its input status again after each new FREEZE command.
The DP slave does not resume the transfer input data to the DP master until the DP master
has sent the UNFREEZE control command.
Function
According to IEC 1131-3, a function (FC) is a code block without static data. A function
allows transfer of parameters in user program. Functions are therefore suitable for
programming frequently occurring complex functions, e.g. calculations.
Function block
According to IEC 1131-3, a function block (FB) is a code block with static data. An FB allows
the user program to pass parameters. Function blocks are therefore suitable for
programming complex functions, e.g., closed-loop controls, mode selections, which are
repeated frequently.
Functional ground
Grounding which has the sole purpose of safeguarding the intended function of electrical
equipment. With functional grounding you short-circuit interference voltage which would
otherwise have an unacceptable impact on equipment.
Ground
The conductive earth whose electrical potential can be set equal to zero at any point.
Ground potential may be different from zero in the area of grounding electrodes. The term
reference ground is frequently used to describe this situation.
Ground-free
Having no direct electrical connection to ground
Grounding
Grounding means, to connect an electrically conductive component via an equipotential
grounding system to a grounding electrode (one or more conductive components with highly
conductive contact to earth).

Glossary
GSD file
The properties of a PROFINET device are described in a GSD file (General Station
Description) that contains all the information required for configuration.
As with PROFIBUS, you can link a PROFINET device in STEP 7 by means of a GSD file.
In the case of the PROFINET IO the GSD file is in XML format. The structure of the GSD file
is compliant with ISO 15734, which is the world-wide standard for device descriptions.
For PROFIBUS, the GSD file is in ASCII format (according to IEC 61784-1:2002 Ed1 CP
3/1).
Hot-swapping
The removal and insertion of modules during the operation of the ET 200S.
I-Device
The "I-Device" (intelligent IO device) functionality of a CPU permits the exchange of data
with an IO controller, thereby allowing the CPU to be used as an intelligent pre-processing
unit for subprocesses. For this purpose, the I device is linked in the role of an IO device to a
"higher level" IO controller.
The pre-processing is performed by the user program in the CPU with the I device
functionality. The centralized or decentralized (PROFINET IO or PROFIBUS DP) process
values are pre-processed by the user program and delivered to a higher level station by a
PROFINET IO device interface of the CPU.
IM
Interface module: The interface module combines the ET 200S with the DP master or the IO
controller and prepares the data for the electronic modules.
In an ET 200S with IM151-8 PN/DP CPU, the IM 151-8 PN/DP CPU interface module is itself
the
● IO controller or
● DP master (together with the DP master module).
Industrial Ethernet
→ Fast Ethernet
Industrial Ethernet
Industrial Ethernet (formerly SINEC H1) is a technology that allows data to be transmitted
free of interference in an industrial environment.
Standard Ethernet components can be used since the PROFINET is an open system.
However, we recommend setting up PROFINET as Industrial Ethernet.

Glossary
Industrial Wireless LAN

In addition to data communication, Industrial Wireless LAN from SIMATIC NET with the
standard IEEE 802.11, offers a multitude of extensions (I-Features) that are of great benefit
to industrial users. IWLAN is particularly suited for complex industrial applications with
requirement for reliable radio communication, owing to:
● Automatic roaming if connection to Industrial Ethernet is interrupted (Rapid Roaming)
● Cost savings generated by using a single wireless network for secure operation of a
process with both process-critical data (alarm message, for example) and non-critical
communication (service and diagnostics, for example)
● Cost-effective connection to devices in remote, difficult-to-access environments
Instance data block

The STEP 7 user program assigns an automatically-generated DB to every call of a function
block. The instance data block stores the values of input, output and in/out parameters, as
well as local block data.
Internal lightning protection

Shielding of buildings, rooms or devices Corresponds with lightning protection zone 1, 2 or 3.
Interrupt
The operating system of an S7 CPU can distinguish between different priority classes that
control how the user program is executed. These priority classes include interrupts, e.g.
process interrupts. When an interrupt is triggered, the operating system automatically calls
an assigned OB. In this OB the user can program the desired response (e.g. in an FB).
See also Operating system
Interrupt, cyclic interrupt

A cyclic interrupt is generated periodically by the CPU in a configurable time pattern. A
corresponding OB will be processed.
See also Organization Block
Interrupt, delay
The delay interrupt belongs to one of the priority classes in SIMATIC S7 program
processing. It is generated on expiration of a time started in the user program. A
corresponding OB will be processed.
Interrupt, delay
→ Interrupt, delay

Glossary
Interrupt, diagnostic
→ Diagnostic interrupt
Interrupt, process
→ Process interrupt
Interrupt, status
A status interrupt can be generated by a DPV1 slave or a PNIO device respectively. At the
DPV1 master or the PNIO controller respectively the receipt of the interrupt causes the OB
55 to be called.
For detailed information on OB 55, refer to the Reference Manual System Software for S7-
300/400.
Interrupt, time-of-day
The time-of-day interrupt is one of the priority classes in SIMATIC S7 program processing. It
is generated at a specific date (or daily) and time-of-day (e.g. 9:50 or hourly, or every
minute). A corresponding OB will be processed.
Interrupt, update
An update interrupt can be generated by a DPV1 slave or a PNIO device respectively. At the
DPV1 master or the PNIO controller respectively the receipt of the interrupt causes the OB
56 to be called.
300/400.
Interrupt, vendor-specific
A manufacturer-specific interrupt can be generated by a DPV1 slave or a PNIO device
respectively. At the DPV1 master or the PNIO controller respectively the receipt of the
interrupt causes the OB 57 to be called.
300/400.
IO controller
→ PROFINET IO Controller
IO controller
→ PROFINET IO Device
IO controller
→ PROFINET IO Supervisor

Glossary
IO controller
→ PROFINET IO System
IO device
IO device
IO device
IO device
IO supervisor
IO supervisor
IO supervisor
IO supervisor
IO system

Glossary
IP address
To allow a PROFINET device to be addressed as a node on Industrial Ethernet, this device
also requires an IP address that is unique within the network. The IP address is made up of
4 decimal numbers with a range of values from 0 through 255. The decimal numbers are
separated by periods.
The IP address is made up of:
● The address of the (subnet) network
● The address of the node (generally called the host or network node)
IRT
→ Isochronous Real Time communication
Isochronous mode
Process data, transfer cycle via PROFIBUS DP or PROFINET IO and user program are
synchronized with each other to achieve the highest deterministics. The input and output
data of distributed I/O devices in the system are detected and output simultaneously. The
constant bus cycle times of the PROFIBUS DP cycle/PROFINET IO cycle are the clock
generator for this.
Isochronous Real Time communication

Synchronized transmission procedure for the cyclic exchange of IRT / IO data between
PROFINET devices.
A reserved bandwidth within the send clock is available for the IRT / IO data. The reserved
bandwidth ensures that the IRT IO data can be transmitted at reserved, synchronized
intervals whilst remaining uninfluenced even by other greater network loads (e.g. TCP / IP
communication or additional real time communication).
LAN
Local area network. Interconnects computers within an enterprise. The LAN therefore has a
limited geographical span and is solely available to a company or institution.
LLDP
LLDP (Link Layer Discovery Protocol) is a protocol that is used to detect the closest
neighbors. It enables a device to send information about itself and to save information
received from neighboring devices in the LLDP MIB. This information can be looked up via
the SNMP. This information allows a network management system to determine the network
topology.
Load memory
The load memory contains objects generated by the programming device. For the IM 151-8
PN/DP CPU interface module, it takes the form of a plug-in SIMATIC Micro Memory Card
with various memory sizes. There must be a SIMATIC Micro Memory Card inserted in order
to use the IM 151-8 PN/DP CPU interface module.

Glossary
Load power supply

Power supply for the load voltage for the power modules
Local data
→ Data, temporary
MAC Address
Every PROFINET device is assigned a worldwide unique device identification before it
leaves the factory. This 6-Byte long device identification is the MAC address.
The MAC address is divided into:
● 3-Byte manufacturer identification
● 3-Byte device identification (consecutive number)
The MAC address is normally printed on the front of the device.
Example: 08-00-06-6B-80-C0
Master
When a master is in possession of the token, it can send data to other nodes and request
data from other nodes (= active node). The DP masters are, for example, the CPU 315-2 DP
or the IM 151-8 PN/DP CPU interface module with DP master module.
Master
→ Slave
Media redundancy
Function for ensuring the network and system availability. Redundant transmission links (ring
topology) ensure that an alternative communication path is made available if a transmission
link fails.
MIB
An MIB (Management Information Base) is a database of a device. SNMP clients access this
database in the device. The S7 device family supports, among others, the following standard
MIBs:
● MIB II, standardized in the RFC 1213
● LLDP-MIB, standardized in the international standard IEE 802.1AB
● LLDP PNIO-MIB, standardized in the international standard IEE 61158-6-10
Micro Memory Card

→ SIMATIC Micro Memory Card

Glossary
Module parameters
Module parameters are values which can be used to configure module behavior. There are
two different types of parameter: static and dynamic.
NCM PC
→ SIMATIC NCM PC
Nesting depth
A block can be called from another by means of a block call. Nesting depth is referred to as
the number of simultaneously called code blocks.
See also Code Blocks
Network
A network is a larger communication system that allows data exchange between a large
number of nodes.
All the subnets together form a network.
Network
A network consists of one or more interconnected subnets with any number of nodes.
Several networks can exist alongside each other.
Non-isolated
The reference potentials of the control and load circuit of non-isolated I/O modules are
electrically interconnected.
NTP
The Network Time Protocol (NTP) is a standard for synchronizing clocks in automation
systems via Industrial Ethernet. NTP uses the UDP wireless network protocol.
OB
→ Organization blocks
OB priority
The CPU operating system distinguishes between different priority classes, for example,
cyclic program execution or process interrupt-controlled program processing. Each priority
class is assigned organization blocks (OBs) in which the S7 user can program a response.
The OBs are assigned different default priority classes. These determine the order in which
OBs are executed or interrupt each other when they appear simultaneously.
See also Organization block

Glossary
Operating state
SIMATIC S7 automation systems know the following operating states: STOP, STARTUP,
RUN.
See also STARTUP, RUN
Operating system
The CPU OS organizes all functions and processes of the CPU which are not associated to
a specific control task.
Operating system
→ CPU
Organization blocks
Organization blocks (OBs) form the interface between CPU operating system and the user
program. The order in which the user program is executed is defined in the organization
blocks.
Parameter
● Variable of a STEP 7 code block
● Variable used to set the behavior of a module (one or more per module). All modules
have a suitable basic factory setting which can be customized in STEP 7.
There are static and dynamic parameters.
See also static parameters
See also dynamic parameters
Parameter assignment
This means the passing of parameters from the DP master to the DP slave or from the IO
controller to the IO device.
Parameters, dynamic
In contrast to static parameters, you can change dynamic module parameters in runtime by
calling an SFC in the user program, e.g. limit values for an analog input module.
Parameters, static
In contrast to dynamic parameters, static parameters of modules cannot be changed by the
user program. You can only modify these parameters by editing your configuration in STEP
7, for example, by modifying the input delay parameters of a digital input module.

Glossary
PC station
→ SIMATIC PC station
PELV
Protective Extra Low Voltage = extra low voltage with safe isolation
PG
→ Programming device
PLC
→ CPU
PLC
Programmable controllers (PLCs) are electronic controllers whose function is saved as a
program in the control unit. Therefore, the configuration and wiring of the unit does not
depend on the PLC function. The programmable logic PLC has the structure of a computer;
it consists of a CPU with memory, I/O modules and an internal bus system. The I/O and the
programming language are oriented to control engineering needs.
PLC
→ PLC
PNO
→ PROFIBUS International
Prioritized startup
Prioritized startup designates the PROFINET functionality for accelerating the startup of IO
devices in a PROFINET IO system with RT and IRT communication.
The function reduces the time that the correspondingly configured IO devices require in
order to return to the cyclic user data exchange in the following cases:
● after the supply voltage has returned
● after a station has returned
● after IO devices have been activated
Priority class
The S7 CPU operating system provides up to 26 priority classes (or "Program execution
levels"). Specific OBs are assigned to these classes. The priority classes determine which
OBs interrupt other OBs. Multiple OBs of the same priority class do not interrupt each other.
In this case, they are executed sequentially.

Glossary
Process image
The process image is part of CPU system memory. At the start of cyclic program execution,
the signal states at the input modules are written to the process image of the inputs. At the
end of cyclic program execution, the signal status of the process image of the outputs is
transferred to the output modules.
Process interrupt
A process interrupt is triggered by interrupt-triggering modules as a result of a specific event
in the process. The process interrupt is reported to the CPU. The assigned organization
block will be processed according to interrupt priority.
See also Organization Block
Process-Related Function
→ PROFINET components
Product version
The product version identifies differences between products which have the same order
number. The product version is incremented when forward-compatible functions are
enhanced, after production-related modifications (use of new parts/components) and for bug
fixes.
PROFIBUS
PROFIBUS
PROcess FIeld BUS, German process field bus standard specified in IEC 61784-1:2002 Ed1
CP 3/1. It specifies functional, electrical and mechanical properties for a bit-serial field bus
system.
From the perspective of the user program, the distributed I/O is just as sophisticated as the
centralized I/O.
PROFIBUS is available with the protocols DP (= Distributed Peripherals), FMS (= Fieldbus
Message Specification), PA (= Process Automation), or TF (= Technological Functions.)
PROFIBUS address
A node must be assigned a unique PROFIBUS address in order to allow its identification on
PROFIBUS.
The PC/Programming device is assigned PROFIBUS address "0."
The PROFIBUS addresses 1 to 125 may be used for the ET 200S distributed I/O system.

Glossary
PROFIBUS device
→ Device
PROFIBUS device
A PROFIBUS device has at least one or more PROFIBUS ports.
A PROFIBUS device cannot take part directly in PROFINET communication but must be
included over a PROFIBUS master with a PROFINET port or an Industrial
Ethernet/PROFIBUS link (IE/PB Link) with proxy functionality.
PROFIBUS DP
PROFIBUS DP
→ PROFIBUS
PROFIBUS International
Technical committee dedicated to the definition and development of the PROFIBUS and
PROFINET standard.
Also known as the PROFIBUS User Organization membership corporation (PNO.)
Homepage: http://www.profibus.com
PROFINET
PROFINET
Within the framework of Totally Integrated Automation (TIA), PROFINET represents a
consequent enhancement of:
● PROFIBUS DP, the established field bus, and
● Industrial Ethernet, the communication bus for the cell level
Experience gained from both systems was and is being integrated into PROFINET.
PROFINET is an Ethernet-based automation standard of PROFIBUS International
(previously PROFIBUS Users Organization e.V.), and defines a multi-vendor communication,
automation, and engineering model. PROFINET has been part of the standard IEC 61158
since 2003.
PROFINET ASIC
→ ASIC

Glossary
PROFINET CBA
In the context of PROFINET, PROFINET CBA (Component-based Automation) is an
automation concept for:
● Implementation of modular applications with distributed intelligence
● Machine-to-machine communication
PROFINET CBA lets you create distributed automation solutions, based on default
components and partial solutions. This concept satisfies demands for a higher degree of
modularity in the field of mechanical and systems engineering by extensive distribution of
intelligent processes.
Component-based Automation allows you to use complete technological modules as
standardized components in large systems.
PROFINET CBA is implemented by:
● The PROFINET standard for programmable controllers
● The SIMATIC iMAP engineering tool
The components are created in an engineering tool that can differ from vendor to vendor.
Components of SIMATIC devices are created, for example, with STEP 7.
PROFINET components
A PROFINET component encompasses the entire data of the hardware configuration, the
parameters of the modules, and the corresponding user program. The PROFINET
component is comprised of:
● Technological function
The (optional) technological (software) function includes the interface to other PROFINET
components in the form of configurable inputs and outputs.
● Device
The device is the representation of the physical automation device or field device
including the IO devices, sensors, actuators, mechanics, and device firmware.
PROFINET device
→ Device
PROFINET device
A PROFINET device always has at least one Industrial Ethernet port. A PROFINET device
can also have a PROFIBUS port as a master with proxy functionality.

Glossary
PROFINET IO
Within the framework of PROFINET, PROFINET IO is a communication concept for the
implementation of modular, distributed applications.
PROFINET IO allows you to create automation solutions, which are familiar to you from
PROFIBUS.
PROFINET IO is based both on the PROFINET standard for programmable controllers and
on the STEP 7 engineering tool. This means that you have the same application view in
STEP 7, regardless of whether you are configuring PROFINET or PROFIBUS devices.
Programming your user program is essentially the same for PROFINET IO and PROFIBUS
DP if you use the extended blocks and system status lists for PROFINET IO.
PROFINET IO Controller
Device via which the connected IO devices are addressed. That means: the IO controller
exchanges input and output signals with assigned field devices. The IO controller is often the
controller on which the automation program runs.
PROFINET IO Device
PROFINET IO Device
Distributed field device assigned to one of the IO controllers
(e.g. remote IO, valve terminals, frequency converters, switches).
PROFINET IO Device
PROFINET IO Device

Glossary
PROFINET IO Supervisor
PG/PC or HMI device for commissioning and diagnostics.
PROFINET IO System
PROFINET IO System
PROFINET IO System
PROFINET IO controller with assigned PROFINET IO devices.
Programming device
Basically speaking, PGs are compact and portable PCs which are suitable for industrial
applications. They are identified by a special hardware and software for programmable logic
controllers.
Proxy
→ PROFINET device
Proxy
The PROFINET device with proxy functionality is the substitute for a PROFIBUS device on
Ethernet. The proxy functionality allows a PROFIBUS device to communicate not only with
its master but also with all nodes on PROFINET.
You can easily integrate existing PROFIBUS systems into PROFINET communication, for
example with the help of an IE/PB link or an IM 151-8 PN/DP CPU interface module. The
IE/PB link / IM 151-8 PN/DP CPU handles communication via PROFINET as a substitute for
the PROFIBUS components.

Glossary
Publisher
Publisher
The publisher is a sender in the direct data exchange.
RAM
RAM (Random Access Memory) is a semiconductor read/write memory.
Real Time
Real time means that a system processes external events within a defined time.
Determinism means that a system reacts in a predictable (deterministic) manner.
In industrial networks, both these requirements are important. PROFINET meets these
requirements. PROFINET is implemented as a deterministic real-time network as follows:
● The transfer of time-critical data between different stations over a network within a
defined interval is guaranteed.
To achieve this, PROFINET provides an optimized communication channel for real-time
communication : Real Time (RT).
● An exact prediction of the time at which the data transfer takes place is possible.
● It is ensured that seamless communication can take place in the same network by means
of other standard protocols, such as industrial communication for programming device /
PC.
Real Time
→ Real Time
Reference ground
→ Ground
Reference potential
Reference potential for the evaluation / measuring of the voltages of participating circuits.
Restart
When the IM 151-8 PN/DP CPU interface module starts up (for example, after changing the
mode selector switch from STOP to RUN or after a POWER ON), organization block OB 100
(warm restart) is executed before cyclic program processing (OB 1). On restart, the input
process image is read in and the STEP 7 user program is executed, starting at the first
instruction in OB1.

Glossary
Retentive memory
A memory area is considered retentive if its contents are retained even after a power loss
and transitions from STOP to RUN. The non-retentive area of bit memory, timers and
counters is reset following a power failure and a transition from the STOP mode to the RUN
mode.
Retentive can be the:
● Bit memory
● S7 timers
● S7 counters
● Data areas
Router
→ Default router
Router
→ Switch
Router
A router connects two subnetworks with each other. A router works in a way similar to a
switch. With a router, however, it is also possible to specify which communications nodes
can communicate via the router and which cannot. Communication nodes on different sides
of a router can only communicate with each other if you have explicitly enabled
communication between the two nodes via the router. Real time data cannot be replaced
beyond subnetwork limits.
RT
→ Real Time
Runtime error
Errors occurred in the PLC (that is, not in the process itself) during user program execution.
Scan cycle check point

The cycle control point is the section of the CPU program processing in which the process
image is updated.
Segment
→ Bus segment

Glossary
SELV
Safety Extra Low Voltage
SFB
→ System function block
SFC
→ System function
Shared Device
The "Shared Device" functionality permits the sub-modules of an IO device to be distributed
between various IO controllers.
SIMATIC
The term denotes Siemens products and systems for industrial automation.
SIMATIC Micro Memory Card

SIMATIC Micro Memory Cards are storage media for the IM 151-8 PN/DP CPU interface
module
SIMATIC NCM PC
SIMATIC NCM PC is a version of STEP 7 designed specifically for configuring PCs. It
provides the complete STEP 7 functionality for PC stations.
SIMATIC NCM PC is the central tool with which you configure the communication services
for your PC station. The configuration data generated with this tool must be downloaded to
the PC station or exported. This makes the PC station ready for communication.
SIMATIC NET
Siemens business area for industrial communication, networks, and network components.
SIMATIC PC station
A "PC station" is a PC with communication modules and software components within a
SIMATIC automation solution.
Slave
→ Master

Glossary
Slave
A slave can only exchange data after being requested to by the master.
SNMP
SNMP (Simple Network Management Protocol) makes use of the wireless UDP transport
protocol. It consists of two network components, similar to the client/server model. The
SNMP manager monitors the network nodes and the SNMP agents collect the various
network-specific information in the individual network nodes and stores it in a structured form
in the MIB (Management Information Base). This information allows a network management
system to run detailed network diagnostics.
STARTUP
A STARTUP routine is executed at the transition from STOP to RUN mode. Can be triggered
by means of the mode selector switch, or after power on, or by an operator action on the
programming device. A restart has been carried out on the IM 151-8 PN/DP CPU interface
module.
See also Mode selector switch
See also Restart
STEP 7
Engineering system. Contains programming software for the creation of user programs for
SIMATIC S7 controllers.
Subnet mask
The bits set in the subnet mask determine which part of the IP address contains the address
of the subnet/network.
In general:
● The network address is obtained by an AND operation on the IP address and subnet
mask.
● The node address is obtained by an AND NOT operation on the IP address and subnet
mask.
Subnetwork
All the devices connected by switches are located in the same network, called a subnet. All
the devices in a subnet can communicate directly with each other.
All devices in the same subnet have the same subnet mask.
A subnet is physically restricted by a router.
Subscriber

Glossary
Subscriber
The subscriber is a recipient in the direct data exchange.
Substitute
→ Proxy
Substitute value
Substitute values are configurable values which output modules transfer to the process when
the CPU switches to STOP mode.
In the event of an I/O access error, a substitute value can be written to the accumulator
instead of the input value which could not be read (SFC 44).
Switch
PROFIBUS is based on a line topology. Communication nodes are interconnected by means
of a passive cable known as the bus.
By contrast, Industrial Ethernet is made up of point-to-point connections: Each
communication node is interconnected directly with one other communication node.
A node is interconnected with several other communication nodes via the port of an active
network component (switch). Other communications nodes (including switches) can then be
connected to the other ports of the switch. The connection between a communication node
and the switch remains a point-to-point connection.
The task of a switch is thus to regenerate and distribute received signals. The switch "learns"
the Ethernet address(es) of a connected PROFINET device or of other switches, and passes
only the signals intended for the connected PROFINET device or switch.
A switch has a certain number of ports. Connect only one PROFINET device or a further
switch to any one of the ports.
SYNC
Control command a DP master may broadcast to a group of DP slaves.
With the SYNC control command the DP master causes the DP slave to freeze the statuses
of the outputs at the current value. The DP slave stores the output data contained in the next
frame, but does not change the state of its outputs.
After each new SYNC control command, the DP slave sets the outputs it has saved as
output data. The outputs are not updated cyclically again until the DP master has sent a
UNSYNC control command.
System diagnostics
System diagnostics refers to the detection, evaluation, and signaling of errors that occur
within the PLC, for example programming errors or module failures. System errors can be
indicated by LEDs or in STEP 7.

Glossary
System function
A system function (SFC) is a function integrated in the operating system of the CPU that can
be called when necessary in the STEP 7 user program.
System function block

A system function block (SFB) is a function block integrated in the operating system of the
CPU that can be called when necessary in the STEP 7 user program.
System memory
System memory is an integrated RAM memory in the CPU. System memory contains the
address areas (e.g. timers, counters, bit memory) and data areas that are required internally
by the operating system (for example, communication buffers).
System status list

The system status list contains data that describes the current status of an ET 200S with IM
151-8 PN/DP CPU interface module. You can always use this list to obtain an overview of:
● the configuration of the ET 200S
● The current CPU parameter assignments and configurable electronic modules
● The current statuses and processes in the CPU and the configurable electronic modules
Terminating module
The ET 200S distributed IO system is completed by the terminating module. If you have not
inserted a terminating module, the ET 200S is not ready for operation.
Terminating resistor
The terminating resistor is used to avoid reflections on data links.
Time-of-day interrupt
→ Interrupt, time-of-day
Timer
→ Timers
Timers
Timers are part of CPU system memory. The content of timer cells is automatically updated
by the operating system, asynchronously to the user program. STEP 7 instructions are used
to define the precise function of the timer cell (for example, switch-on delay) and to initiate
their execution (for example, start).

Glossary
Token
Allows access to the PROFIBUS DP for a limited time.
Topology
Structure of a network. Common structures include:
● Bus topology
● Ring topology
● Star topology
● Tree topology
Twisted Pair
Fast Ethernet via twisted-pair cables is based on the IEEE 802.3u standard (100 Base-TX).
Transmission medium is a shielded 2x2 twisted-pair cable with an impedance of 100 Ohm
(AWG 22). The transmission characteristics of this cable must meet the requirements of
category 5.
The maximum length of the connection between end device and network component must
not exceed 100 m. The ports are implemented according to the 100 Base-TX standard with
the RJ-45 connector system.
Update Time
Within this time interval, an IO device / IO controller in the PROFINET IO system is supplied
with new data by the IO controller / IO device. The update time can be configured separately
for each IO device and determines the interval at which data is sent from the IO controller to
the IO device (outputs) as well as data from the IO device to the IO controller (inputs).
User program
In SIMATIC, a distinction is made between the operating system of the CPU and user
programs. The user program contains all instructions, declarations and data for signal
processing required to control a plant or a process. It is assigned to a programmable module
(for example CPU) and can be structured in smaller units (blocks).
User program
→ Operating system
User program
→ STEP 7
Voltage group
A group of electronic modules supplied by one power module.

Glossary
WAN
Wide Area Network; extends beyond LAN limits and allows worldwide communication. Legal
rights do not belong to the user, but to the provider of the WAN networks.
Work memory
The work memory is integrated in the CPU and cannot be extended. It is used to run the
code and process user program data. Programs only run in work memory and system
memory.
See also CPU

Index
Procedure with the hardware, 144

Procedure with the software, 145
( PROFIBUS DP, 165
PROFINET IO, 172
(Simple Network Management Protocol), 40
Reaction to errors, 146
Software requirement, 145
Commissioning stage, 228
A
Communication
Accessories Communication protocols, 41
IM 151-8 PN/DP CPU, 244 Data consistency, 40
Address area Data set routing, 38
of the I/O modules, 134 OP communication, 36
Address assignment Open IE communication, 41
for analog and digital modules, 134 Programming device communication, 35
Addresses S7 communication, 36
Start addresses, 136 Services of the IM 151-8 PN/DP CPU interface
Addressing module, 33
Assignment of addresses, 136 Communication load
slot-oriented, 133 configured, 252
Unassigned, 136 Dependency of actual cycle time, 253
Application transfer areas, 106 Influence on the actual cycle time, 253
Application View, 96 Communications concept, 96
Asynchronous error, 207 Component-Based automation, 96
Automation concept, 96 Compression, 121
Connect the PROFINET connector, 130
Connect the RJ45 connector, 130
B Connecting
IM 151-8 PN/DP CPU, 128
Back up
PG, 158
Operating system, 181
Connecting the supply voltage, 131
The firmware, 181
Connection
Basic knowledge required, 3
DP master module, 132
Blocks, 100
Consistency, 137, 139
compatibility, 100
Constant bus cycle time, 168
Deleting, 121
Cross circuit detection, 199
Delta download, 120
Cycle time
Download, 117
Calculation, 250
Encryption, 119
Definition, 247
Reloading, 120
Extension, 249
Upload, 120
Process image, 247
Bus terminator, 188, 190
Sequence of cyclic program processing, 248
Time slice model, 247
C
Commissioning D
Check list, 147
Data consistency, 40
Hardware Requirements, 143
Data set routing, 38
IM 151-8 PN/DP CPU as a DP master, 166
Default addressing, 133

Index
Deleting, 121 G
Delta download, 120
Guide
Diagnostics
Operating Instructions, 6
in DP Master mode, 224
with Diagnosing Hardware, 210
with LEDs, 213
I
with system functions, 209
Diagnostics address, 225 I&M data, 202
Diagnostics buffer, 208, 227 I/O process image, 113
Diagnostics Concept, 228 I/O transfer areas, 106
Dimensional diagram Identification and maintenance data, 202
DP master module, 246 Identification data, 202
IM 151-8 PN/DP CPU, 245 I-Device
Direct data exchange, 170 Application transfer areas, 106
Display elements I/O transfer areas, 106
DP master module, 26 IP address assignment, 139
Display languages IM 151-8 PN/DP CPU
of the web server, 54 Accessories, 244
Disposal, 6 commissioning as a DP master, 167
Documentation Connecting, 128
Additional, 261 Dimensional diagram, 245
Download installing, 127
of blocks, 117 Memory reset, 151
DP master module Properties, 16
connecting, 132 Response after replacement, 189
Dimensional diagram, 246 Technical specifications, 230
Display elements, 26 IM 151-8 PN/DP CPU factory settings
installing, 132 Lamp images during reset, 157
Properties, 19 Properties, delivery state, 156
Technical specifications, 242 Restore delivery state, 156
Industrial Ethernet, 95
Installing
E DP master module, 132
IM 151-8 PN/DP CPU, 127
Error
interfaces
Asynchronous, 207
PROFIBUS DP interface:Time synchronization, 32
Synchronous, 207
Interfaces
Error displays, 25
PROFIBUS DP interface, 32
ET 200S with IM 151-8 PN/DP CPU
PROFIBUS DP interface:Connectable devices, 33
initial power on, 150
PROFINET interface, 27
Event recognition, 226
PROFINET interface properties, 28
PROFINET interface: configuring the port
properties, 29
F
PROFINET interface:Addressing the ports, 30
Failure PROFINET interface:Connectable devices, 28
ET 200S (PROFINET IO), 188, 190 PROFINET interface:Disabling a port, 29
Firewall, 53 PROFINET interface:Send clock, 30
Firmware PROFINET interface:Time synchronization, 27
Back up, 181 PROFINET interface:Update Time, 30
Forcing, 205 PROFINET send clock interface, 31
FREEZE, 169 PROFINET Update Time interface, 31
Internet

Index
Service & support, 7 Creating a connection to the IM 151-8 PN/DP CPU

Interrupt response time interface module, 163
Definition, 259 Creating a variable table, 161
IM 151-8 PN/DP CPU, 259 Modifying variables, 162
Process interrupt processing, 260 Monitor variable, 161
IRT, 103 opening the VAT, 163
Saving the variable table, 163
setting the trigger points, 162
L MRP, 108
LAN, 128
LED
N
LED, 19
Load memory, 109 Network Diagnostics, 211
Local data, 115 Network node, 37
Longest response time Non-whole number send clock, 31
Calculation, 259
Conditions, 258
O
OB 83, 102
M
OB86, 102
Maintenance data, 202 OP communication, 36
Media redundancy, 128 Open user communication, 78
Memory Operating Instructions
Compression, 121 Changes since previous version, 4
Memory areas Purpose, 3
Load memory, 109 Operating system
System memory, 109 Back up, 181
Work memory, 110 Update, 182
Memory functions Order numbers
Compression, 121 Accessories, 244
Deleting blocks, 121 Cables, 244
Delta downloading for blocks, 120 Connector, 244
Download of blocks, 117 DP master module, 243
Downloading blocks, 120 IM 151-8 PN/DP CPU, 243
Memory reset, 121 Organization blocks, 102
Promming, 121 OUC, 78
RAM to ROM, 121
Restart, 121
Uploading blocks, 120 P
Warm start, 121
Parameterization
Memory reset, 151
Reference junction, 193
with mode selector switch, 152
PELV, 128
Mode selector switch, 24
PG
Memory reset, 152
Connecting, 158
Modifying
Pin assignment
of variables, 204
Bus connector, 132
Monitor
Pin assignment for supply voltage, 131
of variables, 204
RJ45 connector, 130
Monitoring and modifying variables
Power module
Controlling outputs in STOP of the IM 151-8 PN/DP
Status byte, 199
CPU interface module, 164
Power on

Index
initial, 150 Load memory, 110

Requirements, 150 Retentive behavior of the memory objects, 111
Process interrupt processing, 260 System memory, 110
PROFIBUS, 165 Ring topology, 27
PROFIBUS DP Routing
Commissioning, 165 Access to a CPU on another subnet, 37
Direct data exchange, 170 Network node, 37
PROFIBUS DP interface, 32 Requirements, 38
PROFIBUS International, 96
PROFINET, 172
Device replacement without removable S
medium, 104
S7 Block Privacy, 119
I-Device, 106
S7 communication, 36
Implementation, 96
S7 connections
Isochronous mode, 105
Distribution, 47
Isochronous real time communication, 103
End point, 44
Media redundancy, 108
IM 151-8 PN/DP CPU, 48
Objectives, 95
Time sequence for allocation, 46
Prioritized startup, 103
Transition point, 44
Shared Device, 107
Scope
Switch, 128
Operating Instructions, 3
PROFINET CBA, 96
Security
PROFINET interface, 27
of the web server, 53
IO device, troubleshooting, 222
SELV, 128
PROFINET IO, 172
Service & Support, 7
Commissioning, 172
Service case, 228
Programming device communication, 35
Service data
Properties
Application, 201
Procedure, 201
IM 151-8 PN/DP CPU, 16
SF LED
Evaluation, 215
SFB 52, 101
R
SFB 53, 101
RAM to ROM, 121 SFB 54, 101
Recycling, 6 SFB 81, 101
Reference junction SFC 12, 100
Parameter assignment, 193 SFC 14, 137, 139
Reloading, 120 SFC 15, 137, 139
Replacing SFC 49, 100
DP master module, 191 SFC 58, 100
IM 151-8 PN/DP CPU interface module, 189 SFC 59, 100
Response time SFC 70, 101
Calculating the longest, 259 SFC 71, 101
Calculation, 257 SFC102, 101
Conditions, 257 SFC13, 100
Conditions for the longest, 258 SFC5, 100
Definition, 255 Shortest response time
DP cycle times, 255, 256 Calculation, 257
Factors, 255 Conditions, 257
Fluctuation width, 255 SIMATIC Manager, 160
Restart, 121 start, 160
Retentive memory, 110 SIMATIC Micro Memory Card

Index
Properties, 116 V
Service life, 117
Variables
Slot, 24
Forcing, 205
Slot assignment
Modifying, 204
ET 200S, 134
Monitor, 204
Slot-oriented addressing of the centralized I/O
modules, 133
SNMP, 40, 211
W
Startup
IM 151-8 PN/DP CPU as a DP master, 167 WAN, 128
IM 151-8 PN/DP CPU as an IO controller, 177 Warm start, 121
IM151-8 PN/DP CPU as an I device, 178 Watchdog interrupt, 260
Status and error LEDs Web access to IM 151-8 PN/DP CPU
PROFINET IO devices, 222 via HMI devices, 52
Status byte, 199 via PDA, 52
Status displays, 25 via programming device / PC, 52
Stepping mode, 204 Web server, 51
Switch, 128 Access only by HTTPS, 57
SYNC, 169 activate, 56
Synchronous error, 207 Automatic update, 58
System and Standard Functions, 100, 101 Display classes of the messages, 58
System memory, 109 Display languages, 54
I/O process image, 113 Printing refresh status, 59
Local data, 115 Screen content refresh status, 59
Security, 53
Set the language, 57
T Status of the modules, 67
Topology, 80
User list, 57
User pages, 91
IM 151-8 PN/DP CPU, 230
without SIMATIC Micro Memory Card, 53
Time-delay interrupt, 260
Work memory, 110
Training center, 6
Transfer memory
Access from the user program, 137, 139
Troubleshooting, 207
U
Update
Operating system, 182
Upload, 120
Useful life of a SIMATIC Micro Memory Card, 117
User program
Deleting, 121
Delta download, 120
Reloading, 120
Upload, 120
User-oriented addressing of the I/O Modules, 136

Index


SECTION 3.4.
Input / Output list
▹▹▷

LOCATION COLOMBIA
DOCUMENT NAME INPUT/OUTPUT LIST
DOCUMENT CODE M_3108_IOL_0
P&ID 23749
JOB No. 11880
SERIAL No. 3108
REVISION HISTORY
00 First issue 05/07/2018 Corradi GP M. Pettenati G. Opl
BRAM‐COR S.p.A
Tel. +39 0521 538711
Fax: +39 0521 538770
Page 1 of 3
INPUT/OUTPUT LIST
Customer: FARMALOGICA S.A. Job no.: 11880 Document code: M_3108_IOL_0 Rev.: 00
I/O No. Descrizione Description TAG No.
AI‐PEW256 PRESSIONE VAPORE PURO (‐1/5 bar) PURE STEAM PRESSURE (‐1/+5 bar) 20 PT‐001

AI‐PEW258 LIVELLO COLONNA (0‐100%) COLUMN LEVEL (0‐100%) 20 LT‐001
AI‐PEW260 RISERVA SPARE
AI‐PEW262 RISERVA SPARE
AO‐PAW256 VALVOLA MODULANTE VAPORE INDUSTRIALE 20 PV‐001 20 PV‐001 INDUSTRIAL STEAM MODULATING VALVE 752RP1

AO‐PAW258 RISERVA SPARE
DI‐E0.0 PROTEZIONE CIRCUITO 220 VAC 220 VAC CIRCUIT PROTECTION 101QF1/101QF2

DI‐E0.1 PROTEZIONE CIRCUITO 24 VDC 24 VDC CIRCUIT PROTECTION 102QF3
DI‐E0.2 TERMICO POMPA P‐2001 P‐2001 PUMP OVERLOAD 110QM1
DI‐E0.3 RISERVA SPARE
DI‐E0.4 RESET CIRCUITO D'EMERGENZA EMERGENCY CIRCUIT RESET 201SH1

DI‐E0.5 RIPRISTINO CIRCUITO D'EMERGENZA EMERGENCY CIRCUIT RESTORE 201KA1
DI‐E0.6 PULSANTE EMERGENZA ATTIVO EMERGENCY PUSHED ACTIVE 200SB1
DI‐E0.7 RESET SIRENA SIREN RESET 350SB1
DI‐E1.3 MANCANZA ARIA 20 PS‐001 AIR LACK 20 PS‐001 751P1

DI‐E1.4 MANCANZA VAPORE INDUSTRIALE 20 PS‐002 INDUSTRIAL STEAM LACK 20 PS‐002 351P1
Page 2 of 3
INPUT/OUTPUT LIST
Customer: FARMALOGICA S.A. Job no.: 11880 Document code: M_3108_IOL_0 Rev.: 00
I/O No. Descrizione Description TAG No.
DI‐E1.7 ACQUA ALIMENTO DISPONIBILE FEED WATER AVAILABLE
DO‐A0.0 RESET CIRCUITO EMERGENZA EMERGENCY CIRCUIT RESET 400KA1

DO‐A0.1 P‐2001 MARCIA POMPA ACQUA ALIMENTO P‐2001 WATER INLET PUMP START 400KA2
DO‐A0.2 RISERVA SPARE
DO‐A0.3 COMANDO SIRENA SIREN COMMAND 400KA3

DO‐A0.6 RICHIESTA ACQUA ALIMENTO FEED WATER REQUEST 400KA4

DO‐A0.7 RICHIESTA SCORTA CLIENTE CUSTOMER SPARE REQUEST 400KA5
DO‐A1.0 VALVOLA 20 XV‐001 ACQUA INGRESSO ALIMENTO 20 XV‐001 WATER INLET VALVE 401YV1
DO‐A1.1 VALVOLA 20 XV‐002 BY‐PASS ACQUA ALIMENTO 20 XV‐002 BY‐PASS WATER INLET VALVE 401YV2
DO‐A1.2 VALVOLA 20 XV‐003 SCARICO 20 XV‐003 DISCHARGE VALVE 401YV3
DO‐A1.3 VALVOLA SCORTA SPARE VALVE 401YV4
Page 3 of 3

SECTION 3.5.
PLC/HMI software identification form
▹▹▷

LOCATION COLOMBIA
DOCUMENT NAME SOFTWARE IDENTIFICATION FORM
DOCUMENT CODE M_3108_SIF_0
SYSTEM PURESTEAM GENERATOR
JOB No. 11880
SERIAL No. 3108
REVISION HISTORY
0 First issue 06/08/2018 S. Magri V. Cucci A. Scala
BRAM‐COR S.p.A
Tel. +39 0521 538711
Fax: +39 0521 538770
Page 1 of 2
SOFTWARE IDENTIFICATION FORM
M_2800_SIF_0
SOFTWARE DI SVILUPPO / DEVELOPMENT SOFTWARE
Software utilizzati per lo sviluppo dei programmi PLC ed HMI/SCADA/ Software used for the development of the application software.
SW SVILUPPO PLC ‐ PLC SYSTEM DEVELOPMENT SW SW SVILUPPO KTP ‐ KTP SYSTEM DEVELOPMENT SW
Nome ‐ System name Costruttore ‐ Manufacturer Versione SW ‐ SW Version Nome ‐ System name Costruttore ‐ Manufacturer Versione SW ‐ SW Version
STEP 7
STEP 7 SIEMENS TIA PORTAL SIEMENS TIA PORTAL ver. 13 + SP1
ver. 5.5 + SP4 + HF11
SOFTWARE APPLICATIVI / APPLICATION SOFTWARE
Programmi applicativi PLC ed HMI/SCADA ‐ PLC and HMI/SCADA application programs.
SW APPLICATIVO PLC ‐ PLC SYSTEM SW SW APPLICATIVO KTP ‐ KTP SYSTEM SW
Programmatore
Nome file ‐ File name Programmatore‐Programmer Nome file ‐ File name
Programmer
SCALA A. M_3108_SW_0 SCALA A. M_3108_SW_0.zap13
Supporto di Back‐up Programma / Program back‐up Support
Zip Archive
Page 2 of 2

SECTION 3.6.
Alarms list and actions
▹▹▷

LOCATION COLOMBIA
DOCUMENT NAME ALARM LIST AND ACTIONS
DOCUMENT CODE M_3108_ALA_0
P&ID 23749
JOB No. 11880
SERIAL No. 3108
REVISION HISTORY
0 First issue 03/08/2018 S. Magri V. Cucci A. Scala
BRAM‐COR S.p.A
Tel. +39 0521 538711
Fax: +39 0521 538770
Page 1 of 4
ALARM LIST AND ACTIONS
Customer: FARMALOGICA S.A. Job no.: 11880 Document code: M_3108_ALA_0 Rev.: 0
Plant Delay time/ Alar.

Alarm TAG No. Alarm Name Alarm description Action
Stop Set point Rev.
The PLC activate an error message due to PLC The pure steam generator stops with alarm.
G_004 ‐ PLC INTERNAL ERROR Yes 0 s 0
anomaly. Activation of acoustic signal.
When the thermal protection is OFF, the pure steam
CIRCUIT 230 VAC ‐ INTERVENTION The thermal protection off 230 V AC switches
G_010 ‐ Yes generator stops with alarm. Activation of acoustic 0 s 0
PROTECTION OFF.
signal.
CIRCUIT 24 V DC ‐ INTERVENTION
G_012 ‐ Yes The thermal protection off 24 V DC switches OFF. generator stops with alarm. Activation of acoustic 0 s 0
PROTECTION (24VP FAILURE)
signal.
FEED WATER PUMP ‐ ENGINE The thermal protection for pump P‐2001 switches
G_030 P‐2001 Yes generator stops with alarm. Activation of acoustic 0 s 0
PROTECTION OFF.
signal.
When the emergency button is pressed and the
operator tries to reset the emergency circuit, the
G_070 ‐ EMERGENCY CIRCUIT NOT RESTORABLE Yes The emergency circuit has not been restored. 2 s 0
pure steam generator does not restart. Activation of
acoustic signal.
When the pure steam generator emergency button
The pure steam generator emergency buttons is
G_072 ‐ EMERGENCY BUTTON PRESSED Yes is pressed, the pure steam generator stops with 0 s 0
pressed.
alarm. Activation of acoustic signal.
Page 2 of 4

Stop Set point Rev.
When the compressed air pressure drops below the
The compressed air pressure drops below the
G_090 20 PS‐001 COMPRESSED AIR LACK Yes value set into 20PS‐001, the pure steam generator 5 s / 5 bar 0
value set into 20PS‐001.
stops with alarm. Activation of acoustic signal.
When the industrial steam pressure drops below the
The industrial steam pressure drops below the
G_092 20 PS‐002 MISSING INDUSTRIAL STEAM Yes value set into 20PS‐002, the pure steam generator 60 s / 2 bar 0
value set into 20 PS‐002.
stops with alarm. Activation of acoustic signal.
When the measured value of pressure is higher than
The pure steam pressure measured by 20PT001 is
G_203 20 PT‐001 PURE STEAM ‐ PRESSURE (bar) ‐ HH Yes maximum set point, this alarm will appear. 3 s / 4.5 bar 0
over the maximum set‐point.
Activation of acoustic signal.
When the water level in the column C‐2001 is under
30 s / 30 %
Water level inside column is under the minimum the minimum level of 20LT‐001, the pure steam
G_400 20 LT‐001 COLUMN C‐2001 MINIMUM LEVEL Yes by Customer 0
level signed by instrument 20LT‐001. generator stop with alarm. Activation of acoustic
(0 ‐ 100 %)
signal.
When the water level in the column C‐2001 is over
15 s / 90 %
Water level inside column is over the maximum the maximum level of 20LT‐001, the pure steam
G_402 20 LT‐001 COLUMN C‐2001 MAXIMUM LEVEL Yes by Customer 0
level signed by instrument 20LT‐001. generator stops with alarm.
(0 ‐ 100 %)
Activation of acoustic signal.
When the level value is lower than minimum level
Water level inside column is under the minimum floating of instrument 20LT‐001 during initial filling
PURE STEAM ‐ PRODUCTION ‐ FILLING
G_450 20 LT‐001 Yes level signed by instrument 20LT001 during the phase (with the pump in run), after a delay time he 1200 s 0
FAILED C‐2001
initial filling after a fixed time. pure steam generator stops with alarm. Activation of
acoustic signal.
Page 3 of 4

Stop Set point Rev.
When there is no presence of the internal signal
When the machine is active and the signal from
G_490 ‐ FEED WATER INLET NOT AVAILABLE Yes coming from the customer, the PS generator stops 5 s 0
customer's control system is off.
with alarm. Activation of acoustic signal.
Page 4 of 4

SECTION 3.7.
PLC / HMI software recovery procedures
▹▹▷

IO 73_01_04 Rev. 1
PLC Software Application Recovery Procedure Page 1 of 12
Simatic S7
Standard Operating Procedure for PLC Software Application Recovery

Simatic S7
REVISIONS HISTORY
REV DESCRIPTION DATE ISSUED by VERIFIED by APPROVED by
00 First emission 18.02.2011 A. Zanisi C. Opl A.Scala
01 General revision 02.11.2017 P.Gandolfi C. Opl A.Scala
BRAM-COR S.P.A.
Via Mercalli 12/A - 43122 Parma
Tel. 0039 0521 538711
Fax: 0039 0521 538770
e-mail: info@bram-cor.com
IO 73_01_04 Rev. 1
Page 2 of 12
PLC Software Application Recovery Procedure
Simatic S7
INDEX
1. GENERAL INFORMATION ................................................................................................................. 3
1.1. SCOPE AND APPLICATION ................................................................................................................ 3
1.2. NECESSARY TOOLS ........................................................................................................................... 3
1.3. MAIN REFERENCES ........................................................................................................................... 3
1.4. TERMINOLOGY AND ABBREVIATIONS .............................................................................................. 3
2. RECOVERY PROCEDURE ................................................................................................................... 4
2.1. PERSONAL COMPUTER/PLC COMMUNICATION............................................................................... 4
2.2. FILE TRANSFER.................................................................................................................................. 4
2.3. DB TRANSFER ................................................................................................................................. 10
File name: IO 73_01_04

IO 73_01_04 Rev. 1
Page 3 of 12
Simatic S7
1. GENERAL INFORMATION

This procedure provides technical information for the PLC Application Software Recovery.
This SOP is intended for Maintenance and Automation Technicians who are directly involved in the Plant
system management.
Please refer to SIEMENS products documentation (available on the CD ROM supplied by BRAM-COR) for
general information.
In the following pages, all texts are available ONLY in Italian language, since the program is installed in
the language of the developer’s country.
1.2. NECESSARY TOOLS

To carry out the PLC software recovery, following items are necessary.
 PERSONAL COMPUTER (or SIEMENS PG)
 SIEMENS SIMATIC MANAGER
 SIMATIC S7 PC ADAPTER (code 6ES7 972 0CB20-0XA0) or similar
 CD ROM (supplied by BRAM-COR) with the last version of PLC/SCADA program
1.3. MAIN REFERENCES

 Hardware technical documentation & manuals
 Industrial PC – Operating manual
Acronymes Description
DB Data Block
HMI Human-machine Interface
IM Interface Module
OIT Operator Interface Terminal
PID Proportional–Integral–Derivative controller
PW Purified Water
RO Reverse Osmosis
SCADA Supervisory Control and Data Acquisition
SOP Standard Operating Procedure
SW Software
UPS Uninterruptible Power Supply

IO 73_01_04 Rev. 1
Page 4 of 12
Simatic S7
2. RECOVERY PROCEDUREPERSONAL COMPUTER/PLC COMMUNICATION

 Turn off the main switch and open the control board.
 Connect the SIMATIC S7 PC ADAPTER to the PLC and to the Personal computer (or SIEMENS PG).
 Copy the final version of the PLC program stored in the CD ROM on the desktop of your computer.
2.2. FILE TRANSFER

Open the SIMATIC MANAGER program.
Through the TOOLBAR, enlarge the FILE menu, press on the command “DISARCHIVIA” to open the PLC
program file.
This action is necessary in order to unzip the compressed file of the program.

IO 73_01_04 Rev. 1
Page 5 of 12
Simatic S7
Now, you must specify the actual position of the file that you want to unzip.
In the example, the file is on the desktop.
Automatically, SIMATIC MANAGER suggests the correct location to save the unzipped file; in this case the
folder is called S7proj.

IO 73_01_04 Rev. 1
Page 6 of 12
Simatic S7
Now, the file is unzipped: the system automatically requires if the user wants open the file.
For confirmation press Sì. (YES).
After pressing the “Sì” (YES) key, the SIMATIC MANAGER PROGRAM opens the screenshot below.

IO 73_01_04 Rev. 1
Page 7 of 12
Simatic S7
Click on icon to down-load the file.
On the following page, the system has checked the CPU selected before by writing the program against the
actual CPU.
In this case, of course, this check was positive and the communication between the personal computer and the
PLC can be activated.
By Clicking on the icon “CARICA” (LOAD) in the upper tools bar, the data transfer from the PLC starts
automatically.

IO 73_01_04 Rev. 1
Page 8 of 12
Simatic S7
If other data are filed in PLC memory, the system requires confirmation in order to cancel old data and to
consequently save new data.
Press the “Sì” (YES) key to proceed to the following step in the transfer phase which starts immediately.
To transfer the file, the program automatically stops the CPU. In this way the plant (if running) is stopped.
In the following page, the system requires confirmation for stopping the CPU. Press the OK key for
confirmation.
After pressing the OK key, the system shows the status of the program transfer. In the example below,
the FC201 transfer is in progress.

IO 73_01_04 Rev. 1
Page 9 of 12
Simatic S7
Transfer in
progress for
FC201
As soon as the program transfer is completed, the CPU (which was in STOP) must be re-started. Click on
the “Sì” (YES) key in the confirmation window to restart the CPU.

IO 73_01_04 Rev. 1
Page 10 of 12
Simatic S7
2.3. DB TRANSFER
During the initial development of the program, the functional parameters for normal plant operation are
set in the appropriate parts of the program.
At the end of the start-up and final configuration phase at the Customer’s facility, the information
contained in the Data Blocks can be saved in a special software section: this function, called DBONLINE,
allows saving the set-up functional parameters, in order to recover these data whenever a re-installation
is needed. This function allows therefore an easy re-start of the plant with its original configuration.
IMPORTANT NOTE:
If, after the start-up phase, the Customer did some modifications to the parameters on the Data Blocks
(or DBs) without saving these modifications, the same modifications on the parameters shall be repeated
when the program is re-loaded, because the CD-ROM supplied by BRAM-COR provides the back-up of the
program “AS LEFT” after the start-up.
To transfer the Data Blocks, proceed as follows:
Click on icon “Blocchi Offline” (OFFLINE BLOCKS)
Click on the command “ CARICA” (LOAD). As for the PLC program transfer, the OFFLINE blocks can
be transferred in the standard configuration of the plant.

IO 73_01_04 Rev. 1
Page 11 of 12
Simatic S7
The SIMATIC MANAGER program can check the blocks actually saved on the CPU and of the Data Block to
be transferred.
Click in the OK key to confirm this operation in order to proceed

IO 73_01_04 Rev. 1
Page 12 of 12
Simatic S7
Now select the “NODO” (KNOT) to allow communication between the Personal Computer and the PLC (see the
correct configuration in following picture).
If other blocks are saved in the PLC memory, the system requires to cancel old data and to save new data.
Press the “Sì” (YES) key to confirm file overwriting.
As soon as this transfer has been completed, the plant can be re-started in the same configuration saved on the BACK-UP
CD-ROM.

IO 73_01_14 Rev. 01
PANEL HMI Application Software Page 1 of 6
Recovery Procedure – Tia Portal
Standard Operating Procedure for PANEL HMI Application Software Recovery

Tia Portal
REVISIONS HISTORY
REV DESCRIPTION DATE ISSUED by VERIFIED by APPROVED by
00 First issue 07.01.2015 F. Fresegna C. Opl A.Scala
01 General revision 02.11.2017 P.Gandolfi C. Opl A.Scala
BRAM-COR SPA
Via Mercalli 12/A - 43122 Parma
Tel. 0039 0521 538711
Fax: 0039 0521 538770
e-mail: info@bram-cor.com
IO 73_01_14 Rev. 01
Page 2 of 6
PANEL HMI Application Software
INDEX
1. GENERAL INFORMATION ................................................................................................................................ 3
1.1 Scope and application .................................................................................................................................... 3
1.2 Necessary tools .............................................................................................................................................. 3
1.3 Main references ............................................................................................................................................. 3
1.4 Terminology and abbreviations ...................................................................................................................... 3
2. RECOVERY PROCEDURE .................................................................................................................................. 4

IO 73_01_14 Rev. 01
Page 3 of 6
1.1 Scope and application
This procedure provides technical information for the PANEL HMI Application Software Recovery.
This SOP is intended for Maintenance and Automation Technicians who are directly involved in the Plant
system management.
Please refer to SIEMENS products documentation (available on the CD ROM supplied by BRAM-COR) for
the other general information.
1.2 Necessary tools

To carry out the HMI software recovery, following items are necessary.
 PERSONAL COMPUTER (or SIEMENS PG)
 ETHERNET CABLE or SIMATIC S7 PC ADAPTER (code 6ES7 972 0CB20-0XA0 or similar)
 CD ROM (supplied by BRAM-COR) with the last version of application software.
1.3 Main references

 Hardware technical documentation & manuals
 Operating manual
1.4 Terminology and abbreviations
Acronymes Description
CD-ROM Compact Disc - Read-Only Memory
DB Data Block
HMI Human-machine Interface
IM Interface Module
MPI Multi Point Interface
OIT Operator Interface Terminal
PID Proportional–Integral–Derivative controller
PW Purified Water
RO Reverse Osmosis
SCADA Supervisory Control and Data Acquisition
SOP Standard Operating Procedure
SW Software
UPS Uninterruptible Power Supply
IO 73_01_14 Rev. 01
Page 4 of 6
2. RECOVERY PROCEDURE
 If the HMI PANEL has only a MPI interface, connect it to the Personal computer (or SIEMENS PG) with
SIMATIC S7 PC ADAPTER. If the HMI PANEL has an Ethernet interface, connect it to the Personal
computer (or SIEMENS PG) with an Ethernet cable.
 Turn on the main switch of the control board.
 Copy the file of BACKUP SOFTWARE by BRAM COR, stored in the CD-ROM, on the computer
connected to the HMI.
 Unzip this file: select the file and click the right mouse button on the voice “Extract Here”.
At the end of the process, a new folder will be present. With a double click, enter in the new folder.
IO 73_01_14 Rev. 01
Page 5 of 6
 The new folder contains some files: select the file “Siemens.Simatic.Hmi.PackNGo.exe” and
enable it with a double click. The transfer procedure application starts.
IO 73_01_14 Rev. 01
Page 6 of 6
 Select the “Load settings” options according to the desired setting.

If “Overwrite recipes” is selected, all the recipes present on the panel are overwritten.
If “Overwrite password list” is selected, all the users and passwords present on the panel are
overwritten.
 To start the transfer procedure, click over the Loading button.
 Wait until the transfer procedure is over.
 Disconnect the SIMATIC S7 PC ADAPTER or Ethernet cable.
 Turn on the main switch of the control board.

Section 4
Piping, fittings and welding documentation

4.1. Material list and certificates


SECTION 4.1.
Material list and certificates
▹▹▷

MATERIALS LIST SECTION 4 ‐ PIPING, FITTING AND WELDING DOCUMENTATION
Page 1 of 2
CUSTOMER: SYSTEM: EQUIPMENT:

FARMALOGICA S.A. PURE STEAM GENERATOR CPSG ST 1000
Description Details (mm) Material Manufacturer Heat No. Attachment No.
Concentric Reducer 1½" T.C. ‐ ½" T.C. Ø38.10 thick 1.65 / Ø12.07 thick 1.65 AISI 316L DOCKWEILER 5E791002 1
Elbow 90° ¾" T.C. Ø19.05 thick 1.65 AISI 316L DOCKWEILER N12888 2
Elbow 90° ¾" T.C. Ø19.05 thick 1.65 AISI 316L DOCKWEILER N11038 3
Elbow 90° 1½" T.C. Ø38.10 thick 1.65 AISI 316L DOCKWEILER Y9H2 4
Elbow 90° 2" T.C. Ø50.80 thick 1.65 AISI 316L DOCKWEILER 848966 5
Ferrule from ½" to 2" T.C. From Ø12.70 to Ø50.80 thick 1.65 AISI 316L TOPLINE STAINLESS TPL17TL014 // 17175 6
Tee ¾" T.C. Ø19.05 thick 1.65 AISI 316L DOCKWEILER 208860.848804 7
Tee 1½" T.C. Ø38.10 thick 1.65 AISI 316L DOCKWEILER 099F.848966 8
Tee 2" T.C. Ø50.80 thick 1.65 AISI 316L DOCKWEILER K3C5 9
Tee Reduction ¾" T.C. ‐ ½" T.C. Ø19.05 thick 1.65 / Ø12.07 thick 1.65 AISI 316L DOCKWEILER 508778.848966 10
Tee Reduction 1½" T.C. ‐ ½" T.C. Ø38.10 thick 1.65 / Ø12.07 thick 1.65 AISI 316L DOCKWEILER 848966.Y8H8 11
Square 50x50 50x50 AISI 316L VIRAJ 42707 12
Pipe ¾" T.C. Ø19.05 thick 1.65 AISI 316L DOCKWEILER J183 13
Pipe 1½" T.C. Ø38.10 thick 1.65 AISI 316L DOCKWEILER 852220 14
Pipe 2" T.C. Ø50.80 thick 1.65 AISI 316L DOCKWEILER 850089 15
Gasket ½" T.C. N.A. PTFE NEWMAN 42RXG0050 16
Gasket ¾" T.C.. N.A. PTFE NEWMAN 42RXG0075 17

MATERIALS LIST SECTION 4 ‐ PIPING, FITTING AND WELDING DOCUMENTATION
Page 2 of 2
CUSTOMER: SYSTEM: EQUIPMENT:

FARMALOGICA S.A. PURE STEAM GENERATOR CPSG ST 1000
Description Details (mm) Material Manufacturer Heat No. Attachment No.
Gasket 1½" T.C. N.A. PTFE NEWMAN 42RXG0150 18
Gasket 2" T.C. N.A. PTFE NEWMAN 42RXG0200 19

Attachment 1
▹▹▷

TECHNICAL DOCUMENTATION ‐ M_3108_TD SECTION 4.1.
A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1466 1030122615 July 10, 2018

1080235015 / 900008 1800336413


- - -
REDUCER CONCENTRIC DT-4.1.3-1 WW 38,10 mm 1,500 " x 1,65 mm 0,065 " / 19,05 mm 0,750 " x 1,65 mm 0,065 " - S31603 (316L)
DOCKWEILER KB4062 38.10x1.65 mm/19.05x1.65 mm S31603 HT:5E791002 ASME BPE SF1

- -
Everfit Technology Co., Ltd. 5E791002 1700292654
5E791002 ASTM A479

1 5E791002 S31603 (316L) - 0,014 0,410 1,710 0,028 0,014 16,75 10,05 0,0541
1 - 2,030 - - - - - - - - - -

Wärmebehandlung - Heat treatment: 5E791002 1060 °C, quenched in water B05
Materialverwechselungsprüfung - P.M.I.: 5E791002 OK D04


1 5E791002 - 270 - - - 580 55 72 %

- - -
1 5E791002 - - - - - 80 B -
1
- - - - - - -
1 5E791002 - - - - -
- - - - -
1 5E791002 - - -

- - - -
1 5E791002 - -


- - - - -
1 5E791002 - - -
- - - - - -
1 5E791002 - - - -

- 0,22 µm 0,25 µm 0,33 µm - - -

- - - - - - -

2


Merkblatt HP0
3

Attachment 2
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
941 1030120043 May 22, 2018

1080228710 / 900002 1800311363

ASME BPE-2016 SF1 150,00 St/Pcs - - -

- - -
ELBOW 90° DT-4.1.1-1 (DT-7) - 19,05 mm (0,750 ") x 1,65 mm (0,065 ") - SEAMLESS - S31603 (316L)
DOCKWEILER KA3495 19.05x1.65 mm S31603 HT:N12888 ASME BPE SF1

- -
Clean Tube Creation Inc. N12888 1700262991
N12888 ASTM A269

1 N12888 1.4404/S31603 (316L) - 0,013 0,408 0,605 0,030 0,008 17,04 12,05 0,0093
1 - 2,027 - - - - - - - - - -

Wärmebehandlung - Heat treatment: N12888 - B05
Materialverwechselungsprüfung - P.M.I.: N12888 OK D04


1 N12888 - 271 - - - 572 55 79 %

- - -
1 N12888 - - - - - - -
1
- - - - - - -
1 N12888 OK - - OK -
- - - - -
1 N12888 - - -

- - - -
1 N12888 - -


- - - - -
1 N12888 - - OK
- - - - - -
1 N12888 - - - -

0,16 µm 0,18 µm 0,36 µm 0,49 µm - - -

- - - - - - -

Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 May 22, 2018
2


Merkblatt HP0
3

Attachment 3
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
792 1030119056 April 12, 2018

1080226355 / 900001 1700272100

ASME BPE-2016 SF1 150,00 St/Pcs - - -

- - -
ELBOW 90° DT-4.1.1-1 (DT-7) - 19,05 mm (0,750 ") x 1,65 mm (0,065 ") - SEAMLESS - S31603 (316L)
DOCKWEILER KA3490 19.05x1.65 mm S31603 HT:N11038 ASME BPE SF1

- -
Clean Tube Creation Inc. N11038 1700262986
N11038 ASTM A269, ASTM A270

1 N11038 1.4404 / S31603 - 0,012 0,347 0,843 0,033 0,008 16,96 12,28 0,0109
1 - 2,085 - - - - - - - - - -

Wärmebehandlung - Heat treatment: N11038 - B05
Materialverwechselungsprüfung - P.M.I.: N11038 - D04


1 N11038 - 317 - - - 592 48 -

- - -
1 N11038 - - - - - 80 B -
1
- - - - - - -
1 N11038 OK - - OK -
- - - - -
1 N11038 - - -

- - - -
1 N11038 - -


- - - - -
1 N11038 - - OK
- - - - - -
1 N11038 - - - -

0,15 µm 0,19 µm 0,40 µm 0,56 µm - - -

- - - - - - -

Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 April 12, 2018
2


Merkblatt HP0
3

Attachment 4
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ITALY
449 1030102676 June 2, 2017

1080194058 / 900004 1600249555

ASME BPE SF1 126,00 St/Pcs - - -

- - AOD, EAF
DOCKWEILER HB0150 38.10x1.65 mm S31603 HT:Y9H2 ASME BPE SF1

- -
RathGibson Janesville LLC Y9H2 1600228743
Y9H2 ASTM A269-15a, ASTM A270-15-S2, ASME SA-249M-E15

1 Y9H2 S31603 (316L) - 0,022 0,200 1,630 0,029 0,010 16,50 10,00 0,0400
1 - 2,030 - - 0,360 - - - - - - -

Wärmebehandlung - Heat treatment: Y9H2 1040 °C, bright annealed, Inert Gas Atmosphere, B05
solution annealed
Materialverwechselungsprüfung - P.M.I.: Y9H2 OK D04


1 Y9H2 - 349 50600 - - 607 58 -
1

- - -
1 Y9H2 - - - - - 81 B -
- - - - - - -
1 Y9H2 OK OK - OK -
- - - - -
1 Y9H2 - OK OK

- - - -
1 Y9H2 - -


- - - - -
1 Y9H2 - - OK
- - - - - -
1 Y9H2 - - - -

- 0,28 µm 0,52 µm 0,59 µm - - -

- - - - - - -

2


Merkblatt HP0
3

Attachment 5
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ITALY
2080 1030112843 December 1, 2017

1080213413 / 900002 1700259547

ASME BPE-2016 SF1 250,00 St/Pcs - - -

- - AOD, EAF
DOCKWEILER HB6258 50.80x1.65 mm S31603 HT:848966 ASME BPE SF1

- -
848966 ASTM A269-15a, ASTM A270-15, ASME SA249-E15

1 848966 S31603 (316L) - 0,010 0,460 1,460 0,032 0,009 16,60 10,20 0,0600
1 0,004 2,040 - - 0,380 - - - - - 0,0700 -

solution annealed


1 848966 - 358 51800 - - 621 58 -
1

- - -
1 848966 - - - - - 85 B -
- - - - - - -
1 848966 OK OK - OK -
- - - - -
1 848966 - OK OK

- - - -
1 848966 - -


- - - - -
1 848966 - - OK
- - - - - -
1 848966 - - - -

- 0,15 µm 0,53 µm 0,58 µm - - -

- - - - - - -

2


Merkblatt HP0
3

Attachment 6
▹▹▷

TOPLINE STAINLESS

HARDNESS
HB
1 316L 0.017 0.58 1.74 0.021 0.025 10.10 16.53 2.04 218 525 47
2 316L 0.017 0.58 1.74 0.021 0.025 10.10 16.53 2.04 218 525 47
3 316L 0.019 0.57 1.76 0.022 0.023 10.09 16.51 2.03 216 522 48
4 316L 0.019 0.57 1.76 0.022 0.023 10.09 16.51 2.03 216 522 48
5 316L 0.021 0.62 1.56 0.031 0.018 10.05 16.55 2.09 214 520 42
STAMP:

Attachment 7
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1466 1030122615 July 10, 2018

1080235015 / 900001 1800313966

ASME BPE-2016 SF1 40,00 St/Pcs - - -

- - AOD, EAF
DOCKWEILER KA9817 19.05x1.65 mm S31603 HT:848804/208860 ASME BPE SF1

- -
Iljin 208860 1700280580

208860 ASTM A269, ASTM A270


1 208860 S31603 (316L) - 0,014 0,310 1,560 0,035 0,007 16,93 12,17 0,0260
2 848804 S31603 (316L) - 0,009 0,390 1,490 0,034 0,009 16,70 10,20 0,0600
1 - 2,210 - - - - - - - - - -
2 0,004 2,040 - - 0,480 - - - - - 0,1000 -

Wärmebehandlung - Heat treatment: 208860 - B05

solution annealed
848804 OK
1


1 208860 - 232 - - - 570 49 -
2 848804 - 449 65000 - - 690 47 -

- - -
1 208860 - - - - - 77 B -
2 848804 - - - - - 81 B -
- - - - - - -
1 208860 OK - - OK -
2 848804 OK OK - OK -
- - - - -
1 208860 - - -
2 848804 - OK OK

- - - -
1 208860 OK -
2 848804 - -


- - - - -
1 208860 - - OK
2 848804 - - OK
- - - - - -
1 208860 - - - -
2 848804 - - - -

2
- 0,09 µm 0,75 µm 1,05 µm - - -

- - - - - - -


Merkblatt HP0
3

Attachment 8
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ITALY
394 1030117208 March 1, 2018

1080221919 / 900010 1700254594

ASME BPE-2016 SF1 50,00 St/Pcs - - -

- - AOD, EAF
DOCKWEILER KA6478 38.10x1.65 mm S31603 HT:848966/099F ASME BPE SF1

- -
RathGibson Janesville LLC 099F 1700271021

099F ASTM A269-15a, ASTM 270-15-S2, ASME SA249-E15


1 099F S31603 (316L) - 0,019 0,410 1,700 0,026 0,011 16,60 10,00 0,0400
2 848966 S31603 (316L) - 0,010 0,460 1,460 0,032 0,009 16,60 10,20 0,0600
1 - 2,010 - - 0,490 - - - - - - -
2 0,004 2,040 - - 0,380 - - - - - 0,0700 -

Wärmebehandlung - Heat treatment: 099F 1040 °C, bright annealed, Inert Gas Atmosphere, B05
solution annealed
solution annealed
Materialverwechselungsprüfung - P.M.I.: 099F OK D04
848966 OK
1


1 099F - 349 50600 - - 607 58 -
2 848966 - 380 55100 - - 621 54 -

- - -
1 099F - - - - - 82 B -
2 848966 - - - - - 89 B -
- - - - - - -
1 099F OK OK - OK -
2 848966 OK OK - OK -
- - - - -
1 099F - OK OK
2 848966 - OK OK

- - - -
1 099F - -
2 848966 - -


- - - - -
1 099F - - OK
2 848966 - - OK
- - - - - -
1 099F - - - -
2 848966 - - - -

2
- 0,20 µm 0,73 µm 0,97 µm - - -

- - - - - - -

Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 March 1, 2018


Merkblatt HP0
3

Attachment 9
▹▹▷

A04
Zertifiziert nach ISO 9001, Richtlinie 97/23/EG Anhang I
BRAM-COR S.p.A. A06 Kap. 3.1 und 4.3 sowie AD 2000 Merkblatt W0
Quartiere S.P.I.P. Certified as per ISO 9001, directive 97/23/EC Annex I
Section 3.1 and 4.3, and AD 2000 Merkblatt W0
Via G. Mercalli 12/A
I-43122 PARMA www.dockweiler.com
2242 1030071025 December 3, 2014

1080117975 / 900035 1400123028

ASME BPE SF1 7,00 St/Pcs

AOD, EAF
DOCKWEILER FA4406 50,80x1,65/50,80x1,65 S31603 HT:K3C5 ASME BPE SF1

RathGibson Janesville LLC K3C5 1300108991
K3C5 ASTM A269-10, ASTM A270M-10, ASME SA-249M-E10, ASME BPE-09

1 K3C5 S31603 (316L) 0,023 0,260 1,420 0,033 0,011 16,70 10,00 0,0400
1 2,030 0,340

Wärmebehandlung - Heat treatment: K3C5 1040 °C, bright annealed, quenched in gas, solution B05
annealed
Materialverwechselungsprüfung - P.M.I.: K3C5 OK D04


MPa psi MPa psi MPa % %
1 K3C5 293 593 64
1
Kerbschlagbiegeversuch - Impact test Härte - Hardness C30

1 K3C5 81 B
1 K3C5 OK OK OK
1 K3C5 OK OK

ASTM A262 Pract. E

1 K3C5 OK


1 K3C5 OK
1 K3C5

Oberflächenkontrolle: OK außen - outside D03 Materialverwechslung: D04
EN ISO 4287, ASME B46.1 EN ISO 4287, ASME B46.1 EN ISO 6507-1 EN 1435 EN 571-1
Ra(avg) Ra(max) Ra(avg) Ra(max)
0,30 µm 0,33 µm 0,31 µm 0,33 µm
max avg max avg


2

Zertifiziert nach DIN EN ISO 3834-2, DIN EN ISO 15614-1, ASME BPVC Section IX, Modul A1 der Richtlinie 97/23/EG sowie
AD 2000-Merkblatt HP0
Certified as per DIN EN ISO 3834-2, DIN EN ISO 15614-1, ASME BPVC Section IX, Module A1 of Directive 97/23/EC and AD 2000 Merkblatt
HP0
3

Attachment 10
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
746 1030119055 April 24, 2018

1080227461 / 900001 1800324143

ASME BPE-2016 SF1 80,00 St/Pcs - - -

- - AOD, EAF
DOCKWEILER KA9046 19.05x1.65 mm/12.70x1.65 mm S31603 HT:848966/508778 ASME BPE SF1

- -
Iljin 508778 1700278402

508778 DIN EN 10216-5, ASTM A269, ASTM A270-S2, ASME SA-213, PED 97/23/EC, NACE MR0175

1 508778 1.4404 / S31603 - 0,020 0,300 1,130 0,036 0,008 16,79 12,22 0,0280
2 848966 S31603 (316L) - 0,010 0,460 1,460 0,032 0,009 16,60 10,20 0,0600
1 - 2,070 - - - - - - - - - -
2 0,004 2,040 - - 0,380 - - - - - 0,0700 -

Wärmebehandlung - Heat treatment: 508778 - B05

quenched in gas, solution annealed
848966 OK
1


1 508778 - 249 - - - 589 53 -
2 848966 - 369 53500 - - 600 58 -

- - -
1 508778 - - - - - 76 B -
2 848966 - - - - - 82 B -
- - - - - - -
1 508778 OK - - - -
2 848966 OK OK - OK -
- - - - -
1 508778 - - -
2 848966 - OK OK

- - ASTM A262 -
1 508778 OK 7,6
2 848966 - -


- - - - -
1 508778 - - OK
2 848966 - - OK
- - - - - -
1 508778 - - - -
2 848966 - - - -

2
- 0,27 µm 0,68 µm 1,07 µm - - -

- - - - - - -

Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 April 24, 2018

Merkblatt HP0
3

Attachment 11
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ITALY
2157 1030113069 November 13, 2017

1080212392 / 900004 1700254589


- - AOD, EAF
DOCKWEILER KA0224 38.10x1.65 mm/12.70x1.65 mm S31603 HT:848966/Y8H8 ASME BPE SF1

- -

RathGibson Janesville LLC Y8H8 1700254794

Y8H8 ASTM A269-15a, ASTM A270M-15, ASME SA249-E15

1 848966 S31603 (316L) - 0,010 0,460 1,460 0,032 0,009 16,60 10,20 0,0600
2 Y8H8 S31603 (316L) - 0,021 0,210 1,600 0,029 0,009 16,60 10,00 0,0500
1 0,004 2,040 - - 0,380 - - - - - 0,0700 -

2 - 2,010 - - 0,430 - - - - - - -

solution annealed
Y8H8 1040 °C, bright annealed, Inert Gas Atmosphere,
solution annealed
Y8H8 OK
1


1 848966 - 380 55100 - - 621 54 -
2 Y8H8 - 465 67400 - - 669 47 -

- - -
1 848966 - - - - - 89 B -
2 Y8H8 - - - - - 90 B -
- - - - - - -
1 848966 OK OK - OK -
2 Y8H8 OK OK - OK -
- - - - -
1 848966 - OK OK
2 Y8H8 - OK OK

- - - -
1 848966 - -
2 Y8H8 - -


- - - - -
1 848966 - - OK
2 Y8H8 - - OK
- - - - - -
1 848966 - - - -
2 Y8H8 - - - -

2
- 0,23 µm 0,46 µm 0,71 µm - - -

- - - - - - -

Anlagen - Attachment No Dr. Jan Rau, DOCKWEILER AG Z03 November 13, 2017

Merkblatt HP0
3

Attachment 12
▹▹▷

N. Bolla 12619 del 26/07/2017 - Materiale BEB05060 - 316 BQL 50 X 50 L=6000
Quantità 120 kg - Colata 42707 - N. Ord. 733700 - 10 - Rif. Cliente 1265

Attachment 13
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1237 1030121532 June 14, 2018

1080232439 / 900002 1800323884

ASME BPE-2016 SF1 - 24,00 M - -

- - AOD, EAF, VOD

TUBE 19,05 mm (0,750 ") x 1,65 mm (0,065 ") - SEAMLESS - S31603 (316L)
DOCKWEILER-LA4021-19,05 x 1,65mm-3/4" x 0,065"-UNS S31603-ASTMA269/A270S NDE-ASME SA213 avg.Wall-Heat J183-Q11-TPS

GERMANY ASME BPE SF1
- -
TPS Technitube Röhrenwerk GmbH J183 1800318785
J183 ASTM A269-15a, ASTM A270-17-S2, ASME SA213 2017 avg. wall

1 J183 S31603 (316L) - 0,014 0,300 1,140 0,033 0,008 16,88 12,28 0,0300
1 - 2,070 - - - - - - - - - -

Wärmebehandlung - Heat treatment: J183 1040 °C, quenched in gas, solution annealed B05
Materialverwechselungsprüfung - P.M.I.: J183 OK D04


1 J183 - 244 - - - 571 60 -
1

- - -
1 J183 - - - - 145 HV - -
- - - - - - -
1 J183 OK - - OK -
- - - - -
1 J183 - - -

- - ASTM A262 Pract. E, DIN EN ISO -

3651-2A
1 J183 OK 6,5


- - - - ASTM E 426, ASTM A 1016

1 J183 - - OK
- - - - - -
1 J183 - - - -

0,21 µm 0,42 µm 0,19 µm 0,21 µm - - -

- - - - - - -

2

Merkblatt HP0
3

Attachment 14
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1237 1030121532 June 14, 2018

1080232439 / 900003 1700263847

ASME BPE-2016 SF1 - 292,80 M - -

- - AOD, EAF
DOCKWEILER KA3925 38,10 MM X 1,65 MM AVG S31603 ASTM A269M/A270M/S2 WNDE ASME SA249M/S6/S7 HT# 852220 LMM
- -
852220 ASTM A269M-15a, ASTM A270M-15s2, ASME SA-249M-E15, ASME BPE

1 852220 S31603 (316L) - 0,016 0,380 1,420 0,025 0,011 16,60 10,20 0,0500
1 0,002 2,050 - - 0,740 - - - - - 0,1000 -

solution annealed


1 852220 - 347 50300 - - 600 59 -
1

- - -
1 852220 - - - - - 82 B -
- - - - - - -
1 852220 OK OK - OK -
- - - - -
1 852220 - OK OK


1 852220 OK -


- - - - -
1 852220 - - OK
- - - - - -
1 852220 - - - -

0,30 µm 0,38 µm 0,28 µm 0,30 µm - - -

- - - - - - -

2

Merkblatt HP0
3

Attachment 15
▹▹▷

A04
Certified as per
BRAM-COR S.p.A. A06
ISO 9001:2015 Cert. No. 07 100 980183
43122 PARMA ISO 3834-2:2005 Cert. No. 50164/3
1237 1030121532 June 14, 2018

1080232439 / 900001 1700275416

ASME BPE-2016 SF1 - 61,00 M - -

- - AOD, EAF
DOCKWEILER KA7964 50,80 MM X 1,65 MM AVG S31603 ASTM A269M/A270M/S2 WNDE ASME SA249M/S6/S7 HT# 850089 TMH
- -
850089 ASTM A269-15a, ASTM A270M-15, ASME-SA249M-E17, BPE-16

1 850089 S31603 (316L) - 0,013 0,420 1,470 0,034 0,012 16,60 10,10 0,0500
1 0,004 2,040 - - 0,400 - - - - - 0,0700 -

solution annealed


1 850089 - 354 51300 - - 614 56 -
1

- - -
1 850089 - - - - - 84 B -
- - - - - - -
1 850089 OK OK - OK -
- - - - -
1 850089 - OK OK


1 850089 OK -


- - - - -
1 850089 - - OK
- - - - - -
1 850089 - - - -

0,25 µm 0,31 µm 0,67 µm 0,70 µm - - -

- - - - - - -

2

Merkblatt HP0
3

Attachment 16
▹▹▷


Attachment 17
▹▹▷


Attachment 18
▹▹▷


Attachment 19
▹▹▷


SECTION 4.2.
▹▹▷


SECTION 4.2.1.
WPS: Welding procedure specification
▹▹▷


SECTION 4.2.2.
WPQR: Welding procedure qualification record
▹▹▷


SECTION 4.2.3.
WPQ: Welding performance qualification
▹▹▷

Area : ITALY
Region :
Certificato No. : QS-ITA-18-05429-rev.0
Certificate No. :
Rif. Interno : 18.IT.3163843.138
Internal No. : P17211/18/EM/em
Notified Body Yes
1. CERTIFICATO DI QUALIFICA SALDATORE IN ACCORDO A UNI EN ISO 9606-1: 2017

(WELDER QUALIFICATION TEST CERTIFICATE IN ACCORDANCE WITH UNI EN ISO 9606-1:2017)
1a Riconduzione del certificato N° (Renewal of certificate N°):
2. DESIGNAZIONE(I): A) ISO 9606-1, 141, T, BW, FM5, S, s1.65, D12.7, H-L045, ss gb, sl
3. N° riferimento WPS (WPS reference No): 09-01 Rev. 3

4. Nome e Cognome del Saldatore (Welder’s name ): Ciro D'Errico
5. Data e luogo di nascita (Date and Place of birth): 02/02/1987 - San Severo - FOGGIA - ITALY
4a. Identificazione (Identification): C.I. N. AT0968305 5a. Met. di identif. (Ident. Method): STAMP CE
6. Datore di lavoro (Manufacturer): Bram Cor SpA - via G. Mercalli, 12/A - Q.re SPIP - 43122 - Parma - Italy
7. Saggio d’angolo supplementare (Supplementary fillet weld test): Si (Yes)  No (No) 

8. Conoscenze tecniche / Job Knowledge: Accettabile (Acceptable)  Non verificato (Not tested) 
9. Variabili (Variables) 42. Dettagli della prova pratica 43. Campo di validità della qualifica
(Test piece details) (Range of qualification)
10. Procedimento(i) saldatura (Welding process (es)) A) 141 A) 141, 142, 143 and 145
11. Modalità di trasferimento (Transfer mode)
12. Lamiera o tubo (Plate or pipe) T T

13. Tipo di saldatura (Type of weld) BW BW, FW, BC >= 60°
14. Particolari di saldatura (Weld details) A) ss gb A) ss mb, ss gb, bs
15. Multistratoo strato singolo (Multilayer –singlelayer) sl sl

16. Gruppo (Parent material group(s)) 8 1 to 11 (8 without FM)
17. Gruppo del Metallo d’apporto (Filler material group(s)) A) FM5 A) FM5
18. Tipo del Metallo(i) d’apporto (Filler material types) A) S A) S, M, nm
19. Tipo di gas (Shielding gas) EN ISO 14175 A) I1 A) Appropriated shielding gas protection
20. Materiali ausiliari (Auxiliaries) A) No
21. Tipo di corrente e polarità (Type of current and polarity) A) DC EP
22. Dimensioni (Dimensions) :

23. Spessore(i) materiale (Material thickness) 1,65
24. Spessore (Deposited thickness metal A) A) 1,65 A) 1,65 to 3,3
25. Spessore (Deposited thickness metal B)
26. Ø esterno tubo (Outside pipe Ø ) 12,70 12,7 to 25,4
27. Posizione saldatura (Welding position) H-L045 P BW:
P FW:
T BW: ALL EXCEPT VERTICAL DOWN
T FW: ALL EXCEPT VERTICAL DOWN
Branch:ALL EXCEPT VERTICAL DOWN
28. Tipo di prova 29.Effettuato 30.Non 31. Prolungamento della qualifica da parte del datore di lavoro o del
ed accettabile verificato
(Type of test) (Performed and (Not verified) supervisore per i successivi 6 mesi
acceptable) (Prolongation for approval by employer/supervisor for the following 6 months)
44. Data (Date) 45. Firma (Signature) 46. Posizione (Position)
32. Esame visivo (Visual test)  
33. Radiografia (Radiographic Examination)  
34. Ultrasuoni (Ultrasonic Examination)  
35. Frattura (Fracture test)  
36. Prova di piega (Bend test)  
37. Macrografia (Macrographic examination)  
38. Prove complement. FW sup. (Addit.tests)  
39. Nome dell’ispettore (Examiner name) Enrico Morini 45. Firma (Signature) 44. Data (Date) 46. Timbro (Stamp)
Approver
40. Data inizio validità (Start of qualification) : 30/05/2018 04/07/2018
41. Validità della qualificazione:
fino a (data): 29/05/2021
(Welding performance qualification valid until)
v1.0.188
BUREAU VERITAS ITALIA Ed.10/2017 http://www.bureauveritas.it Contact : Bureau Veritas Milan Office tel 02.270911 WE/008-ITA Rev.5 Pag 1/2
Area : ITALY
Region : Pagina
CERTIFICATO DI QUALIFICA SALDATORE Certificato No. : QS-ITA-18-05429-rev.0 Page
Certificate No. :
APPROVAL TEST CERTIFICATE FOR WELDER 18.IT.3163843.138 2 / 2
P17211/18/EM/em
Prolungamento della qualifica da parte del datore di lavoro o del supervisore per i successivi 6 mesi - (punto 9.2)
Prolongation for approval by employer/supervisor for the following 6 months (see clause 9.2)
Data Firma Posizione o titolo Data Firma Posizione o titolo
Date Signature Position or title Date Signature Position or title
Rivalidazione della qualifica tramite nuova esecuzione saggio e prove per i successivi 3 anni (punto 9.3.a)
Revalidation of qualification by retesting for the following 3 years (clause 9.3.a)
Data Firma Posizione o titolo Note / Note
Date Signature Position or title
Rivalidazione della qualifica tramite prove per i successivi 2 anni (punto 9.3.b)
Revalidation of qualification by testing for the following 2 years (clause 9.3.b)
Identificazione Data di saldatura/ Prove effettuate / Risultati / Results Conformità dei risultati Rivalidazione / Revalidation
provino Date Performed tests / Conformity of results
Sample SI / YES NO
identification
Area : ITALY
Region :
Certificato No. : QS-ITA-18-05431-rev.0
Certificate No. :
Rif. Interno : 18.IT.3163843.138
Notified Body Yes
1. CERTIFICATO DI QUALIFICA SALDATORE IN ACCORDO A UNI EN ISO 9606-1: 2017

(WELDER QUALIFICATION TEST CERTIFICATE IN ACCORDANCE WITH UNI EN ISO 9606-1:2017)
2. DESIGNAZIONE(I): A) ISO 9606-1, 141, T, BW, FM5, S, s1.65, D50.8, H-L045, ss gb, sl

4. Nome e Cognome del Saldatore (Welder’s name ): Ciro D'Errico
4a. Identificazione (Identification): C.I. AT0968305 5a. Met. di identif. (Ident. Method): STAMP CE
6. Datore di lavoro (Manufacturer): Bram Cor SpA - via G. Mercalli, 12/A - Q.re SPIP - 43122 - Parma - Italy
7. Saggio d’angolo supplementare (Supplementary fillet weld test): Si (Yes)  No (No) 

8. Conoscenze tecniche / Job Knowledge: Accettabile (Acceptable)  Non verificato (Not tested) 
10. Procedimento(i) saldatura (Welding process (es)) A) 141 A) 141, 142, 143 and 145
11. Modalità di trasferimento (Transfer mode)
12. Lamiera o tubo (Plate or pipe) T T, P

13. Tipo di saldatura (Type of weld) BW BW, FW, BC >= 60°
14. Particolari di saldatura (Weld details) A) ss gb A) ss mb, ss gb, bs
15. Multistratoo strato singolo (Multilayer –singlelayer) sl sl

16. Gruppo (Parent material group(s)) 8 1 to 11 (8 without FM)
17. Gruppo del Metallo d’apporto (Filler material group(s)) A) FM5 A) FM5
18. Tipo del Metallo(i) d’apporto (Filler material types) A) S A) S, M, nm
19. Tipo di gas (Shielding gas) EN ISO 14175 A) I1 A) Appropriated shielding gas protection
20. Materiali ausiliari (Auxiliaries) A) No
21. Tipo di corrente e polarità (Type of current and polarity) A) DC EP
22. Dimensioni (Dimensions) :

23. Spessore(i) materiale (Material thickness) 1,65
24. Spessore (Deposited thickness metal A) A) 1,65 A) 1,65 to 3,3
25. Spessore (Deposited thickness metal B)
26. Ø esterno tubo (Outside pipe Ø ) 50,80 >= 25,4
27. Posizione saldatura (Welding position) H-L045 P BW: ALL EXCEPT VERTICAL DOWN
P FW: ALL EXCEPT VERTICAL DOWN
T BW: ALL EXCEPT VERTICAL DOWN
T FW: ALL EXCEPT VERTICAL DOWN
Branch:ALL EXCEPT VERTICAL DOWN
28. Tipo di prova 29.Effettuato 30.Non 31. Prolungamento della qualifica da parte del datore di lavoro o del
44. Data (Date) 45. Firma (Signature) 46. Posizione (Position)
32. Esame visivo (Visual test)  
38. Prove complement. FW sup. (Addit.tests)  
Approver
fino a (data): 29/05/2021
v1.0.188
BUREAU VERITAS ITALIA Ed.10/2017 http://www.bureauveritas.it Contact : Bureau Veritas Milan Office tel 02.270911 WE/008-ITA Rev.5 Pag 1/2
Area : ITALY
Region : Pagina
CERTIFICATO DI QUALIFICA SALDATORE Certificato No. : QS-ITA-18-05431-rev.0 Page
Certificate No. :
APPROVAL TEST CERTIFICATE FOR WELDER 18.IT.3163843.138 2 / 2
P17212/18/EM/em
Revalidation of qualification by testing for the following 2 years (clause 9.3.b)
Sample SI / YES NO
identification
Area : ITALY
Region :
Certificato No. : QOS-ITA-18-00294-rev.0
Certificate No. :
Rif. Interno : 18.IT.3163843.138
Notified Body Yes
1. CERTIFICATO DI QUALIFICA DELL’OPERATORE IN ACCORDO CON UNI EN ISO 14732:2013

(APPROVAL TEST CERTIFICATE FOR WELDING OPERATOR IN ACCORDANCE WITH UNI EN ISO 14732:2013)

3. Nome e Cognome del Saldatore (Welder’s name): Ciro D'Errico
4a. Identificazione (Identification): C.I. AT0968305 4.b. Met. di identif. (Ident. Method): STAMP CE
5. Datore di lavoro (Manufacturer): Bram Cor SpA - via G. Mercalli 12/A - Q.re SPIP - 43122 - Parma - Italy
6. Conoscenze tecniche / Job Knowledge : Accettabile (Acceptable)  Non verificato (Not tested) 

8. Procedimento(i) saldatura (Welding process (es)) 142 142
9. Impianto di saldatura (Welding unit) Orbital Compact One Same equipment
10. Attrezzatura di saldatura (Welding equipment) CWH 115
11. Variabiliper saldatura meccanizzata (Details for mechanized welding)

12. Controllo visivo diretto o indiretto (Visual control direct or remote) Direct Direct
13. Controllo aut. della lunghezza d’arco (Automatic arc lenght control) With With
14. Controllo Automatico del giunto (Automatic Joint tracking) With With
15. Posizione di saldatura (Welding position) PC PC
16. Passata singola / multi passata (Single run/ multi run) Single Single
17. Materiale di supporto (Material backing) Without With or without
18. Inserto Consumabile (Consumable insert) Without With or without
19.Variabili per saldatura automatica (Details for automatic welding)

20.Tastatore (Joint sensor)
21. Sensore di controllo dell’arco (Arc sensor control)
22.Passata singola o multi passata (Single run or multi run)
23.Tipo dell’impianto di saldatura (Type of welding unit)
24.Metodo di qualificazione / The qualification is based on :

25. (4.1a) WPQR in accordo con le parti rilevanti della EN ISO 15614 /Welding procedure test in accordance with the relevant part of EN ISO 15614 
26. (4.1b) Prove di saldatura di pre-produzione o produzione in accordo con EN ISO 15613 / Pre or production welding test in accordance with EN ISO 15613 
27. (4.1c) Prove di saldatura in accordo con le parti rilevanti della EN ISO 9606 / Test piece in accordance with the relevant part of EN ISO 9606 
28. (4.1d) Campionatura di produzione o saggio di produzione / Production test or production test sample 
29. Tipo diprova 30.Effettuato 31.Non 32. Prolungamento della qualifica da parte del datore di lavoro o del
33. Esame visivo (Visual test)   41. Data (Date) 42. Firma (Signature) 43. Posizione (Position)

39. Magnetoscopico (Magn.part. examination)  
40. Altre prove (Other tests)  

Correlazione fra i parametri ed il risultato finale / Correlation between parameter deviations and welding results 
Messa a punto dei parametri in accordo alla WPS / Control parameters setting at the welding unit according to WPS 
Prova di funzionalità dell’impianto in accordo alla WPS / Test the operational items of the welding unit according to WPS 

Individuazione malfunzionamenti influenzanti la saldatura / Welding unit malfunction report influencing the weld 
Approver
fino a (data): 29/05/2021
v1.0.188 Pag. 1/2
BUREAU VERITAS ITALIA Ed.05/2016 http://www.bureauveritas.it Contact : Bureau Veritas Milan Office tel 02.270911 IT-IND-F-007_WELD.PRS.ME Rev.2
Area : ITALY
Region : Pagina
CERTIFICATO DI QUALIFICA DELL’OPERATORE Certificato No. : QOS-ITA-18-00294-rev.0 Page
Certificate No. :
APPROVAL TEST CERTIFICATE FOR WELDING OPERATOR Rif. Interno : 18.IT.3163843.138 2
Internal No. : P17219/18/EM/em /
2
Revalidation of qualification by testing for the following 3years (clause 5.3.b)
Sample SI / YES NO
identification

SECTION 4.2.4.
Pickling and Passivation Report
▹▹▷


SECTION 4.2.5.
Filler material (for manual welding)
▹▹▷

43126 PARMA / ITALY
TEL. 0521/993377 - FAX 0521/988690

Pagina 1 di 1
03/05/2016 1,2 mm 3,2 mm
2,0 mm

Valore / Value


510,0000(N/mm) 2 0,0000 (N/mm) 2
Tensile Strenght Rm
320,0000(N/mm) 2 0,0000 (N/mm) 2
Yield Strenght
Allungamento
30,0000(%) 0,0000 (%)
Elongation A


SECTION 4.2.6.
▹▹▷


Section 5
Manuals and spare parts

5.1. Use and maintenance manual
5.2. Operating manual
5.3. Suggested Spare parts list


SECTION 5.1.
Use and maintenance manual
▹▹▷

LOCATION COLOMBIA
DOCUMENT NAME USE AND MAINTENANCE MANUAL
DOCUMENT CODE M_3108_MA_0
JOB No. 11880
SERIAL No. 3108
REVISION HISTORY
0 First issue 24/07/2018 S. Magri V. Cucci M. Pettenati
BRAM‐COR S.p.A.
Tel. 0039 0521 538711
Fax: 0039 0521 538770

TABLE OF CONTENTS
1. GENERAL INFORMATION ................................................................................................................................. 3
1.1. SCOPE AND APPLICATION.................................................................................................................................. 3
1.2. TERMINOLOGY AND ABBREVIATIONS ............................................................................................................... 3
1.3. REGULATORY STANDARDS ................................................................................................................................ 3
1.4. REFERENCE DOCUMENTATION ......................................................................................................................... 4
1.5. GENERAL INFORMATION ABOUT THIS DOCUMENT .......................................................................................... 4
2. SAFETY INFORMATION .................................................................................................................................... 5
2.1. KEY CONCEPTS ................................................................................................................................................... 5
2.2. SAFETY CONCEPTS ............................................................................................................................................. 6
2.3. SPECIFICATIONS FOR SECURITY ......................................................................................................................... 6
2.4. DANGER SIGNS AND WARNING LABELS ............................................................................................................ 7
2.5. RESIDUAL RISKS: PROTECTION AGAINST BURNING RISK ................................................................................... 7
2.6. GENERAL EMERGENCY PUSH BUTTON .............................................................................................................. 8
2.7. ASSISTANCE REQUEST ....................................................................................................................................... 8
2.8. ORDER OF SPARE PARTS .................................................................................................................................... 8
2.9. GUARANTEE AND TEST ...................................................................................................................................... 8
3. INFORMATION FOR TRANSPORT AND INSTALLATION ....................................................................................... 9
3.1. LOADING – TRANSPORT – UNLOADING ............................................................................................................ 9
3.2. HANDLING AND CARRIAGE .............................................................................................................................. 10
3.3. LIFTING OF THE EQUIPMENT WITH HYDRAULIC FORK LIFT ............................................................................ 10
3.4. EQUIPMENT POSITIONING .............................................................................................................................. 11
3.5. ELECTRIC CONNECTION ................................................................................................................................... 11
3.6. UTILITIES CONNECTION ................................................................................................................................... 11
4. EQUIPMENT DESCRIPTION ............................................................................................................................. 12
4.1. GENERAL INFORMATION ................................................................................................................................. 12
4.2. PURE STEAM GENERATOR ‐ PRODUCTION PROCESS ...................................................................................... 13
4.3. INSTRUMENTATION ........................................................................................................................................ 14
4.4. CONTROL SYSTEM ........................................................................................................................................... 14
5. USE AND MANAGEMENT OF THE SYSTEM ...................................................................................................... 15
5.1. PRELIMINARY OPERATIONS AND TECHNICAL DATA ........................................................................................ 15
5.2. START‐UP: PHASES DESCRIPTION .................................................................................................................... 17
5.3. SYSTEM SHUTDOWN ....................................................................................................................................... 21
5.4. CONDENSATION EMPTYING ............................................................................................................................ 21
5.5. RECOMMENDATIONS ABOUT THE GOOD SAMPLING PRACTICES ................................................................... 21
6. MAINTENANCE AND CLEANING OPERATIONS ................................................................................................ 22
6.1. GENERAL RULES TO BE FOLLOWED FOR A PERIODICAL MAINTENANCE ......................................................... 22
6.2. ORDINARY PREVENTION MAINTENANCE ........................................................................................................ 22
6.3. MAINTENANCE SCHEDULE .............................................................................................................................. 23
6.4. EQUIPMENT STERILIZATION ............................................................................................................................ 29
6.5. EQUIPMENT CLEANING ................................................................................................................................... 29
6.6. TROUBLESHOOTING ........................................................................................................................................ 30
6.7. EQUIPMENT AND CONTROL SYSTEM DISMANTLEMENT AND RETIREMENT .................................................. 31

USE AND MAINTENANCE MANUAL – M_3108_MA_0 PAGE 2 OF 31

This handbook was issued by BRAM‐COR S.p.A. Documentation Dept. and provides technical
information for the safe start‐up, use and maintenance of the Pharmaceutical System described in
chapters 4 and 5.
This Manual is intended for Users, Operators and Maintenance Technicians who are directly engaged
in this system management.
The following key‐steps in the system lifecycle were taken into consideration:
 Loading, Unloading, Transportation and Installation
 Use and Management
 Maintenance and troubleshooting
 Dismantlement and retirement

A description of the rationale of this handbook is provided in section 1.5.
Key‐concepts are repeated throughout the different sections.

User: the person in charge with the normal functioning and ordinary maintenance.
Operator: the person in charge with the transport, installation and start‐up of the equipment.
Maintenance Technician: the skilled person in charge with extraordinary interventions and
reparations.
As described in the operator panel manual instructions, either User and Operator or Maintenance
Technician shall receive adequate training.
The Maintenance Technician is authorized to make changes to the operating parameters of the
system.

HMI = Human Machine Interface
P&ID = Piping and Instrumentation Diagram
TIE IN = Plan of connections and utilities
PLC = Programmable Logic Controller
PW = Purified Water
PS = Pure Steam
WFI = Water for Injections

1.3. REGULATORY STANDARDS
 2006/42/CE “Directive for Machinery”.
 UNI EN 10893 “Technical Documentation of Product: Instructions for Use”.


1.4. REFERENCE DOCUMENTATION
Following reference documentation is filed in the Technical Documentation books of the equipment:
 Operating Manual
 TIE‐IN Drawing
 Piping and Instrumentation Diagrams ‐ P&ID
 Part List
 Electrical Scheme
 Alarms List
 Spare Parts List

1.5. GENERAL INFORMATION ABOUT THIS DOCUMENT
1.5.1. How to use this manual
 Chapter 2 provides SAFETY INFORMATIONS for the safe use of the system;
 Chapter 3 provides INFORMATION FOR TRASPORT AND INSTALLATION;
 Chapter 4 describes EQUIPMENT DESCRIPTION;
 Chapter 5 explains the USE AND MANAGEMENT OF THE SYSTEM;
 Chapter 6 explains how to perform MAINTENANCE OPERATIONS AND TROUBLESHOOTING.
The Control System of the Plant is described in detail in the Manual for Operator Panel of the
equipment, as identified in section 1.4, which is supplied as a separate document.
1.5.2. Document conservation
This handbook was especially issued for the customized system manufactured for the Customer. It is
intended to follow the system throughout its lifecycle, from installation until retirement. The
information shall be treated as "confidential" and should not be provided to third parties without the
permission of the manufacturer. BRAM‐COR S.p.A. supplies this document in hard copy and also in
electronic version. The Use and Maintenance Instructions shall be stored carefully as a key‐reference
for the System management.

1.5.3. Document language
This original document was issued in English language by BRAM‐COR S.p.A.
Any translation shall be considered as an “unverified version” by the Supplier. The Supplier does not
assume any liability in case of failures due to misunderstandings in translation.

1.5.4. Limitations
The pictures of the system in this manual are for example.
Characteristics, data, images and drawings herein belong to BRAM‐COR S.p.A. and are only intended
for authorized personnel for the internal use in your factory. Unauthorized copying and diffusion
thereof are not allowed.

1.5.5. Revisions
After authorized modifications or functional substitutions on the supplied equipment, a revised copy
that will substitute the previous version of the manual shall be provided.

2. SAFETY INFORMATION
2.1. KEY CONCEPTS
This Use and Maintenance Manual is intended as a tool for personnel involved in installation, running
and maintenance with view to avoid any malfunction and/or maintenance errors as well as uses not
envisaged at the design stage of each individual marketed product.
Correct, complete and careful maintenance is fundamental to long‐time product performance.
BRAM‐COR S.p.A. does not assume responsibility whatsoever if the customer does not observe the
designed running conditions.
Exceeding design temperature or pressure limit even temporarily (e.g. when starting or stopping)
should be absolutely avoided since the system could be damaged.
All actions could compromise the mechanical resistance of the equipment with the result that the
equipment could become dangerous for things and persons.
BRAM‐COR S.p.A. cannot be held responsible for any damage to persons or property resulting from
failure in observing the operating instructions described.
The employer has to inform them about the following topics that refer to operating security during the
use of the system:
 risks of accidents;
 protection devices for the operator’s security;
 general accident prevention rules or according to international regulations and the laws of
the country where the supply is sent.

Before starting any activity on the system, the operator will have to read this manual carefully in order
to know the position and functioning of commands and the characteristics of the system.

LEGEND
DANGER:
There are (remaining) risks for the operator; you have to pay attention to.

PROHIBITION:
For the security of the operator you are not allowed to perform the following
operations.
OBLIGATION:
For the security of the operator, carefully follow this indication.

NOTE:
This sign catches the operator’s attention to particular indications that he has to
know for the right use of the system.


2.2. SAFETY CONCEPTS
Most accidents during the work depend on people’s behavior; for this reason the personnel in charge
with the different operations on the equipment has to pay the greatest attention.
It is therefore necessary to:
 follow the accident prevention and safety rules of the country and factory you work for in a
scrupulous way;
 entrust people who are mentally and psychically fit and not under the influence of alcohol,
drugs or similar substances;
 protect eyes, hands, feet with suitable protective accessories from heated surfaces and
during maintenance activities on the machine.

The operator of the unit shall:
 communicate the found faults, above all those ones concerning safety;
 never disconnect safety devices or remove protections or carter that are installed to protect
components;
 avoid to perform regulations and switch on switches, valves, sensors, photocells or
commands unless he perfectly knows their functioning and/or after a specific authorization;
 follow the cleaning and disinfection program carefully;
 maintain the indicated temperature, procedure and time.

2.3. SPECIFICATIONS FOR SECURITY
According to EU Safety regulations related to the System plant, the following definitions are
highlighted:
Dangerous Area
Any area around the Unit or near it where the exposed person’s safety and health is in danger.
Exposed Person
Any person that is in the dangerous area.

VERY IMPORTANT WARNING:
The operator who is charge with the automatic functioning of the unit during the
production has to be in front of the control board.
Unskilled personnel is not allowed to approach any part of the System Plant.


2.4. DANGER SIGNS AND WARNING LABELS
The following danger signs and warning labels are fixed (in a position clearly visible to the Operator)
next to the dangerous area of the equipment.

ATTENTION!
Cut off tension before opening the door or the protection.
Area or part approachable only to authorized personnel for
maintenance and control operations.

CAUTION! – EARTHING
Connecting point to the grounding network.

 Electrical power on
 Turn off voltage before opening this cover
 Turn off voltage before removing the protection
 Only trained personnel can perform and carry out maintenance activities or
repairs on the unit
CAUTION! – HIGH TEMPERATURES

2.5. RESIDUAL RISKS: PROTECTION AGAINST BURNING RISK
Read the following paragraph carefully before performing the first starting of the System.
All hot parts that are not protected and at risk of burn are residual risks (i.e. they cannot be removed
during the design phase) and will be countersigned with the proper symbol near the dangerous area.

WARNING:
The System is designed for hot running; it is insulated with fiberglass and covered
by stainless AISI 304 steel sheet satin finish; burning risk is present nearby the un‐
insulated zones.
Condensed Pure Steam from the sampling point is a hot fluid and should be very
carefully handled by skilled personnel to prevent burns.
Discharge from the safety valve shall be conveyed to a safe place, to avoid any
damage from hot fluids in pressure, which constitute a risk for the user.
Periodical check and calibration of the safety valve shall be executed according
to local regulations.

Care should always be taken when working on or near steam pipes (especially near the sampling point)
due to the very high temperatures involved. Thermal gloves, overalls that cover arms and eye
protection must be used.
Similarly, all condensation drainage operations must be performed with protective garments and
devices in order to avoid any burning risk.


2.6. GENERAL EMERGENCY PUSH BUTTON

RED
In an emergency, push the “emergency push button” on the control board
(figure 2.1): the equipment stops immediately.
YELLOW
FIGURE 2.1
2.7. ASSISTANCE REQUEST
Any request of intervention to the technical assistance service shall be sent by mail to the following
address:
e‐mail: customerservice@bram‐cor.com

It will be necessary to specify in detail:
1. equipment type, serial number and year of installation;
2. failure;
3. person to contact.

2.8. ORDER OF SPARE PARTS
Each request for spare parts has to be sent by mail to "Customer Service" to the following address:

e‐mail: customerservice@bram‐cor.com or info@bram‐cor.com

To identify the needed spare parts rapidly, following details are required:
1. equipment type, serial number and year of installation;
2. serial/TAG number of the Unit;
3. position where this particular piece appears, its description and quantity
4. person to contact
5. shipping address.

It is absolutely forbidden to carry out modifications or alter the original structure of the
machine.

2.9. GUARANTEE AND TEST
The whole system undergoes in our workshops all functional tests throughout and after its
construction.
Only after positive test result in the customer’s presence, the system is sent to its final destination to
be re‐tested on site, during local commissioning activities.
Our products are covered by a contract guarantee on the mechanical parts and on the electrical
parts. In this period the constructor undertakes to replace faulty parts if the system has been used in
accordance with the indications of this Use and Maintenance Manual.

3. INFORMATION FOR TRANSPORT AND INSTALLATION
3.1. LOADING – TRANSPORT – UNLOADING

The System is delivery in multiple package.
For each type of packing, fork lifting equipment should be
used, properly positioned at the bottom of the wood case
in the position indicated by crowfoots. Use also as
reference the indications in the label positioned on the
packing.

During the installation at Customer site, the units will be
re‐connected as specified into Tie‐in drawing.
These operations must be performed by suitable and
Qualified Personnel.

During unpacking operations, pay attention not to cut or
damage electric cables, hydraulic pipes by using, if
necessary, combination pliers, hammer and cutter. Make

sure that the personnel in charge is properly skilled and
sufficiently protected for these activities and use
appropriate tools.
During the material handling you have to assure a proper
free space to guarantee safe operation and not to allow
the presence of unauthorized persons.

All system units should be stored in a covered room with suitable conditions if not immediately
installed in the final site, following the indication of table 3.1:

TABLE 3.1: STORAGE CONDITIONS FOR PHARMACEUTICAL EQUIPMENT
All equipment shall be stored in dry, closed and possibly tidy rooms
No direct or indirect exposure to atmospheric agents (rain, sun, frost, moisture) to protect
electronic devices
No contact with dusty environments (do not store the equipment close to loose construction
materials, such as cement/lime bags)
Room temperature between 0°C and + 35°C
Max. humidity 70%


3.2. HANDLING AND CARRIAGE
Equipment can be moved by crane lift , through a baricentrical hold point.
Before moving the equipment, check carefully to avoid wires, piping, and
structural damages.
WARNING:
Do not move the equipment in narrow areas or passages or when staff is close to
it.

3.3. LIFTING OF THE EQUIPMENT WITH HYDRAULIC FORK LIFT

WARNINGS:

Lifting operations must be performed by qualified personnel.
Before lifting, verify the barycenter of the equipment to balance the load.
You must be sure that there is enough space for the operation. People NOT
involved in the operation must not interfere and shall be kept away.

When you use the lifting truck to lift the case, make sure that the forks are
correctly positioned below the unit.


3.4. EQUIPMENT POSITIONING
When you have selected the position where the unit will be installed it is important to consider a
suitable operative and maintenance space all around the unit.
It is therefore advisable to leave a free space (1 meter at least) all around the perimeter of the
equipment.
The operative area has to be lighted.
Make sure that the floor surface is as uniform and levelled as possible.
The solidity of the floor surface must be suitable to the weight of the unit.

3.5. ELECTRIC CONNECTION
Make sure that the characteristics of electrical voltage and current available on site are in accordance
with indications contained into the electrical scheme. Moreover the connection cables should be of
suitable section and quality.

IMPORTANT!
1. In case of direct connection with the electric network, the connection
must be carried out only by an electrician and according to EN 60204‐1
regulations.
2. In case of direct connection with the electric network, the pump
rotation phases must not be changed.
3. In case of plug connection you have to insert the plug and rotate the
general locking device on the plug control board clockwise.
4. In every case it is important to install a safety magneto‐thermal
switchgear of adequate power.
5. Metallic mass earthling is necessary and should be verified with an
instrument.

3.6. UTILITIES CONNECTION
Make sure that the characteristics of utilities are in accordance with indications contained into P&ID
and Tie‐in drawing. These documents are collected in the section 1 of the “Technical Documentation”
supplied with the equipment.

Discharge from the safety valve shall be conveyed to a safe place, to avoid any
damage from hot fluids in pressure, which constitute a risk for the user.
Periodical check and calibration of the safety valve shall be executed according
to local regulations.


4. EQUIPMENT DESCRIPTION
4.1. GENERAL INFORMATION
The Pure Steam Generator system has been specially designed to fulfill the various needs of
pharmaceutical and chemical industry.
The system produces Pure Steam (PS) suitable for any applications for pharmaceutical use such as:
 sterilization of storage tanks
 sterilization of solution tanks
 sterilization of distribution loops
 sterilization of any other pharmaceutical equipment
 sterilization of filters.
The System is designed and manufactured by BRAM‐COR in accordance to the cGMP and FDA rules.
The following sections describe the major components selected by BRAM‐COR to build the system.
The instructions for operation and maintenance of each sub‐component are contained inside
individual manuals supplied with the system and collected in Technical Documentation –Components
Datasheets and Manuals.
A drawing of the machine with its main components is provided below:

A E

B F

C

D

G

FIGURE 4.1

A = Safety Valve (20 PSV‐001) E = Column Vessel (C‐2001)
B = Capacitive Level Probe (20 LT‐001) F = Control Board (CB‐2010)
C = Modulating Valve (20 PV‐001) G = Exchanger (E‐2001)
D = Multistage Pump (P‐2001)


4.2. PURE STEAM GENERATOR ‐ PRODUCTION PROCESS
The Pure Steam production process consists of feedwater evaporation followed by pure steam
separation according to following process steps, with reference to the enclosed P&ID of the system
and to following picture:
1) Feed water is pressurized by a centrifugal pump (P‐2001) to the evaporation column through the
inlet valves (one of the two valves is equipped with a closing stroke limiter to limit the feed water
flow during normal running). Water level inside the column is continuously checked by the level
control 20 LT‐001. This system allows the CPSG to produce Pure Steam with a content of un‐
condensable gasses lower than 3,5 %.
2) Feed‐water enters into the evaporator column from the bottom, filling the evaporator column
itself and the exchanger tubes (the exchanger is piped “in parallel” with the evaporator column).
3) Industrial steam enters the shell side of the heat exchanger causing water boiling and
evaporation.
4) The vapor or clean steam enters the upper half of the evaporator column. The height of the
evaporator column, the low velocity of the clean steam inside it, and a baffle demister installed in
the upper part of the column effect the separation of the pyrogens and other contaminants and
of the water droplets from the clean steam, yielding pyrogen‐free pure steam.
5) The contaminants removed return to the feed‐water in the lower half of the evaporator column.
A small quantity of the feed‐water will be removed through intermittent blow‐down, averting any
exceeding concentration of contaminants. The blow‐down flow‐rate will be set during Factory
Testing.
6) When the pressure into the evaporator reaches the set‐point (tolerance  0,2 barg), the
modulating valve 20 PV‐001 (industrial steam regulation valve) starts closing, according to the
signal coming from pressure transducer PT‐001.
Pure Steam is controlled and maintained at the desired pressure, through the algorithm which
controls the industrial steam modulating valve (20 PV‐001).

FIGURE 4.2


4.3. INSTRUMENTATION
The System is equipped with measuring and control devices suitable to ensure full automatic
operation of the plant, minimizing operator intervention for the constant monitoring of the process
values.
The equipment part list details all instruments embedded in the system including:
 pressure transducer
 capacitive level transmitter
All information thereof is included in the Technical Documentation–Components Datasheets and
Manuals supplied with the equipment.

4.4. CONTROL SYSTEM
The whole system is controlled through the Operator Panel (HMI – Human Machine Interface) located
on the control board, type “KTP700 BASIC”.

All information thereof is described and specified in “Operating Manual” (Technical Documentation).

5. USE AND MANAGEMENT OF THE SYSTEM
5.1. PRELIMINARY OPERATIONS AND TECHNICAL DATA
The System was tested during FAT activities in BRAM‐COR S.p.A. factory. The machine is able to work
immediately, after some simple preliminary operations.
Following operations will be performed by Bram‐Cor Technician before the initial start‐up:
 Fill the centrifugal pump with water;
 Fix the safety valve;
 Check that all electrical connections are correctly executed with reference to the Electrical
Scheme;
 Check that all hydraulic & pneumatic connections are correctly executed
 Check that the safety valve has been connected to an exhaust line conveyed to a safe place.

5.1.1. Mechanical Components
All mechanical components of the system are supplied with their technical data sheet or use manual,
included in the Technical Documentation –Components Datasheets and Manuals.
Usually before the shipment, some components (safety valve, conductivity cell, pressure transducer,
temperature probe etc.) installed on the machine could be removed to prevent any damage. They
must be reassembled by the user before the initial start‐up. The user shall close the clamp connections
and tighten electrical connectors on the head of instruments. More information can be found in the
Instruction manuals supplied in the Technical Documentation –Components Datasheets and Manuals.

5.1.2. Electrical and Pneumatic connection
Check all electrical and pneumatic connections (Fig.5.1 – 5.2) according to the electrical scheme.
Connect the power line to the terminal inside the control board (CB‐2010 as shown in Fig. 5.3), strictly
following the electrical scheme of the equipment.
See section 3.5 for electrical safety instructions.
Connect the pneumatic line to the quick hitch connections. The example is shown in fig. 5.2.

CHECKUP OF SAFETY DEVICES

The Operator must check if the ground connections of the main electrical line
comply with safety regulations.
Electrical connections can be performed only by qualified and skilled operators by

tension OFF.
Fixed protection must be tight to the equipment structure.
Protection and safety devices must be operative and shall not be removed or
modified. The operator has to keep the efficiency of all safety devices by effective

maintenance procedures.
Any modification on the equipment parts is strictly forbidden.
BRAM‐COR S.p.A. is not liable for damages or injuries due to equipment
modification especially on safety devices or for failed maintenance.
The equipment is not explosion proof.

Refer to following data for electrical connections:

ELECTRICAL POWER
R‐S‐T PE TENSION 440 V AC

FREQUENCY 60 Hz
POWER 1,5 kW

CURRENT 3 A (3P+G)
CONNECTIONS

Item Fittings Wire section Terminal
R PHASE Min 1x4 mmq X1‐R

S PHASE Min 1x4 mmq X1‐S
T PHASE Min 1x4 mmq X1‐T
FIGURE 5.1 (example)
PE GROUND Min 1x4 mmq Ground terminal
FIGURE 5.2 (example)

Fixed protection must be tight to the equipment structure.
Protection and safety devices must be operative and shall not be removed or
modified.

The operator has to keep the efficiency of the safety devices by effective
maintenance procedures.


5.2. START‐UP: PHASES DESCRIPTION
START‐UP will be implemented though the following phases:
1. Utilities connection
2. Acknowledgement of control board
3. Start‐up

5.2.1. Phases 1: Utilities connections
After having executed the operations described in section 5.1, proceed with following operations using
these documents as reference:
1. P&ID
2. TIE‐IN drawing
3. Electrical scheme

The P&ID also indicates the battery limits.
All drawings are included in the Technical Documentation supplied with equipment, section 1.
The technical specifications for all utilities which are necessary for running the equipment are included
the TIE‐IN drawing of the equipment.

Connections:
Before connecting the Pure Steam Generator to all the utilities and services, check:
1. availability of compressed air;
2. availability of feed water;
3. availability of industrial steam;
4. availability of electric supply and regular connections, in accordance with the electrical
scheme.

After that:
1. connect the Utilities as per P&ID and TIE‐IN drawing (feed water inlet, compressed air,
nitrogen, etc.) to the System;
2. verify the correct position of all electric connections (see section 5.1.3);
3. close the full drainage manual valve.

NOTE:
Recommended inlet pressures for raw water are indicated in the P&ID and
Tie‐in drawing.
NOTE:
Connections should be made with pipes and pipe fittings made of suitable
material and proper sections. For all links follow P&ID indications.


5.2.2. Phase 2: Acknowledgement of control board
The System is equipped with an electrical board CB‐2010 (figure 5.3), which contains a PLC suitable to
the correct operation and protection of the PS generation system. Through the Control Board it is
possible to set all the parameters, functions and management of the System.

On the door of the CB‐2010, following items are present:

A

D

B E

C F

FIGURE 5.3

A = HMI – Operator Panel D = Emergency Push Button
B = Tension presence indicator E = Siren Reset button
C = Emergency reset button F = General Switch

Through the Control Board it is possible to set all the parameters, functions and management of the
System.
The instrument, alarm lights and push‐buttons installed on these control boards are described in the
following sections.
Inside this Control Board there is a PLC suitable to the correct operation and protection of the system.


5.2.2.1. Switches and alarm lights on the front panel

TENSION
PRESENCE
TENSION PRESENCE: a bright warning light indicating the presence of

power supply to the equipment.

FIGURE 5.4
EMERGENCY RESET Push Button with blue warning light, allowing the
EMERGENCY machine emergency reset, after an event (either unexpected or induced)
RESET blocking the equipment to a forced arrest.
State of the light: switched OFF
To unblock the system press the push button and re‐start the system
production.
State of the light: switched ON

FIGURE 5.5 Once the emergency status is over, press the “RUN” key to re‐start the
production.
RESET
SIREN
RESET SIREN yellow Push Button enabling the total reset of system
production alarms.

FIGURE 5.6

EMERGENCY STOP Push Button, for immediate system SWITCH OFF.
The important and specific function of this push‐button is described in
section 2.6.

FIGURE 5.7


5.2.2.2. HMI – Operator panel

Installed on the front the Control Boards CB‐2010:

A “SIMATIC KTP700 BASIC” by SIEMENS, constitutes
the Human Machine Interface (figure 5.8).
Through this HMI all systems functions may be
monitored and controlled.
Datasheet and specification of the HMI are provided in
the Hardware Design Specification, (see Technical
Documentation.)
Its control functions are thoroughly described in the
Operating Manual, supplied as separate document in
the Documentation.
FIGURE 5.8

5.2.3. Phase 3: Start‐up
After checking the fulfilment of the required conditions, proceed as follows:
1. rotate the main electrical switch on the control board
on position "ON"; (figure 5.9);
2. the white lamp of “tension presence” will light up
(figure 5.4);
ON 3. rotate and pull the emergency push button on the
control board (figure 2.1 and 5.7);
4. press the “Blue” push button (figure 5.5) on the
control board “Reset Emergency” (if the circuits are
really restored, the buttons will lights up);
5. check compressed air pressure on manometers
OFF installed on the filter air reducer (positioned beside
the control board);
6. insert in the main page of the Operator Panel the
password to enter data (please referred for Operating
FIGURE 5.91 Manual);
7. now it is possible to start the System.


5.3. SYSTEM SHUTDOWN
If a shutdown should be necessary, please act as follows:
1. disable the active phase;
2. push the Emergency Button;
3. turn off the electrical main switch;
4. open the discharge valve to totally drain the column and the exchanger (pipe side);
5. now it is possible to perform all intervention activities.
6. after maintenance activities, restore the initial conditions.

5.4. CONDENSATION EMPTYING
Condensation emptying from the drainage valves through the stream traps is recommended daily
and/or at each equipment start.

5.5. RECOMMENDATIONS ABOUT THE GOOD SAMPLING PRACTICES
Correct sampling is the key to pharmaceutical water quality compliance.
SOPs for sampling shall be established by the Quality Control Department of the pharmaceutical user
company of BRAM‐COR equipment, based on the unit operation and regulatory expectations for the
desired product water.
For further information, see attachment 3 of this manual.


6. MAINTENANCE AND CLEANING OPERATIONS
6.1. GENERAL RULES TO BE FOLLOWED FOR A PERIODICAL MAINTENANCE
Maintenance procedures
Maintenance schedule as described in the following section shall be respected.
Basic concepts for safe maintenance operation:
 After all checks ensure that:
 All the instruments used for the operations have been removed from the machine.
 All the safety devices are perfectly efficient (see Chapter 2).
 Any maintenance operation can be accomplished only after switching off the system.
 Wear protective overall and devices to protect hands, feet and face.

6.2. ORDINARY PREVENTION MAINTENANCE
Please carefully respect the following indications and suggestions.
The following activities shall be periodically accomplished by the User:
 Check pneumatic valves
 Check modulating valves on steam inlet
 Check instruments
 Check the pump.

The instruction manual of the components, which are included in the Technical Documentation
supplied with the equipment, should be carefully read before any operation.

NOTE:
To prevent economic loss caused by production stop due to components
failure, a suitable provision of spare parts, as listed the Technical
Documentation of the equipment, is highly recommended.
The manufacturer declines any responsibility for accidents or damages caused
by improper or insufficient maintenance.


6.3. MAINTENANCE SCHEDULE

FREQUENCY CHECKS AND ACTIONS PERSONNEL IN CHARGE
Check normal working conditions and working
Daily User
parameters of the equipment.
Drain condensation from the drainage valves through
Daily User
the stream traps
Check mechanical seal for modulating valve on
Weekly Maintenance technician
industrial steam.
Weekly Compressed air reducer: drain condensate. Maintenance technician
Product sampling to verify compliance to the
Weekly User
specifications.
Drain column and refill with fresh feed water according
Monthly Maintenance technician
to the specifications.
Half yearly or in
Check clamp seals. Maintenance technician
case of leaks
Half yearly Check tightening of the bolts and flanges. Maintenance technician
Yearly Check gaskets. Maintenance technician
Yearly Check pneumatic valves. Maintenance technician
Yearly Replace vent filter (if applicable). Maintenance technician
Yearly Check pump seals (if applicable). Maintenance technician
Check scaling on inner surfaces of column and
Yearly Maintenance technician
exchanger. Apply cleaning procedure if necessary.
Check instruments accuracy and calibration status
Check relevant bulletin to prepare a correct plane of re‐
Yearly Maintenance technician
calibration activities following internal calibration
procedures.
Yearly Check level gauge. Maintenance technician


6.3.1. Actions in the event of an alarm
When the emergency stop button is pressed in case of alarm, the plant stops but remains powered.
Switch off the main switch on the control board prior to any maintenance operation to prevent
electrocution!

Proceed according to Troubleshooting indications (attachment 1).

6.3.2. Instruments calibration
 DRY SENSORS (conductivity, flow‐rate temperature, pressure, level – where applicable): 1 year
from equipment start‐up.

Re‐calibration of the critical instruments (i.e. the instrument monitoring quality critical attributes or
critical process parameters) should be performed with annual periodicity, if the equipment is running
in good ambient conditions, or more frequently in case of hostile environments (such as rooms with
high or exceedingly low temperature, acid atmosphere, exposure to direct sunlight, etc.), following
internal SOPs for calibration.

The Quality Department of the pharmaceutical facility should therefore assess re‐calibration frequency
according to the local operating conditions of in‐line instrumentation (see also “Recommendations for
Calibration Frequency” attachment 2 of this manual).

6.3.3. Stand‐by status
In case of a long period of stop, it is advisable to shut down electric supply and drain the system.


6.3.4. Clamp connections
CLAMP connection consist of a terminal that is composed by two tightened at pressure “A” jaws on
the two final heads of CLAMP “B” STUB PIPE that have to be connected (figure 6.1).

FIGURE 6.1

By acting on the tightening of the two “A” jaws by means of “D” screw, the two final heads of CLAMP
stub pipe “B” will compress against a Teflon “E” gasket that ensures the tightness of the joint
(figure6.2).

FIGURE 6.2

If there is a leak, the operator must try to tighten the terminal of the joint by acting on “D” screw
before substituting the gasket “E” (figure 6.2).


6.3.5. Substitution of Gasket of clamp connections
To substitute the gasket of the joint the operator must proceed according to the following description:
 loose the terminal till the tightening screw “D” turns from position “1” to position “2” (figure
6.3);

FIGURE 6.3

To avoid a sudden misalignment of the two final heads of CLAMP stub pipe “B” (in addition to it, to
avoid the fall of joint and gasket on the floor, it will be necessary to support the terminals during the
loosening operation).

 open and withdraw the two terminals “A” of the two heads “B” (figure 6.4);

FIGURE 6.4

 separate the two heads of CLAMP stub pipes “B” in order to substitute the Teflon gasket “E”
easily (figure 6.5);

FIGURE 6.5

Before inserting the new gasket, it is necessary to clean accurately the seats on the two final heads of
“B” stub pipes.

 substitute the gasket with a new one of the same type, dimensions and material, and
assemble it again following a procedure that is opposite to that one over described.

6.3.6. Flanged connections
The pressure seal of the gaskets is ensured by a series of bolts that are placed along the external
diameter of the flange for the closing and connection (see the following figure).
To perform the tightening operation rightly, it will be necessary to provide a couple of monkey
spanners that are suitable for the screws to be tightened.

To perform this operation, act as follows:
1. by means of one of the monkey spanners, block the ”B” bolt (figure 6.6);
2. go on blocking the “B” bolt with the first monkey spanner and tighten the “A” screw by using the
other wrench spanner (figure 6.7).

FIGURE 6.6

The position of the “G1” gasket is indicated in the following picture together with the section on the
relevant tightening bolt.

FIGURE 6.7

The direction of the pressure exerted by the tightening of the screw (by means of the relevant flanges)
on the pressure gasket is indicated by two arrows (figure 6.7).

In order to warrant the perfect seal of the gasket, turn the bolts of the flange
clockwise.

Perform the tightening of bolts at different times and apply the same pressure on each tightening
screw.


After maintenance, remove any tool you used.

The gaskets do not warrant an unlimited seal lasting throughout the whole life of
the equipment; the only guarantee of their perfect seal can be obtained only by
replacing all gaskets periodically.

6.3.7. Replacement of the gaskets on the head of flanges
This operation has to be performed only when the programmed tightening operations do not solve
possible leakage of liquids or pressure.

To perform the right replacement of the gasket, use a couple of monkey spanners that are suitable for
tightening the screws of the flange.

By means of one of the monkey spanners, block the ”B” bolt (figure 6.8); proceed blocking the “B” bolt
with the first monkey spanner, loosen and take away the “A” screw by means of the other wrench
spanner.

FIGURE 6.8

Repeat the same operation for all the tightening screws of the flange where you have to replace the
gasket.
After removing the last screw from the flange, carefully separate the two heads of the “C” flanges
(figure 6.9).

FIGURE 6.9

Pull out the “G3” gasket and replace it with a new one.

After the replacement, re‐connect the two “B” heads.

6.4. EQUIPMENT STERILIZATION
The System works at temperatures higher than 121°C. It is therefore self‐sterilized during normal
operation.

6.4.1. Sterilization of sampling point
If the system is endowed with a condensation + sampling point, a periodical sterilization of the same is
recommended.

CAUTION: Burning risk for PS high temperature. Use Personal Protection Devices
against high temperature.

Do not stay close to the sampling point during hot purging.

1. Close cooling water supply valve
2. Open the drain valve and the sampling point valve
3. Let pure steam flush through the sampling point to provide sampling point purging for at least 10
minutes
4. Restore the original conditions after the sampling point sterilization.
The control system will prompt a high temperature alarm during this operation. Reset the system after
this operation.

6.5. EQUIPMENT CLEANING
6.5.1. Cleaning of external surfaces
To avoid irreversible damage to plastic surfaces, never use strong solvents (Trichloroethylene, nitro,
alcohol, gasoline, etc.) to clean plastic parts and components installed on the equipment, such as:
 push buttons, lights and touchscreen on the Control Board;
 transmitters on the control boards.

Similarly, do not clean the printed labels with diluents or alcohol to prevent cancellation of the printed
data.
Clean stainless steel surface with suitable specific detergents. Mild detergents (such as glass‐cleaning
sprays or mild soap‐based degreasers) and soft cloths are recommended for the whole equipment.

Please test the detergent before using it on the equipment to ensure its suitability.


6.5.2. Chemical Cleaning
To obtain a successful cleaning of the inner side equipment, apply following procedure:
1. STOP the equipment.
2. Drain column and exchanger through the bottom valve.
3. Disconnect the Pure Steam outlet from the PS distribution line.
4. Open the column head.
5. Remove head and demister inside the column.
6. In a separate tank, prepare a solution of citric acid (10%) and purified water or WFI (90%).
7. Pour the solution into the column, after closing the bottom valve. Fill the column until reaching the
connection pipe between the column and the exchanger.
8. Wait at least for 4/5 hours until the solution has effected its descaling action.
9. Drain the column through the bottom valve.
10. Close the bottom valve an fill the column upside down with fresh WFI.
11. Repeat point 10 until rinsing the column until the outlet water is clean.
12. Open the exchanger head and check if inner surfaces are clean.
13. If any scaling is detected, proceed with chemical washing repeating actions 6 to 11 or perform a
mechanical cleaning.
14. Close the equipment, carefully tightening all bolts, and start the equipment (the first PS production
shall be sent to drain).
15. Replace gaskets before reassembling the parts.

6.5.3. Mechanical Cleaning
1. Stop the equipment;
2. Drain column and exchanger through the bottom valve;
3. Disconnect the exchanger from the column;
4. In vertical position, scrub inner pipes surfaces with a pull‐through in stainless steel, nylon or brass
to remove scale deposits;
5. Thoroughly rinse with WFI water and reassemble the components;
6. Replace gaskets before reassembling the parts.

6.6. TROUBLESHOOTING
In case of alarm set‐off:
1. Check the HMI to understand the cause;
2. Apply the corrective action detailed in the attachment 1 to this manual (Troubleshooting for Pure
Steam Generator) for the detected alarm.


6.7. EQUIPMENT AND CONTROL SYSTEM DISMANTLEMENT AND RETIREMENT
The equipment does not contain dangerous products for the environment.
At the end life cycle of the equipment, respect following rules:
1. Check that the vessel has been completely emptied;
2. Disconnect the unit from the power supply;
3. Disconnect hydraulic connections;
4. Make sure to properly signal the area involved with the operations;
5. Charge qualified and authorized personnel for dismounting the equipment;
6. Make available to these operators this Operating Manual;
7. Provide separate disposal for metallic, electric and insulation material.

Appropriate Control System Retirement activities ensure that correct controls are in place when a GxP
system is removed from operational use to ensure other systems and data are unaffected and to
ensure the availability of GxP regulated data and records for the required retention period. The System
Retirement Process should be documented in a System Retirement Plan, involving input from
functions, such as the Process Owner, Quality Unit, System Owner, and Engineering or IT. This System
Retirement Plan should be issued by the user according to “GAMP 5 Example System Retirement Plan
Template” and should at least consider:

1 Impact of the retirement on the business area technology strategy;
2 Impact of system retirement on the user base;
3 Data and Record Migration, Archiving, and Destruction;
4 System replacement;
5 Change Management;
6 Retirement Execution.


ATTACHMENT 1
TROUBLESHOOTING
▹▹▷

USE AND MAINTENANCE MANUAL
ATTACHMENT 1
TROUBLESHOOTING USE AND MAINTENANCE MANUAL
Alarm
Tag Description Possible Cause Corrective Action (one or more)
Code
Module breakdown or interruption of MPI or
a. Open the main control board and check connections, modules and
G_004 _ PLC INTERNAL ERROR PROFIBUS connection. Possible SW anomaly after
wiring integrity.
uploading.
a. Open the main control board and check that the 400/230 V AC
transformer is not in short‐circuit.
CIRCUIT 230 V AC ‐ INTERVENTION
G_010 _ Short‐circuit of a device fed by 230 V AC. b. With the electrical scheme on hand, check if any device fed by 230
PROTECTION
V AC (ex: board instrumentation, electrical plugs, etc.) is in short‐
circuit.
a. Open the main control board and check through the electrical
CIRCUIT 24 V DC ‐ INTERVENTION
G_012 _ Short‐circuit of a device fed by 24VP. scheme if any of the devices using 24 VP (such as the output lock) is
PROTECTION (24VP FAILURE)
in short‐circuit.
a. Open the main control board and check through the electrical
Short‐circuit in the pump connection or failure in the
scheme the correct presence of phases overall the pump circuit.
G_030 P‐2001 FEED WATER PUMP ‐ ENGINE PROTECTION pump phases reception. Possible mechanical failure of
b. Check the electrical connection of the pump.
the pump.
c. Detect a possible mechanical failure.
a. Turn the emergency pushbutton on and press the emergency reset
key to restore the system.
The emergency pushbutton is on with failure of circuit
G_070 _ EMERGENCY CIRCUIT NOT RESTORABLE b. Open the main control board and check through the electrical
restoring attempts.
scheme the correct connection of the emergency pushbutton. Verify
the emergency reset circuit.
a. Turn the emergency pushbutton on and press the emergency reset
key to restore the system.
G_072 _ EMERGENCY BUTTON PRESSED The emergency pushbutton is on.
b. Open the main control board and check through the electrical
scheme the correct connection of the emergency pushbutton.
Page 1 of 3 PURE STEAM GENERATOR
ATTACHMENT 1
Alarm
Code
a. Check air inlet to the 20 PCV‐001 pressure reducer.
Insufficient compressed air delivered to the
G_090 20 PS‐001 COMPRESSED AIR LACK b. Open the main control board and check the correct running of the
equipment.
20 PS‐001 pressure switch through the electrical scheme.
a. Check steam inlet to the CPSG.
b. Check the actual pressure switch setting towards the standard
Insufficient industrial steam delivered to the value indicated in the Alarm list.
G_092 20 PS‐002 MISSING INDUSTRIAL STEAM
equipment. c. Check if the 20 PS‐002 pressure switch is correctly running.
d. Check the electrical connection between the pressure switch and
the main control board.
a. Turn off the industrial steam and check any mechanical failure of
the modulating valve of industrial steam inlet.
b. Verify the correct running of the electro‐pneumatic converter
High steam pressure in the column or wrong reading inside the control board, since the industrial steam modulating valve
G_203 20 PT‐001 PURE STEAM ‐ PRESSURE (bar) ‐ HH
of the pressure transducer. shall be constantly fed by compressed air at 6 psi at rest.
c. Carefully pour off the pressure inside the column, take off the
instrument and compare with a reference instrument. Proceed with
calibration if necessary.
a. Check feed water inlet to the system.
b. Check correct running of the feeding pump and air absence (allow
air to escape through the valve on the pump body).
c. Check that the feedvalve is correctly open without mechanical
Minimum level during the running phase in
G_400 20 LT‐001 COLUMN C‐2001 MINIMUM LEVEL failure.
C‐2001 column. Failure of the minimum level.
d. Check regular compressed air inlet to the feedvalve. Open the
control board, check the correct running of the pneumatic interface
against the electrical scheme.
e. Verify if the minimum level of the level probe is correctly running.
ATTACHMENT 1
Alarm
Code
a. Drain C‐2001 column and verify the correct running of the
maximum level of 20 LT‐001 level probe.
Maximum level inside C‐2001 column. Failure of the
G_402 20 LT‐001 COLUMN C‐2001 MAXIMUM LEVEL b. Check that the feedvalve are correctly open without mechanical
maximum level.
failure.
c. Verify if the pump is off.
a. Check feedwater presence in the system.
b. Check correct running of the feeding pump and air absence (allow
air to escape through the valve on the pump body).
c. Check that the feedvalves are correctly open without mechanical
PURE STEAM ‐ PRODUCTION ‐ FILLING Failed filling of C‐2001 column after a feeding preset failure.
G_450 20 LT‐001
FAILED C‐2001 time. d. Check regular compressed air inlet to the feedvalve. Open the
control board, check the correct running of the pneumatic interface
against the electrical scheme.
e. Verify if the 20 LT‐001 minimum level is correctly running.
f. Check that the manual drain valve of the column is not open.
No external consent of inlet water from an upstream a. Check feedwater inlet to the CPSG. Through the electrical scheme,
G_490 _ FEED WATER INLET NOT AVAILABLE
utility of the Customer. verify the relevant contact to the PLC.

ATTACHMENT 2
RECOMMENDATIONS FOR CALIBRATION FREQUENCY
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RECOMMENDATIONS Rev. 00
Page 1/6
FOR CALIBRATION FREQUENCY
Contents
1. Scope and application ................................................................................................................................. 2

1.1. Disclaimer................................................................................................................................................ 2
2. Responsibility .............................................................................................................................................. 2
3. References................................................................................................................................................... 2
4. General considerations ............................................................................................................................... 2
4.1. Validity of manufacturer’s certificates.................................................................................................... 3
5. Process and ambient conditions ................................................................................................................. 3
6. Recommendations for calibration frequency. ............................................................................................ 4
6.1. Conductivity meters ..................................................................................................................................... 4
6.2. Flowmeters – Liquid (Ultrasonic, Electromagnetic, Vortex, Coriolis) .......................................................... 4
6.3. Flowmeters – Gas (Coriolis, Vortex, Thermal) ........................................................................................ 4
6.4. Mechanical Flowmeters – Gas/Liquid (Positive Displacement, Turbine) ............................................... 4
6.5. Pressure and Differential Pressure Devices (including hydrostatic level)............................................... 5
6.6. Temperature – Elements and Transmitters ............................................................................................ 5
6.7. pH Equipment ......................................................................................................................................... 5
6.8. Level Devices (Capacitance) .................................................................................................................... 5
6.9. TOC .......................................................................................................................................................... 5
6.10. Recorders, Data Loggers, Indicators ................................................................................................... 5
REVISIONS HISTORY
00 First issue 11/14 C. Opl A. Scala F. Pedrelli
REV DESCRIPTION DATE ISSUED VERIFIED APPROVED

Page 2/6
1. Scope and application

The scope of this guide is to provide general information for the calibration frequency of in-line instruments in
pharmaceutical equipment.
This information is based on the recommendations of the instruments manufacturers, on field experience and
good practice, and is related to the need to perform calibration on a periodic basis to ensure that the device is
still within an acceptable condition and performance for a given application. The operation of the instruments
should be however inspected frequently to ensure correct process monitoring.
1.1. Disclaimer
BRAM-COR makes no warranties, express or implied, with respect to the contents of this document, and shall in
no event be liable for any consequences caused by using the information described in this document.
2. Responsibility
The re-calibration and maintenance interval for each device is the responsibility of the end user and must be
established within the scope of application of the instrument, its required accuracy, and its criticality to the
process and any legislative constraints imposed on the duty.
“The calibration of instruments, apparatus, gauges and recording devices at suitable intervals in accordance with a
written program containing specific directions, schedules, limits for accuracy and precision and provisions for
remedial action in the event of accuracy and/or precision limits are not met” is a requirement of 21 CFR PART
211.160 (Current Good Manufacturing practice for Finished Pharmaceuticals”.
3. References
 GAMP Good Practice Guide “A Risk based approach to calibration management” Second Edition 2010
 ISPE Good Practice Guide “Calibration Management” 2002
 21 CFR part 211
 EN ISO 9001:2008 Quality Management
 EN ISO 10012 Requirements for measurements processes and measuring equipment
 ISO 17025 General Requirements for the competence of testing and calibration laboratories
 VIM: International Vocabulary of Basic and General Terms in Metrology
 ANSI/ISA – 51.1-1979 (R1993) Process Instrumentation Terminology
 EN 13306: Maintenance Terminology
 ISA-TR91.00.02-2003: Criticality Classification Guideline for Instrumentation
4. General considerations
Re-calibration of an instrument should be considered after repair or replacement of any major components
associated with the device.
If during scheduled maintenance and inspection the instrument appears physically damaged or the calibration seal
has been removed then re-calibration should be considered.
Re-calibration should be considered if the operation personnel suspects that the instrument readings are incorrect.
If the instruments involved are intelligent or smart and have on board diagnostics it may be viewed only necessary by
the user to test the instrument if the device reports a tendency to failure. In this event the end user should establish
that the diagnostics fully validate the operation of the device within its specific duty. It should be noted that
diagnostics do not substitute the need to inspect or calibrate the device.
Devices within the measurement loop, which are purely used for indication purposes, may not need re-calibration.
Page 3/6
For these devices scheduled maintenance and inspection could be sufficient or calibration on a less frequent basis
could be considered
During the operating life of an instrument within a specific application the historical calibration data should be
regularly reviewed. Based on this data suggestions for changes in the calibration periodicity can be considered. This
can be to lengthen or shorten the periods between calibrations. In case where the instruments reliability in service
seems poor then a review of the installed conditions should be undertaken or an alternative measuring technique or
instrument type considered.
In applications where the absolute accuracy of the device is critical to the process then the periodicity should be set
accordingly. An indicator for certain instrument types for how often they should be checked can be based on the
manufacturer’s accuracy and drift statements as noted in instrument datasheet or instructions manual.
If the devices have any pneumatic operating parts then the calibration periodicity will need to be more frequent than
the stated recommendation for an electronic device operating on the same fundamental principle. This will be
dependent on the quality of the instrument air, but as a rule of thumb divide the recommended periodicity of the
electronic instrument by two.
If during plant operation a major process upset occurs (Over pressure, temperature or adverse chemical reaction) or
the final product quality deviates from specification, then inspection and re-calibration of the relevant instruments
should be considered.
4.1. Validity of manufacturer’s certificates

Instruments are considered product-critical when their accuracy may impact on final product (PW/WFI) quality and
patient safety.
Instruments on the pretreatment+ RO line (in case of RO system before the EDI), for instance, are therefore not
product-critical, since there are further purification stages downstream that are monitored and alarmed. Hence non-
critical instruments are supplied, as a standard, without calibration certificates, while critical instruments are supplied
with the manufacturer’s certificate.
All product- and process- critical instruments are in fact delivered by BRAM-COR with
 manufacturer’s or quality certificates for conductivity cells, ORP probes, Oxygen sensors: these certificates can
be considered as calibration certificates on one point), since the manufacturers uses a buffer solution to check
the accuracy of the sensor.
 manufacturer’s calibration certificates or calibration reports for temperature gauges, pressure transducers,
pressure gauges, etc.
 Dry sensors (conductivity, flow-rate, temperature, pressure, level): 1 year from equipment start-up
 Sensors with fluid in the cell (pH, redox, oxygen): 1 year from the date of the manufacturer’s certificate.
Since most measurements of critical process parameters depends on local utility features, site calibration of the
measurement chains (transmitters + cables + probes), by subject matter experts, is highly recommended, as per GMP
regulations, before production start-up and validation.
5. Process and ambient conditions

The main factors, which can greatly influence the periodicity of calibration and maintenance, are the conditions of
the process fluid that the device is measuring and the ambient conditions in which the device is located. The
following categorize the typical conditions that might be found on industrial applications.
Process conditions
 Stable: Homogenous process fluid at stable temperature
 Heavy: Widely fluctuating process conditions. Risk for build-up, abrasive or corrosive process fluid
Page 4/6
Ambient conditions
 Normal: Protected room, low ambient humidity and normal temperature, no dust and vibrations
 Hostile: high humidity, high temperature, direct exposition to sunlight, strong vibrations or acid or corrosive
atmosphere (such as chlorine gas).
The Quality Department of the pharmaceutical facility should consequently assess the local functional risks for the
equipment with its in-line instrumentation, in order to establish calibration frequency.
Following recommendations shall be considered a general guide for calibration frequency in optimal running
conditions.
6. Recommendations for calibration frequency.
6.1. Conductivity meters

Conductivity meters on pharmaceutical equipment are usually to be considered critical instruments, since they
monitor a quality critical attribute, especially if installed on the final process steps of a water treatment systems, or
on PW or WFI distribution loops, or on preparation tanks, etc.
The accuracy of in-line conductivity meters should be frequently checked.
They should be therefore calibrated on an annual basis, in favorable ambient conditions, or more frequently (every 4
to 6 months) in hostile environments.
6.2. Flowmeters – Liquid (Ultrasonic, Electromagnetic, Vortex, Coriolis)

Assuming a homogenous process liquid at a stable temperature with the instrument working under normal ambient
conditions then re-calibrate every 4-6 years.
If the normal process conditions apply but the device is operating in hostile ambient conditions then reduce the
calibration periodicity to 1-4 years dependent on the extremes of the environment.
If the process fluid conditions are heavy ( during cleaning in place for example) or the device is operated at the
extremes of its temperature limits then re-calibration on an annual basis may need to be considered.
If the process fluid is abrasive or corrosive then the calibration intervals should be reduced accordingly.
The use of electronic verification tools, to check the sensor status and electronics performance can be applied on a 1-
2 year basis. If this is combined with maintenance and inspection routines then the calibration intervals suggested
above can be extended by a factor of two.
6.3. Flowmeters – Gas (Coriolis, Vortex, Thermal)

If the gas is clean and dry and the instrument is operating under normal ambient conditions then re-calibrate every
5-10 years.
If the same process conditions apply but the device is located outside then reduce the calibration periodicity to 3-5
years dependent on the hostility of the environment.
If the gas is wet, has particles within or is corrosive then the calibration intervals should be reduced accordingly.
The use of electronic verification tools, to check sensor status and electronics performance can be applied on a 1-3
year basis. If this is combined with periodic maintenance and inspection routines then the calibration intervals
suggested above can be extended by a factor of two.
6.4. Mechanical Flowmeters – Gas/Liquid (Positive Displacement, Turbine)

The guidelines as recommended above should be reduced by a factor of two for mechanical type meters.
Page 5/6
6.5. Pressure and Differential Pressure Devices (including hydrostatic level)

Directly mounted pressure measurement devices which operate with stable process conditions with the instrument
located inside a building or plant (Normal conditions) should be calibrated every 4-6 years.
If the same process conditions apply but the device is located in an hostile environment then reduce the calibration
periodicity to 1-4 years.
If the device is fitted with a diaphragm seal then reduce the calibration period by a factor of two or alternately
consider an interim inspection of the seal to verify its integrity.
If the process pressure continually varies, or over pressure is a possibility, then reduce the calibration period by a
factor of two.
6.6. Temperature – Elements and Transmitters

Temperature assemblies, which are mounted in thermowells and protecting pockets and are operating under
normal ambient conditions, should be calibrated every 5-10 years.
If the head is directly mounted and is subject to high ambient temperatures or excessive vibration then the
temperature insert should be calibrated on an annual basis. If the assembly is directly mounted in the process with
no thermowell then reduce the calibration period by a factor of two.
The calibration period can be extended by a factor of two by on an annual basis checking the integrity of the RTD or
Thermocouple and performing a simulation of the input to the insert using an approved portable calibrator.
6.7. pH Equipment
Generally the calibration interval for buffering of a pH probe should be calculated to approximately 2 to 3 times
during its expected life in the proposed application. This can be calculated using manufacturer data for the specific
probe. The need to calibrate a pH probe is very process related and the historical performance of a specific probe in
the specific application must be reviewed on a regular basis.
Transmitter indication and output should be checked during the standard buffer check. A complete calibration of the
transmitter if mounted in an area of normal ambient conditions should take place every 5-10 years.
If the pH transmitter is located outside then the calibration periodicity should be reduced to 1-5 years dependent
upon the hostility of the environment.
6.8. Level Devices (Capacitance)

Capacitance measurement systems which are installed on duties which are clean non aggressive liquids at stable
temperatures or fine non abrasive powders and solids and the instrument is located inside a building or plant then
recalibrate every 5-10 years
In case of difficult environmental conditions reduce the calibration periodicity to 3-5 years.
If the process conditions are aggressive, corrosive or in the case of solids abrasive then the calibration intervals
should be reduced accordingly.
6.9. TOC
A System Suitability Test with certified reference standards (Sucrose and Benzoquinone solutions with known TOC)
should be performed at start-up and at every UV lamp replacement (every 6 months in normal operating conditions),
according to USP <643>.
6.10. Recorders, Data Loggers, Indicators

Electronic and digital indicators and paperless recorders that are located within a building or plant in stable
ambient conditions should be calibrated every 5-10 years.
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Reduce the calibration periodicity to 3-5 years dependant on the extremes of the ambient conditions.
Analogue indicators, chart recorders and process printers with moving parts that are located within a building or
plant in stable ambient conditions should be calibrated every year.

ATTACHMENT 3
SAMPLING IN PHARMACEUTICAL WATER SYSTEMS
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Manuale delle Procedure
Istruzione Operativa IO 75_03_11 Rev.01
SAMPLING IN PHARMACEUTICAL Page 1/12
WATER SYSTEMS
Contents
1. Overview .........................................................................................................................................2
2. References .......................................................................................................................................2
3. General considerations for sampling ..............................................................................................2
3.1. Consideration about sampling from hoses .............................................................................3
4. Sampling location ............................................................................................................................4
5. Sampling for chemical analysis .......................................................................................................5
6. Microbiological sampling ................................................................................................................7
7. Sampling frequency .........................................................................................................................8
7.1. Sampling frequency during validation phases ........................................................................8
7.2. Sampling frequency on feedwater ..........................................................................................9
7.3. Sampling frequency on bulk pharmaceutical water ...............................................................9
8. Sampling SOP ................................................................................................................................10
8.1. Example of sampling SOP for raw water and purified water ................................................10
8.2. Example of sampling chart for a RO system..........................................................................12
REVISIONS HISTORY
01 Integration in section 7.2. 03/16 C. Opl F. Pedrelli
00 First issue 10/14 C. Opl F. Pedrelli
REV DESCRIPTION DATE ISSUED BY VERIFIED & APPROVED BY
IO 75_03_11
SAMPLING IN PHARMACEUTICAL WATER
Rev. 01
SYSTEMS Page 2/12
1. Overview
The aim of this document is to provide information and recommendations about the Good Sampling
Practices on pharmaceutical water treatment systems, such as:
 Purified water generation , storage and distribution systems

 Water for injection generation , storage and distribution systems
 Pure Steam generation and distribution systems.
Correct sampling is the key to pharmaceutical water quality compliance.

SOPs for sampling shall be established by the Quality Control Department of the pharmaceutical user
company of BRAM-COR equipment, based on the unit operation and regulatory expectations for the
desired product water.
2. References
 ISPE GOOD PRACTICE GUIDE “Commissioning and Qualification of Pharmaceutical Water and
Steam Systems”, page 35
 ISPE GOOD PRACTICE GUIDE “Approaches to Commissioning and Qualification of
Pharmaceutical Water and Steam Systems” 2nd edition
 WHO guidelines for sampling of pharmaceutical products and related materials
 WHO expert committee on specifications for pharmaceutical preparations - 39th report
 ASQ CPGP BASICS “Bulk Pharmaceutical Water Monitoring and Testing” by Robert D. Seltzer
 USP 38 <1231> “Sampling considerations”
 ANSI Z1.4_03_sampling
 European Pharmacopoeia 8th ed.
 21 CFR part 110
 FDA Guide to Inspection of High Purity Water Systems
3. General considerations for sampling

Adequate facilities, well-trained personnel and approved procedures shall be available for the
sampling, inspection and analysis of pharmaceutical water.
The system should be sampled soon after start-up to understand its operating characteristic.
Standard Operating Procedures for sampling and the area in charge shall be defined, as well as the
persons assigned to collect samples.
The sampling SOPs shall include:
1. the sampling method and plan;
2. the equipment to be used;
3. any precautions to be observed to prevent contamination of the sample or any risks to quality;
4. the quantity of the sample(s) to be collected;
5. the sampling points on the equipment under inspection;
6. type of container to be used in sample packaging, labeling,
7. any precautions to be observed, above all regarding the sampling of sterile materials.
Records (manual or electronic) shall be done evidencing that all the sampling, inspection and test
procedures were indeed carried out and any diversions were duly recorded and investigated.
A spreadsheet with cross-reference of sampling points TAG and results for microbial analysis, for
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Rev. 01
SYSTEMS Page 3/12
example, should be prepared to trace the historical evolution of analytical results.

The sampling shall be carried out so as to prevent the occurrence of contamination or other adverse
effects on the sampled product’s quality.
Each container holding samples shall be identified and show the following information:
A. name of the sampled material;

B. batch number;
C. TAG of the sampling point;
D. number of the sample;
E. signature of the person in charge of the collection;
F. sampling date.
3.1. Consideration about sampling from hoses
“The technique for removing water from the system affects the quality of the water that is delivered;
high microbial count water samples may result frequently from insufficient outlet flushing and poorly
maintained hoses. The hoses used for manufacturing applications should be used for QC sampling,
regardless of whether they are found to be connected at the time of sampling.
lt is considered extremely important to maintain manufacturing hoses, gaskets, and other
appurtenances appropriately to minimize biofilm growth or environmental contamination on their
surfaces during storage. Organizations may address these concerns by using only sterilized hoses or
periodically sterilized hoses, and still others may rarely, if ever, use sterile hoses. Each approach has
benefits and risks related directly to how the hoses (and their gaskets) are maintained during and after
use. A hose that is stored wet and in an orientation that prevents draining and drying will eventually
grow biofilm that will contaminate the water that flows through it during production use or sampling.
Hence, frequent hose replacement with a sterile hose is a good idea. lt is aIso a good practice to have a
hose end fitting design and care in handling both the hose end and its gasket during connection to
prevent inadvertent contamination of these surfaces.
Where possible, hoses should not remain attached to POU valves for extended periods of time where
they remain wet near the attachment point. This increases the probability of biofilm growth within
them significantly. When not in use, hoses should be disconnected from water system outlets. Where
hoses are not sterilized between each use, they should be hung in an upside down ·n· orientation to
promote rapid and complete drainage and drying of the hose lumen and minimize the potential for
biofilm growth. The hoses should be of length that permits drainage and drying in an acceptable time
frame. lt may be necessary to blow filtered dry compressed air or nitrogen though hoses to facilitate
drying, particularly of long hoses. lf there is a potential for environmental or product dust
contamination to enter the hose ends (or the POU outlet valves) between uses, it is preferable to use an
air-permeable "bonnet" or dust cover over the open ends, rather than using a sealing end cap that
would prevent drainage and drying and trap biofilm-growing surface moisture. Hoses should be taken
out of service periodically to be cleaned thoroughly and sanitized or sterilized; inspected for internal
cracks or other signs of wear that would justify their replacement to help to minimize the development
of biofilm within the hose”.
From ISPE GOOD PRACTICE GUIDE “Commissioning and Qualification of Pharmaceutical Water and
Steam Systems”, page 35
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4. Sampling location
Water samples can be taken after each purification step of the plant.
Following table, adapted from ISPE GOOD PRACTICE GUIDE “Commissioning and Qualification of
Pharmaceutical Water and Steam Systems”, resumes typical process steps to be sampled in High Purity
Water Generation systems:
Generation & distribution Process steps to be sampled Monitoring

system method
Distillation (Vapor compression Multimedia Filter Pressure Drop, Particulate
or Multi-Effect Still)
Softening Hardness
Carbon bed ORP (oxidation/reduction potential),

free Chlorine, Ammonia, Total Count,
Vapor Compression or Multi Effect Still Conductivity, TOC, Total Count,
Microbial Endotoxins
WFI storage and distribution WFI Storage Conductivity, TOC, Total Count,
WFI Point of use Conductivity, TOC, Total Count,
Raw water Temperature, Turbidity, TDS, Silt
RO/EDI Density Index
Multimedia Filter Pressure Drop, Particulate
Softening Hardness
pH adjustment pH
De-chlorination (either/or) ORP or free Chlorine and Total Count
Carbon ORP or free Chlorine
Bisulfite
Reverse Osmosis Conductivity, flowrate (to provide % of
rejection and recovery) and Total Count
Electro Deionization Conductivity, TOC, Total Count
PW storage and distribution PW Storage Conductivity, TOC, Total Count
PW Point of use Conductivity, TOC, Total Count
Pure Steam Sampling point with Tube-in-tube Conductivity, TOC, Total Count,
exchanger on PS outlet Microbial Endotoxins
Sampling points are marked on BRAM-COR P&ID drawings, tagged and listed in the part-list of the
equipment. For ease of identification, sampling points can be locally marked by the user (with a green
spot, for instance).
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5. Sampling for chemical analysis

Start-up samples and on-line chemical tests are typically obtained and tested to compare differences
during commissioning. Once the reliability of on-line instrumentation is proved with laboratory test,
chemical sampling must be periodically repeated and on-line instruments calibration must be kept
under control.
“Sampling for chemical analysis is also done for in-process control and for quality control purposes.
Unlike microbial analysis, chemical analysis can be performed using on-line instrumentation” (from USP
38, <1231>
Process data should be used for QC purposes to monitor continuous quality.
For laboratory analysis samples should be collected as per internal SOPs.

Containers size is usually 500 ml.
Chemical analysis must be performed according to the specifications of international

Pharmacopoieas and Standards.
Following table provides information about pharmacopoeial major chemical specifications for Purified
Water, Highly Purified Water, Water for Injection and Pure Steam.
PHYSICAL/CHEMICAL SPECIFICATION
PURIFIED WATER IN BULK
PHARMACOPOEIAS EU. Ph. USP
Appearance Colorless, clear Not defined
Conductivity ≤ 4,3 μS/cm@20°C ≤ 1,3 μS/cm@25°C
TOC ≤ 0.5 mg/l ≤ 0.50 mg/L
Oxidable substances(KMnO₄) ≤ 3 mg/l Not defined
Nitrates NO₃ ≤ 0,2 mg/l Not defined
Heavy metals pb,Ag,Hg,Cu,Co ≤ 0,1 ppm Not required
CO₂ Undefined Not required
HIGHLY PURIFIED WATER IN BULK
Conductivity ≤ 1,1 μS/cm@20°C Not defined
TOC ≤ 0.5 mg/l Not defined
Nitrates NO₃ ≤ 0,2 ppm Not defined
Aluminium ≤ 10 ppb Not defined
WATER FOR INJECTIONS IN BULK
Conductivity ≤ 1,1 μS/cm@20°C ≤ 1,3 μS/cm @25°C
TOC ≤ 0.5 mg/l ≤ 0.50 mg/l
Nitrates NO₃ ≤ 0,2 mg/l Not defined
Aluminium ≤ 10 ppb Not defined
PURE STEAM (CONDENSATE)
Conductivity Not defined ≤ 1,3 (25°C) μS/cm
TOC Not defined ≤ 500 ppb
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Since conductivity varies according to temperature, acceptance criteria for conductivity should be
based on following specification (from Eu. Ph. 8th)
Temperature in °C Conductivity in µS/cm

0 0.6
5 0.8
10 0.9
15 1.0
20 1.1
25 1.3
30 1.4
35 1.5
40 1.7
45 1.8
50 1.9
55 2.1
60 2.2
65 2.4
70 2.5
75 2.7
80 2.7
85 2.7
90 2.7
95 2.9
100 3.1
Samples temperature should be monitored by means of a calibrated thermometer.

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6. Microbial sampling
The personnel in charge with microbial sampling shall wear sterile gloves, clean overall and mask.
Samples should be collected as per internal SOPs.
“With regard to sample size, 100 - 300 mL is preferred when sampling WFI systems. Sample volumes
less than 100 mL are unacceptable”. (From FDA Guide to Inspection of High Purity Water Systems)
Sterile capped container size is usually 250 ml.
For microbiological analysis, the containers used in sampling shall be sterilized (or autoclaved) and
plugged and the sampling point shall be duly disinfected with an appropriate agent (such alcohol) and
flushed for 30 seconds before sampling.
The container should however not come in contact with the sampling point during sampling and be
closed immediately after sampling.
Samples containing chemical sanitizing agents (such as chlorine) require neutralization (such as sodium
thiosulphate) prior to microbiological analysis.
The sample should be sent to the laboratory and tested immediately after sampling, or, in any case,
within 24 hours. If analysis cannot be performed within 8 hours after sampling, the sample must be
kept at 2-8°C.
Following table provides information about pharmacopoeial major microbiological specifications for
Purified Water, Highly Purified Water, Water for Injection and Pure Steam.
MICROBIOLOGICAL SPECIFICATION
PURIFIED WATER IN BULK
Bacterial count ≤ 100 CFU/ml ≤ 100 CFU/ml
Bacterial endotoxins < 0.25 IU/ml -
HIGHLY PURIFIED WATER IN BULK
Bacterial count ≤ 10 CFU/100 ml Not defined
Bacterial endotoxins < 0.25 IU/ml Not defined
WATER FOR INJECTIONS IN BULK
Bacterial count ≤ 10 CFU/100 ml ≤ 10 CFU/100 ml
Bacterial endotoxins < 0.25 IU/ml < 0.25 EU/ml
PURE STEAM (CONDENSATE)
Bacterial count Not defined ≤ 10 CFU/100 ml
Bacterial endotoxins Not defined < 0.25 EU/ml
Microbial Count on raw water should be tested @ 22°C (according to UNI EN ISO 6222:2001) to detect
psychrophilic organisms and @ 37°C (UNI EN ISO 6222:2001) to detect mesophilic organisms, which
may exist in feedwater micro Flore independently from any contamination.
For WFI plants, the real concern in WFI is endotoxins. Because WFI can pass the LAL endotoxin test and
still fail the above microbial action limit, it is important to monitor WFI systems for both endotoxins
and microorganisms.
IO 75_03_11
Rev. 01
SYSTEMS Page 8/12
“None of the limits for water are pass/fail limits. All limits are action limits. When action limits are
exceeded the firm must investigate the cause of the problem, take action to correct the problem and
assess the impact of the microbial contamination on products manufactured with the water and
document the results of their investigation.” (From FDA Guide to Inspection of High Purity Water
Systems)
Appropriate investigation for pathogens on feedwater and on all Sampling Points should therefore be
done in case of non-compliant analytical results, tracing all results in a spreadsheet following a
chronological sequence, before and after sanitization or sterilization of the plant.
Samples are usually tested for following pathogens:
(A) Salmonella species

(B) Escherichia coli
(C) Pseudomonas aeruginosa
(D) Staphylococcus aureus.
The correspondent laboratory analysis should be performed according to international standards.
7. Sampling frequency
“Established sampling frequency should be based on system validation data” (USP 38, <1231>)
7.1. Sampling frequency during validation phases
“After all the equipment and piping has been verified as installed correctly and working as specified, the
initial phase of the water system validation can begin.
During this phase the operational parameters and the cleaning/ sanitization procedures and
frequencies will be developed. Sampling should be daily after each step in the purification process and
at each point of use for two to four weeks. The sampling procedure for point of use sampling should
reflect how the water is to be drawn e.g. if a hose is usually attached the sample should be taken at the
end of the hose. If the SOP calls for the line to be flushed before use of the water from that point, then
the sample is taken after the flush.
At the end of the two to four week time period the firm should have developed its SOPs for operation
of the water system.
The second phase of the system validation is to demonstrate that the system will consistently produce
the desired water quality when operated in conformance with the SOPs. The sampling is performed as
in the initial phase and for the same time period. At the end of this phase the data should demonstrate
that the system will consistently produce the desired quality of water.
The third phase of validation is designed to demonstrate that when the water system is operated in
accordance with the SOPs over a long period of time it will consistently produce water of the desired
quality. Any variations in the quality of the feedwater that could affect the operation and ultimately
the water quality will be picked up during this phase of the validation. Sampling is performed
according to routine procedures and frequencies.
For Water for Injection systems the samples should be taken daily from a minimum of one point of
use, with all points of use tested weekly. The validation of the water system is completed when the
firm has a full year worth of data.
IO 75_03_11
Rev. 01
SYSTEMS Page 9/12
While the above validation scheme is not the only way a system can be validated, it contains the
necessary elements for validation of a water system. First, there must be data to support the SOPs.
Second, there must be data demonstrating that the SOPs are valid and that the system is capable of
consistently producing water that meets the desired specifications.
Finally, there must be data to demonstrate that seasonal variations in the feedwater do not
adversely affect the operation of the system or the water quality.” (From FDA Guide to Inspection of
High Purity Water Systems).
7.2. Sampling frequency on feedwater

Since all pharmaceutical water treatment systems are designed starting from local water analysis, a
significant variation in feedwater quality may cause equipment malfunction or non-compliant process
values.
Feed water quality should therefore be monitored according to local water supply features and
standard regulations, because “The incoming feedwater quality may fluctuate during the life of the
system depending upon seasonal variations and other external factors beyond the control of the
pharmaceutical facility.”
Routine sampling of feed water:

 For Potable Water, which is usually municipal, 21CFR part 110 states “the water bill and
analysis should be obtained annually (from the municipal authority) and filed with a periodic of
monthly sanitation control record”.
 For well (or non-potable) water “analysis should be conducted before any new service is used
for processing operation and then at least on a semi-annual basis or more frequently according
with state requirements”.
In case of contamination, feedwater should be sampled daily, as well as other water process steps.
7.3. Sampling frequency on bulk pharmaceutical water

The 1993 FDA guide created the generally accepted sampling frequency and sampling locations within
a bulk pharmaceutical water distribution system.
It recommends daily sampling (except during shutdown) from a minimum of one point of use, with all
points of use tested weekly.
<In common practice, sampling frequency is based on confidence of the data. The pharmaceutical
company needs to be able to justify the sampling frequency based on the consistency of the data, i.e.
the duration times between samples should show little or no deviation between the values or readings
of the samples. Risk analysis and statistical tools can provide a solid scientific basis for reducing
sampling frequencies. The risk analysis should consider sample valve design, location, frequency of
use, and other local factors. That is how the sampling frequency can be justified.
Any sampling should have a flushing or rinse time associated with the sampling method.>01
IO 75_03_11
Rev. 01
SYSTEMS Page 10/12
8. Sampling SOP
“It is up to each drug manufacturer to evaluate their product, the way it is manufactured, and establish
an acceptable action level of contamination, not to exceed the maximum, for the water system, based
on the highest risk product manufactured with the water.” (From FDA Guide to Inspection of High
Purity Water Systems).
An example of sampling SOP is provided in following page.
8.1. Example of sampling SOP for raw water and purified water
1.0 OBJECTIVE:
To lay down the procedure for sampling and testing of Potable and purified water for Microbiological
and chemical analysis.
2.0 SCOPE:
This SOP shall be applicable to Microbiological and Chemical Section of Quality Control.
3.0 RESPONSIBILITY:
Quality Control Chemist and Microbiologist.
4.0 ACCOUNTABILITY:
Sr. Manager Quality Assurance.
5.0 PROCEDURE:
5.1 Chemical Analysis:
5.1.1 Take a clean, dry conical flask (500 ml capacity) and plug it with cotton.
5.1.2 Take the flask to the sampling area.
5.1.3 Open the tap/valve of the sampling point and let the water flow for about 30 seconds.
5.1.4 Unplug the flask and rinse it with the running water.
5.1.5 Collect about 500 ml of the water sample in the flask.
5.1.6 Plug the flask immediately and label it, mentioning the sampling point and date.
5.2 Microbiological Analysis:
5.2.1 Wear sterile overall, mask and gloves
5.2.2.Take a clean, dry conical flask of 250 ml capacity and sterilize by autoclaving @ 7 kg pressure
(121° C) for 15 minutes.
5.2.3 Take the sterile, plugged flask to the sampling area.
5.2.4. Duly disinfect the sampling point
5.2.5 Open the tap/valve of the sampling point and let the water flow for about 30 seconds.
5.2.6 Unplug the flask and collect about 250 ml of the water sample in the flask.
5.2.7 Plug the flask immediately and label it, mentioning the sampling point and date.
5.2.8 Carry out microbiological analysis of the sample as per the specifications.
5.3 Purified Water:
5.3.1 Purified water shall be sampled from the following sampling points every day for chemical
analysis and once in a week (first working day of the week) for microbial analysis.
a. D.M Water Storage Tank
b. Manufacturing Area
c. Washing Area
d. Filling & Sealing Area
e. Granulation
5.3.2 The sampling points of purified water in the production area are marked with a yellow colour for
the ease of identification.
5.3.3 Purified water shall be analysed as per the available specifications.
IO 75_03_11
Rev. 01
SYSTEMS Page 11/12
5.3.4 The results shall be recorded in format. A copy of the report shall be sent to the respective
departments.
5.3.5 The limit of total microbial count of purified water shall be 100 cfu/ml. The alert limit shall be 50
cfu/ml and the action limit shall be 75 cfu/ml.
5.3.6 In case the microbial count of a purified water sample exceeds the alert limit, the maintenance
department and the respective department shall be informed immediately, in writing.
5.4 Raw Water:
5.4.1 Raw water shall be sampled once a month from the raw water storage tank/raw water sampling
point for chemical and microbiological analysis.
5.4.2 Raw water from any one of the following sampling points shall be collected every month on
rotational basis.
a. Manufacturing Area
b. Washing Area
c. Filling & Sealing Area
d. Granulation
5.4.3 The sampling points of raw water in the production area are marked with a green spot for ease of
identification.
5.4.4 Raw water shall be analysed as per the available specifications.
5.4.5 The results shall be recorded in a sampling chart.
Manuale delle Procedure
Istruzione Operativa IO 75_03_11 Rev.01
SAMPLING IN PHARMACEUTICAL Page 12/12
WATER SYSTEMS
8.2. Example of sampling chart for a RO system
PURIFIED WATER
Total microbial count (cfu/ml) Isolated Pathogen Bacteria
PW01 PW02 PW03 PW04 PW05 PW06 PW01 PW02 PW03 PW04 PW05 PW06
Date
10 HV 018 10 HV 019 10 HV 012 10 HV 028 10 HV 025 10 HV 049 10 HV 018 10 HV 019 10 HV 012 10 HV 028 10 HV 025 10 HV 049
Sampling
point
20-Jun-2011 50 50 50 50 50 60 * * example of compilation

SECTION 5.2.
Operating manual
▹▹▷


LOCATION COLOMBIA
DOCUMENT NAME OPERATING MANUAL
DOCUMENT CODE M_3108_MPO_0
JOB No. 11880
SERIAL No. 3108

REVISION HISTORY
0 First issue 03/08/2018 S. Magri V. Cucci M. Pettenati
BRAM‐COR S.p.A.
Tel. 0039 0521 538711
Fax: 0039 0521 538770

TABLE OF CONTENTS

1. GENERAL INFORMATION ......................................................................................................................... 3
SCOPE AND APPLICATION NOTE ............................................................................................................... 3
TERMINOLOGY AND ABBREVIATIONS ...................................................................................................... 3
2. PLC/HMI SYSTEM ARCHITECTURE ............................................................................................................ 4
GENERAL DESCRIPTION ............................................................................................................................ 4
CONTROL SYSTEM ARCHITECTURE ........................................................................................................... 4
USER ACCESS LEVEL .................................................................................................................................. 5
3. OPERATING INSTRUCTIONS ..................................................................................................................... 6
LEGEND ..................................................................................................................................................... 6
HOME PAGE .............................................................................................................................................. 6
CONTROL PUSH BUTTONS ........................................................................................................................ 8
4. PURE STEAM GENERATOR ..................................................................................................................... 11
OPERATING MODES ................................................................................................................................ 11
SYNOPTIC ................................................................................................................................................ 13
TRENDS/STATUS ..................................................................................................................................... 21
OPERATOR PARAMETERS ....................................................................................................................... 23
PID/PLANT PARAMETERS ........................................................................................................................ 24
SETTINGS ................................................................................................................................................ 25
ALARMS .................................................................................................................................................. 31

OPERATING MANUAL – M_3108_MPO_0 PAGE 2 OF 31



This section provides general information about the computerized system used to control and
supervise the plant.
SCOPE AND APPLICATION NOTE

This manual was issued by BRAM‐COR S.p.A. Documentation Dept. to provide technical information
about the PC managing the system: PURE STEAM GENERATOR. The PC stores all trends and alarms
coming from the above mentioned subsystems.
This manual is intended for operators and technicians who are directly involved in operations
management of system.
Please refer to the User and Maintenance Manual for safety and equipment description.
TERMINOLOGY AND ABBREVIATIONS

Operator: Users in charges with the normal operation and ordinary maintenance. He is the less
privileged User and can make changes only to non‐critical system parameters.

Supervisors / Maintenance: Supervisors and Maintenance Technicians shall receive adequate training.
The Maintenance Technicians can make changes to all the operating parameters of the system. They
can be considered privileged Users of the system. They are allowed to modify some operating
parameters of the plant while continuing to maintain the privileges assigned to the Operators User.

BRAM‐COR (Administrator): Users having access to all critical system parameters as well as maintain
the privileges of all other Users of the system.



2. PLC/HMI SYSTEM ARCHITECTURE

With reference to regulations regarding safety on computerized control systems, this section of the
manual will discuss the implemented architecture and the policy of access to the system under
consideration.

NOTE:
This Operator Panel embedded in this machine is intended as Human‐Machine Interface
(HMI) dedicated to machine control only.
It is not conceived for personal use; BRAM‐COR is not liable for improper use of the HMI.

GENERAL DESCRIPTION

The Operator Interface Panel used for this system, is a SIMATIC KTP700 BASIC unit.
In accordance with the right permission level (listed on the next page), by acting on this HMI system the
Operators can control the system in order to activate/deactivate all operating functions, set the
operating parameter, acknowledge the alarm messages and check the whole functioning of this system
during production.
This manual describes the command pages of the Operator Panel, installed on the equipment control
board.

CONTROL SYSTEM ARCHITECTURE
Next image shows the control and supervisory scheme. An ETHERNET network, connects the PLC with
its HMI:



USER ACCESS LEVEL
A safe access policy shall be considered to access the PLC/HMI system. This policy shall include a
password by which supervisory personnel may change the parameters.

Access security is ensured by 3 Password levels for the Customer:
Group User Access level Allowed Operations
System overview; switches on and shuts‐off equipment cycles; can
1 Operator
modify only some operating parameters.
2 Supervisor
modify all operating parameters.
3 Maintenance modify all operating parameters; users management; critical data
management.

BRAM‐COR access configuration provides following standard settings:
 User shall log‐in by digiting user ID + password, the combination of which is unique and may be
changed by the Customer in runtime.
 No password aging.
 Unlimited number of access attempts.
 Minimum password length: 3 normal characters.
 Log‐out time: 5 minutes.
 Passwords Import/Export on encrypted file.
 Only a user of the “Maintenance” level can add, modify, cancel passwords and users.



3. OPERATING INSTRUCTIONS
This manual is intended to provide all the necessary information to easily navigate in the HMI.
This chapter describes the operative instructions to manage the plant through the operator panel and
provides information about how to use control buttons, as well as the related action specifying each
concerned individual subsystem.
LEGEND

The hand icon on the right means that the indicated control button can be used by
the operator.

The following figure show the control bar of the system:
HOME PAGE
After performing the basic operation to start up the plant, which are described in the Use and
Maintenance Manual of the equipment, you will see the home page of the operator panel.

This is the first page of the Operator Panel with the customer logo; for accessing the application, the
login is necessary.


Press on the screen to display the login window, necessary for accessing the application:
Click inside the USER and PASSWORD boxes to digit the access credentials.

Use the keyboard that will appear to fill in the window, User and password and press key to
confirm. As to complete the login press OK button.
As previously seen, BRAM‐COR provides different login levels account with different password.

Passwords are delivered to the system administrator after the commissioning activities and
must be carefully stored to ensure safe access to the system using different login levels.

The set log‐out time is 5 minutes. User can log‐in again from every page, whenever he
wants, following the instructions reported in the previous page.

Remember that only with an adequate level of permission, users can modify these values.


CONTROL PUSH BUTTONS

As far as this paragraph concerns, the pictures related are attached only by way of example.

After login, the following page will appear:

TOP BAR IDENTICATION BAR

BOTTOM BAR CONTROL BAR SIDE BAR
The above‐mentioned types of bars are always fixed in the indicated positions.
For more information about your specific system Control Bars, please refer to Paragraph 3.1.

Following pages furnish an explanation about the use of each control button previously highlighted in
the figure above.


As far as this paragraph concerns, the pictures related are attached only by way of example.

On the TOP BAR is possible to find:

PLC LAST RELEVANT MESSAGES about
HELP PAGE link errors, alarms and diagnostic warnings DATE and TIME

LOG STATUS ‐ current logged User
INFORMATION

On the IDENTIFICATION BAR is present:
CURRENT PAGE
SYSTEM NAME NUMBER
CURRENT PAGE NAME
and PAGES NUMBER

Use this button to switch between the different systems control bars (if applicable).

SIDE BAR control buttons are shown below:
Back to HOME PAGE Exit from the system

ALARMS RESET Turn off the system

The BOTTOM BAR concerns about PLC messages related the system working; they represent a report of
what the system is performing.
ERROR AND WARNINGS MESSAGES

CURRENT SYSTEM MESSAGES


Each system has its own CONTROL BAR with the following buttons:

PLANT PARAMETERS and PID
OPERATING MODES
REGULATION

LAYOUT – SYNOPTIC PAGE SETTINGS

TRENDS and STATUS: Analogic
ALARMS – Actual Alarms
and Digital Inputs and Outputs

OPERATOR PARAMETERS BACK TO PREVIOUS PAGE

The KTP700 owns eight Function Keys (from F1 to F8). In spite of pressing the CONTROL BAR buttons,
the corresponding Function Key, underlying each of them, could be press as to obtain the same action.
Touch BRAM‐COR logo:
to display the HELP PAGE of the current system.
The page displays a list of the CONTROL BAR buttons, in order to ease the User the page choice.



4. PURE STEAM GENERATOR
OPERATING MODES

Touch the symbol indicated below, or F1, to display the OPERATING MODES page:

Below, each sequence is described:

CPSG PURE STEAM

PRODUCTION sequences
identifiers:

SEQUENCES CONTROL BUTTON:
use this command to start/stop SEQUENCE RUNNING LAMP
the sequences

SEQUENCE STATUS LAMP



On operating modes pages, following control buttons may be present:
SCROLL UP OPERATING MODES PAGES logo

SCROLL DOWN OPERATING MODES PAGES logo

Please consider that the following pictures are attached only by way of example.
‐ The SEQUENCE RUNNING LAMP can be visualized as:
Steady green:. It means that the sequence
is ended.

Blinking green: indicating that the
sequence is running.

‐ The SEQUENCE STATUS LAMP can take one of the following colors:
Grey indicates a disabled control.
The sequence is inactive (cannot start nor stop).

Red appears in case of alarm.
The sequence can’t start.

Blue reveals that the system is ready to start the
sequence.
Green means that the sequence
is running.

Yellow is particular of Softener Columns sequences and
means that the Column is in slave mode.
Violet is particular of Softener Columns sequences and
means that the Column is in regeneration.

During the run of one sequence, it is not possible to activate any others.
Wait till the sequence end before starting another one.


SYNOPTIC

Touch the symbol indicated below, or F2 to display the “SYNOPTIC” pages:

On synoptic pages, following control buttons may be present:
Please consider that the following pictures are attached only by way of example.

Grey squares (with white numbers, letters and symbols) represents pipes of
connection between two components. They may be clickable.

Sequences status lamp may appear with different colors with distint
meanings. For further information, please return to paragraph 4.1

Some item tags icons are clickable and from here it is possible to open the
related setting pages; different cases are possible:
 Opening of TREND/STATUS pages
 Opening of PID/PLANT PARAMETERS pages
 Opening of OPERATOR PARAMETERS pages

Following paragraphs describe the general functioning of each above‐
mentioned case.
Please consider that these functions are not always all activated, depending
on the system in object.

Blue rectangles (with fully capitalized white words) may be clickable to reach
the part of the system in object.


4.2.1. ‐ Opening of TREND/STATUS pages

Clicking on the highlighted field,
the operator is able to accessto the relevant trend/status page:
Following page provide additional and general information about control buttons and navigation.



On trends/status pages, following control buttons may be present:
STARTING / STOPPING the update time
Back to the last istant in memory (15 minutes before)
Bring the update time back
Fast the update time foreward
ZOOMING the time line IN
ZOOMING the time line OUT
SHOWING / HIDING time pointer
SHIFTING time pointer LEFT
SHIFTING time pointer RIGHT

Reading trend value:
 Use the two ZOOM controls to regulate the time window and display a related‐to‐time trend
value.
 Use the TIME POINTER to show the line of the required time.
 Then use the TIME SHIFT controls to set the desired time and to extract the related trend.
 Read the value from the record at the bottom of page.

Furthermore, it is possible to start an update time and stop whenever it is necessary. It is suggested to
bring back / forward the time line when the update time is stopped.

NOTE:
The system can keep in memory no more than 900 samples, which corresponds to 15
minutes of trend recording at most.


Under the control buttons, there is a table, where are resumed data about the current trend analysis:

On the right side of the trend pages following control buttons are present:

Scroll up trends/status pages

Scroll down trends/status pages



4.2.2. ‐ Opening of PID/PLANT PARAMETERS pages

Clicking on the highlighted field the operator is able to access
the relevant PID/plant parameters page:




On PID/plant parameters pages, following control buttons may be present:

SCROLL UP PID/PLANT PARAMETERS PAGES logo

SCROLL DOWN PID/PLANT PARAMETERS PAGES logo

To change the values, press the green area and make change using the on screen numeric keypad.

Press key to confirm, as shown below:

IMPORTANT NOTE:
Remember that only with an adequate level of permission,
users can open and modify these values.


4.2.3. ‐ Opening of OPERATOR PARAMETERS pages

Clicking on the highlighted field the operator is able to access
the relevant operator parameters page:




On OPERATOR PARAMETERS pages, following control buttons may be present:

SCROLL UP OPERATOR PARAMETERS PAGES logo

SCROLL DOWN OPERATOR PARAMETERS PAGES logo

To change the values, press the green area and make change using the on screen numeric keypad
Press key to confirm, as shown below:

IMPORTANT NOTE:



TRENDS/STATUS

Touch the symbol indicated below to display the “TRENDS/STATUS” pages:
In the Status pages the user can visualize the Analogic and Digital Inputs and Output and Trend
reports:



For further information about these pages, their control buttons and all browsing
information, please refer to Section 4.2. (Paragraph 4.2.1. ‐ “Opening of TREND/STATUS
pages”).


OPERATOR PARAMETERS

Touch the symbol indicated below to display the “OPERATOR PARAMETERS” pages:

information, please refer to Section 4.2. (Paragraph 4.2.3. ‐ “Opening of OPERATOR
PARAMETERS pages”).


PID/PLANT PARAMETERS

Touch the symbol indicated below to display the “PID/PLANT PARAMETERS” pages:

information, please refer to Section 4.2. (Paragraph 4.2.2. ‐ “Opening of PID/PLANT
PARAMETERS pages”).



SETTINGS
Touch the symbol indicated below to display the “SETTINGS” pages:

Use this control button to enter a section.

Use this control button to return to this menu, from the following areas.




4.6.1. Control Panel

On CONTROL PANEL page, following icons are present:

CHANGE LANGUAGE: to change the language of the operator panel (default language is
English).

LOCK SCREEN FOR CLEANING PAGE: click on this button for disabling the touch panel, in
order to clean the screen.

CHANGE USER: use this command to change the current User (login pop‐up will appear).

LOGOUT PASSWORD: to exit from the system.

MANAGE USERS AND PASSWORDS:To enter in “Manage Users and Passwords” page.
Following page provide additional and general information.



Manage Users and Password

IMPORTANT NOTE:



4.6.2. Timer and Datetime

On TIMER and DATETIME page, following icons are present:
Back to the upper menu.
To increase the number of Timer.
To decrease the number of Timer.
Confirm the insertion of the “Timer New Value: the “Timer Actual
Value” will become identical to the other inserted.

Confirm the insertion of the “Datetime PLC Write”: the Datetime
counterof the system will stop and the Datetime PLC Read” restart
from the time inserted.



To change the values, press the green area and make change using the on screen numeric keypad
Press key to confirm, as shown below

IMPORTANT NOTE:




4.6.3. Counters

Use this control button to reset the values.

IMPORTANT NOTE:



ALARMS

Touch the symbol indicated below, or F7, to display the ALARMS – Actual Alarms” and “MESSAGES –
Actual Messages pages:

On ALARMS page, following icons are present:

Use this button to acknowledge an alarm, after its selection from the list.

Use this button to show the desired troubleshooting, after alarm selection from the list

SECTION 5.3.
Suggested Spare parts list
▹▹▷

Customer
FARMALOGICA S.A.
SUGGESTED SPARE PARTS
Pos. Model Q.ty Supplier
1 Capacitive level transmitter ‐ L=450mm ‐ FMI51‐A1ATJJB1A1D 1 Endress+Hauser
2 Pressure transducer ‐ Range ‐1/+5 bar ‐ dTrans p31 402050 1 Jumo
3 Pressure switch ‐ RT116 0…10bar 1 Danfoss
4 Mechanical seal for multistage pump ‐ CRN1‐7 1 Grundfos
5 Filter air reducer + Manometer ‐ FR 100 1/4 20 08 RMSA + ACC. M 40 1/8 12 1 Metal Work
6 Gasket kit for modulating valve ‐ M805033C 1 Hofmann
7 Membrane for valve ‐ Conn. ½" T.C. ‐ 601 15 D 80 40 5A 00 TS 1536 1 Gemu
8 Membrane for valve ‐ Conn. ¾" T.C. ‐ 612 20 D 80 40 52 01 TS 1536 1 Gemu
9 Membrane for valve ‐ Conn. ¾" T.C. ‐ 625 20 D 80 40 52 1 1/N 1536 2 Gemu
10 Electropneumatic pressure controller ‐ ITV1030 1 SMC
11 2 ways electric valve A‐B ‐ SJ3A60‐5CU‐C4 2 SMC
12 Pressure switch ‐ ISE10‐M5‐B‐GRK 1 SMC
Gaskets PTFE for Tri‐clamp connections 5/8
13 Newman
(please check your system for size and manufacturer information) for each type
Gaskets for components made in Bram‐Cor
14 / FF.GI.
(please refer to constructive drawings for further information)
SUGGESTED SPARE PARTS ‐ M_3108_SP PAGE 1 OF 1

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System:

SYSTEM PURE STEAM GENERATOR

EQUIPMENT TYPE CPSG ST 1000

BASIC TECHNICAL DATA

Rev. Description Date Issued Verified Approved

0 First issue 06/06/2018 C. Opl A. Scala A. Negri

DESIGN QUALIFICATION - M_3108_DQ_0 PAGE 2 of 40

• Attachments: see section 2

DESIGN QUALIFICATION - M_3108_DQ_0 PAGE 3 of 40

1.1. DQ PROTOCOL RATIONALE

1.2. SCOPE AND APPLICATION

BRAM-COR scope of supply includes:

DESIGN QUALIFICATION - M_3108_DQ_0 PAGE 4 of 40

1.3. CHANGE CONTROL

According to contract agreements:

1.5. PROTOCOL APPROVAL

1.6. TERMINOLOGY AND ABBREVIATIONS

AI = Analogic Input OP= Operator Panel

DESIGN QUALIFICATION - M_3108_DQ_0 PAGE 5 of 40

1.7. REGULATORY STANDARDS

DESIGN QUALIFICATION - M_3108_DQ_0 PAGE 6 of 40

1.8. BRAM-COR S.p.A. QUALITY SYSTEM PROCEDURES

Activity Procedure Title Operating Title

PO 75_01 Job Management - -

PO 75_02 Customer’s Properties - -

PO 75_04 Identification and IO 75_04_01 Coding

IO 75_05_02 Roughness test

IO 75_09_01 Piping Cleaning

IO 75_09_02 Pickling and passivation

IO 75_09_03 Coupons-weld identification

IO 75_09_05 Drainability test

PO 76_01 Measuring Instruments Operating procedures for calibration

DESIGN QUALIFICATION - M_3108_DQ_0 PAGE 7 of 40

This document includes following reference documentation:

ATTACHMENT NO. DOCUMENT DESCRIPTION

TAG Identification No. of the component - e.g. PT-001 = pressure transducer

Description Description of the component

Model Model of the component

Position Position of the component in the equipment

Certification Type of certificate supplied with the item

DESIGN QUALIFICATION - M_3108_DQ_0 PAGE 8 of 40

3. FUNCTIONAL DESIGN SPECIFICATION

BRAM-COR develops the project according to:

 Eu. Ph./ USP requirements for Pure Steam

Conductivity ≤ 1,3 μS/cm@25°C Not defined

TOC ≤ 0.50 mg/L Not defined

CLEAN STEAM PHYSICAL PROPERTY DESIGN VALUE (EN 285) 1

Non-condensable gasses < 3.5 ml/100 ml condensate

Dryness > 0,9-0,95

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3.2. UTILITIES REQUIREMENTS, CONSUMPTIONS AND PERFORMANCE

3.2.1. UTILITIES AND CONSUMPTIONS

Flow Rate 1000 l/h

Blow-down Flow Rate 100 l/h

3.2.1.2. INDUSTRIAL STEAM SUPPLY REQUIREMENTS

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3.2.1.3. ELECTRICAL SUPPLY REQUIREMENTS

3.2.1.4. COMPRESSED AIR SUPPLY REQUIREMENTS

Product Parameter Value / Unit Note

Flow Rate 900 Kg/h

Conductivity ≤ 1,3 μS/cm@25°C In-line measurement

Laboratory tests on the condensed

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