simatic s7-1200, sentron pac3200 application … & tools answers for industry. cover...

Applications & Tools

Answers for industry.

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Measuring& Control: Switching Loads with S7-1200 and SENTRON PAC3200 via MODBUS TCP

S7-1200 Set 24

SIMATIC S7-1200, SENTRON PAC3200

Application Description July 2013

Warranty and Liability

2 Switching Loads with S7

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Warranty and Liability

Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Application Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are used correctly. These application examples do not relieve you of the responsibility to use safe practices in application, installation, operation and maintenance. When using these Application Examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Application Examples at any time without prior notice. If there are any deviations between the recommendations provided in these application examples and other Siemens publications – e.g. Catalogs – the contents of the other documents have priority.

We do not accept any liability for the information contained in this document.

Any claims against us – based on whatever legal reason – resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Application Example shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract (“wesentliche Vertragspflichten”). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these Application Examples or excerpts hereof is prohibited without the expressed consent of Siemens Industry Sector. Caution The functions and solutions described in this article confine themselves to the realization of the automation task predominantly. Please take into account furthermore that corresponding protective measures have to be taken up in the context of Industrial Security when connecting your equipment to other parts of the plant, the enterprise network or the Internet. Further information can be found under the Item-ID 50203404. http://support.automation.siemens.com/WW/view/en/50203404

http://support.automation.siemens.com/WW/view/en/50203404

Table of Contents

Switching Loads with S7-1200 and SENTRON PAC3200 Version 1.1, Entry ID: 58856464 3

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Table of Contents Warranty and Liability .............................................................................................. 2 Table of Contents ..................................................................................................... 3 1 Automation Problem ...................................................................................... 5 2 Automation Solution ...................................................................................... 6

2.1 Required Basic Knowledge ................................................................ 6 2.2 Components ...................................................................................... 6 2.2.1 SENTRON PAC3200 ......................................................................... 6 2.3 Load control principle ......................................................................... 7

Data acquisition and switching commands ......................................... 7 Measured data of the SENTRON PAC3200 devices .......................... 8 Base quantity for load control ............................................................. 9 Base load and electrical losses .......................................................... 9 Criteria for switching off loads ............................................................ 9 Criteria for switching loads back on .................................................. 11 Priority list ........................................................................................ 12

2.4 Data logging .................................................................................... 13 2.5 Error messages ............................................................................... 14 2.6 Hardware and programming software of the sample project ............. 15

Products………. ............................................................................... 15 Programming package ..................................................................... 16

2.7 Wiring of the sample project ............................................................. 17 2.8 Communication principle .................................................................. 17

Client-server relationship ................................................................. 17 The MB_CLIENT instruction ............................................................ 18 Access to the Modbus data register ................................................. 19 Serial communication....................................................................... 19 Network addresses .......................................................................... 20

2.9 Program description......................................................................... 20 2.9.1 Block structure ................................................................................. 21

OB100 – “Startup”............................................................................ 21 OB1 – “Main” ................................................................................... 21 FB501 – “LoadSwitching”, DB501 – “LoadSwitching_DB” ................. 21 FB1084 – “MB_CLIENT“ .................................................................. 22 FC502 – “CALC_P_active_av” ......................................................... 22 FC161 – “Event” .............................................................................. 22 FC501 – “Load_shedding” ............................................................... 23 DB503 – “PAC_data” ....................................................................... 23

2.9.2 User parameters .............................................................................. 23 Load-independent parameters in LoadSwitching_DB ....................... 23 Load-dependent parameters in DB “PAC_data” ............................... 25

2.9.3 Program flow in FB501 “LoadSwitching” .......................................... 27 Networks……………. ....................................................................... 27 Sequencer ....................................................................................... 27

2.10 Visualization .................................................................................... 29 Main screen (start screen) ............................................................... 29 “Consumer load list” screen ............................................................. 30 “Error messages” screen.................................................................. 30

3 Configuration ................................................................................................ 31

3.1 SIMATIC software installation .......................................................... 31 3.2 Parameterizing the SENTRON PAC3200 devices ............................ 31 3.3 Configuring the HMI ......................................................................... 32 3.4 Settings on the development system (Windows) .............................. 33 3.4.1 Assigning the IP address to the development system ....................... 33

Table of Contents


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3.4.2 Setting the PG/PC interface ............................................................. 35 3.5 Parameter assignments in the TIA Portal and project download ....... 36

Opening the project ......................................................................... 36 Setting the country-specific local time .............................................. 37 Load settings for the live demo ........................................................ 37 Downloading the control program to the CPU ................................... 38 Setting the CPU clock ...................................................................... 38 Downloading the HMI project part to the KTP600 ............................. 39 Simulating the KTP600 .................................................................... 40

3.6 Expanding the number of SENTRON PAC3200 devices .................. 41 3.6.1 Expansions in data blocks ............................................................... 41

LoadSwitching_DB [DB501] ............................................................. 41 PAC_data [DB503] .......................................................................... 41

3.6.2 Expansions in the “Load list” HMI screen ......................................... 42 3.6.3 Expansions in the “Error messages” HMI screen .............................. 44

4 Live demo ..................................................................................................... 45

4.1 Switching behavior .......................................................................... 45 4.2 Error messages ............................................................................... 46 4.3 Data log ........................................................................................... 46

5 Glossary ........................................................................................................ 49 6 Code Elements ............................................................................................. 51 7 References .................................................................................................... 51 8 History .......................................................................................................... 52

1 Automation Problem


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1 Automation Problem Power utilities charge industrial electricity customers not only for the active energy consumed (in kWh, “kWh rate”), but they also charge another price dependent on a power limit (in kW, “price per kW”). If this power limit specified by the power utility is exceeded, an additional price per kW has to be charged for the entire accounting period (e.g., 1 month or 1 year, depending on the terms of the contract). The power limit is defined as the average of the total electric power imported over a defined measuring period. Generally, this has a duration of 15 minutes. The power utility – starting with the full hour – thus measures the 15-minute energy consumption and then divides this value by the time to calculate 15-minute average power demands. If a single one of these power values exceeds the specified power limit within the accounting period, the price per kW must be paid for the entire accounting period. To avoid this, large-scale electricity customers temporarily switch off dispensable loads. Now the task in this application is as follows: Relative to the start of the respective measuring period, the total average

power demand of all loads is to be permanently determined to forecast it for the end of the measuring period. If it is expected that the power limit will be exceeded, loads are to be temporarily switched off according to a priority list.

The respective total average power demands at the end of the measuring periods are to be logged over at least the accounting period to furnish proof to the power utility.

Figure 1-1: Task

Load 1(interruptible)


Load n(interruptible)

Load 1(non-interruptible)

…


Load n(non-interruptible)

…

Load control

…

Infeed

Measurement of electrical energyand power by power utility

Separate powermeasurement

2 Automation Solution 2.1 Required Basic Knowledge


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2 Automation Solution 2.1 Required Basic Knowledge

A general knowledge of the field of electrical engineering is required to understand this application example. Knowledge of the relevant safety regulations and standards is required for installing and connecting the components. You should be familiar with PLC handling, especially SIMATIC S7-1200 and with the TIA portal as a platform for programming and commissioning. Knowledge concerning load management and optimizing energy delivery is helpful.

2.2 Components

A SIMATIC S7-1200 CPU (see /2/) is used for load control. SENTRON PAC3200 multi-function measuring instruments are used to

measure the power or electrical energy of the loads. A KTP600 operator panel is used as the HMI (see /10/).

2.2.1 SENTRON PAC3200

The link to the multi-function measuring instrument you find in chap. 7 “References” (/1/).

Abbildung 2-1: SENTRON PAC3200

Find a short summary of the measuring device’s features below.

Features The SENTRON PAC3200 is a Power Monitoring Device for displaying all the relevant system parameters in low-voltage power distribution. It is capable of single-phase, two-phase or three-phase measurement and can be used in two-wire, three-wire and four-wire systems.

2 Automation Solution 2.3 Load control principle


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Thanks to its compact design in 96 x 96 mm format, it is an ideal replacement for all conventional analog indicating instruments. Thanks to its large measured voltage range, the SENTRON PAC3200 with multi-range power supply can be connected direct in any low-voltage system up to a rated system voltage of 690 V. For the device version with extra-low voltage power supply, direct connection to systems up to 500 V is permissible. Higher voltages can be measured using voltage transformers. For measuring current, either x/1 A or x/5 A current transformer can be used. The large graphical LC display permits reading even from a distance. The SENTRON PAC3200 has backlighting that can be adjusted in steps for optimal readability even under poor lighting conditions. The combination of four function keys with the multi-language plaintext displays makes intuitive user prompting possible. The experienced operator can also use direct navigation for quicker selection of the desired display menu. The SENTRON PAC3200 has a range of useful monitoring, diagnostics and service functions, a two-tariff active energy and reactive energy counter, a universal counter, and a working hours counter for monitoring the running time of connected loads. The integral Ethernet interface or an optionally available interface module can be used for communication. This application uses the inbuilt interface. In addition, the SENTRON PAC3200 has a multifunctional digital input and digital output. The parameters can be set either direct on the device or via the communications interface. Password protection is integrated via the front of the device to guard against unauthorized access.

2.3 Load control principle

Data acquisition and switching commands The measured data at the power infeed point necessary for load control is acquired individually for each load by the SENTRON PAC3200 multi-function measuring instruments and added up in the PLC. No measurement is necessary at the actual power infeed point. The SENTRON PAC3200 devices transmit the data to the controller via “MODBUS on TCP”. The switching-off of loads that is required when there is an imminent exceeding of the power limit is performed using relays (NC1 contacts) that are controlled directly by the digital output of the relevant SENTRON PAC3200 device. The SENTRON PAC3200 devices receive the associated switching commands from the PLC via MODBUS communication.

Note Power limit monitoring is alone power customer’s funeral. The utility doesn’t deliver any digestible data (measurands, warnings) to the customer, which can be used to switch-off loads in due time. The power customer has to trust in a good accordance of the utility’s measurements and calculations with the own ones that are dealt with in this application example .

1 Normally Closed



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Figure 2-2: Data acquisition and switching commands

Infeed

Measurement of electrical energyand power by power utilityPAC

3200

S7-1200

KTP600

PM1207

TIA-PortalDataLog

……

PAC3200

PAC3200

PAC3200

PAC3200

PAC3200



Load n(interruptible)


…


Load n(non-interruptible)

…

Base Load,Electric Losses

Measured data of the SENTRON PAC3200 devices The multi-function measuring instruments provide a variety of data. For this application, the following selection of measured values is required by each SENTRON PAC and transmitted to the controller: Active Energy Import Tariff 1 (Wh)

The device is able to differentiate between import and export (e.g., generator operation) of energy. Furthermore, the active energy can be added up optionally in tariff 1 or tariff 22. Mostly, these tariffs are referred to as ON PEAK (e.g., in the daytime) and OFF PEAK (e.g., at night).

Working Hours Counter (s) Counts while the measuring instrument is supplied with power. From the count value and the active energy, the average power demands within the measuring period are permanently calculated for each load. The software considers the counter overflow.

Total Active Power (W) “Total” refers to the three phases U, V, W. The instantaneous values of the active powers are only used for display purposes. They are not used as criteria for switching off loads.

2 The SENTRON PAC 3200 has a digital input which can be paramererized for tariff changeover. See Chap. 9.2.6. in /1/. The application uses the default configuration in which the input has no effect and the electrical energy is added in tariff ON PEAK.



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Base quantity for load control The calculations for load switching are based on the instantaneous total average power demand Pav(tn) of all loads that is continually calculated from the start of each measuring period tm. “Continually” means that Pav(tn) is updated with a periodicity of tscan. The individual average power demand Pav of a load permanently results from the active energy provided by the SENTRON PAC relative to the start of the measuring period-current time time interval. This time interval is obtained by continually reading out the working hours counter. In this application, tm=15min and tscan=15s. Therefore, the average power demands Pav(tn) and Pav(tn) are updated 60 times during the measuring period.

Base load and electrical losses When calculating Pav(tn), a not measured optional component Pb which is e. g. made up of base load and electrical losses can be added to the individual average power demands Pav(tn) of the measured loads. If necessary, a respective value (W) is written to a data block.

Criteria for switching off loads A load will be switched off when the following four conditions are simultaneously met at the time tn within the measuring period:

Pav_fc Pmax Pav-fc

3 is the forecast of Pav 3 for the end of the measuring period. Pav_fc is

continually calculated – thus at the interval tscan – from the current gradient of the shape of Pav. Pmax is the power limit, i.e. the average power demand, relative to the measuring period, whose exceeding would result in a higher kilowatthour rate. Figure 2-3: Forecast of the total average power demand (switching off)

Pmax

P

t

Pav(t)

Pav_fctscan

tm

tn

t0 tm

tn-1

)()()(

1

1_ navnm

nn

navnavfcav tPtt

tttPtPP

Pav(tn)

Pav(tn-1)

3 Origin of indices: av=average, fc=forecast



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Eov Eoff Eov(tn) 4 is the consumed energy of all loads from the start of the measuring

period until the current time that exceeds the energy Emax(tn) max. permissible until that time. Emax(tn) is the product of Pmax and tn. Eoff(tn) is the energy that is available for shedding by the next load to be switched off – with the power Poff – according to the priority list from the current time until the end of the measuring period.

Figure 2-4: Energy resource of the next load to be switched off

Pmax

P

t

Pav(tn)

tmtn

t0 tm

);(|)(| 0max ttPtPE nnavov

Poff

Eov

Eoff

);(|))(|( max nmnavoffoff ttPtPPE

Emax

Poff is the power value of the load that defines its switch-off instant. The smaller it is compared to the rated power, the sooner the load will be switched off.

The condition Eov Eoff of this bullet has two tasks: – The accuracy of the forecast Pav_fc is limited, particularly at the start of the

measuring period. The calculation of Pav_fc tends to overreact, which can result in increased switching off/on of the switchable loads. The energy consideration in this bullet counteracts this behavior and attenuates the switching dynamics.

– When considering solely the forecast Pav_fc, a load would always be shed too soon within the measuring period as the power of the next load to be switched off is not considered. As the size of the next load to be shed is known, the software can set the load shedding time so that it is as close to the demanded power limit as possible.

Waiting time between switch-off actions was complied with If successive shedding of several loads is necessary due to quickly increasing total reference power or low rated powers of the individual loads to be switched off next, this is performed with the minimum interval tscan. If the respective processes and conditions require a larger minimum interval, this can be parameterized in multiples of tscan.

4 Origin of indices: ov=overload



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Minimum on time was complied with For each load, a minimum on time can be parameterized to satisfy the permitted dynamics of the load. If a load is to be switched off while its on time is still running, this load will be skipped and the system will continue with the next load in the priority list.

Criteria for switching loads back on The above criteria for switching off loads apply accordingly also to switching loads back on: A load will be switched on when the following four conditions are simultaneously met at the time tn within the measuring period:

Pav_fc < Pmax

Figure 2-5: Forecast of the total average power demand (switching on)

Pmax

P

t

Pav(t)

Pav_fc

tscan

tm

tn

t0 tm

)()()(

1

1_ navnm

nn

navnavfcav tPtt

tttPtPP

tn-1

Pav(tn-1)

Pav(tn)



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Eov Eon

Figure 2-6: Energy resource of the next load to be switched on

Pmax

P

t

Pav(tn)

tm

tn

t0 tm

);(|)(| 0max ttPtPE nnavov

Pon

Eov

Eon

);(|))(|( max nmnavoffoff ttPtPPE

In contrast to Figure 2-4, the blue area representing Eov is below and the green area representing Eon is above the Pmax line in the above figure. Pon is the power value of the load that defines its switch-on instant. The greater it is compared to the rated power, the later the load will be switched on.

Waiting time between switch-on actions was complied with If several loads are successively switched on due to quickly decreasing total reference power or low rated powers of the individual loads to be switched on next, this is performed with the minimum interval tscan. If the respective processes and conditions require a larger minimum interval, this can be parameterized in multiples of tscan.

Minimum off time was complied with For each load, a minimum off time can be parameterized to satisfy the permitted dynamics of the load. If a load is to be switched on while its off time is still running, this load will be skipped and the system will continue with the next load in the priority list.

Priority list The selection of the load to be switched next (on or off) is based on a priority list to be edited by the user. It is represented by a field in a DB and organized as follows:

Table 2-1: Priority list

Priority list

Load that is the first to be switched off and the last to be switched on . . .

Load that is the first to be switched on and the last to be switched off

2 Automation Solution 2.4 Data logging


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When switching off, the list is processed from top to bottom. When switching on, it is processed from bottom to top.

NOTICE Especially highly alternating processes require an exact adjustment with the load control based on the present principle. You can tune the system by …

a parameterizable switching delay (switch_delay, see Table 2-9) factors for the consumer loads’ switch-on and switch-off power

(P_OnOff.OFFfactor, P_OnOff.ONfactor, P_OnOff.threshold, see Table 2-9) the costumer loads’ positions in the priority list (prio_list[..], see Table 2-

10) the adjustable values…

– switch-off power (P_switch_off) – switch-on power (P_switch_on) – off-time (t_remain_off) – on-time (t_remain_on) for each costumer load (see Table 2-10)

With the present load control it cannot be ensured, that each technology respectively each process is controllable in respect of power limit compliance.

2.4 Data logging

A data log is a data area in the load memory or on the memory card to which process values can be written. The data logs are saved in CSV format (comma-separated value). When the controller is connected to a PC via the PROFINET interface, you can use a Web browser to access the data logs via the Web server of the SIMATIC S7-1200 and edit and display them, for example, in an Excel spreadsheet. Access is possible in both RUN and STOP mode of the CPU. When the controller is restarted, a data log will be created with the “DataLogCreate” instruction if it does not exist yet. If it already exists, it will be opened with “DataLogOpen”. At the end of the measuring period, the total average power demand Pav(tm) relative to the measuring period is written to the data log with “DataLogWrite”. The number of process values to be written to the data log can be parameterized by the user. The data log size is limited by the size of the load memory or memory card. The organization corresponds to a ring buffer.

2 Automation Solution 2.5 Error messages


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Figure 2-7: Data logging

Load memory

Webserver

DataLogCreate

DataLogOpen

DataLogWrite

……

……

Pav(tm)

User program

.csv

2.5 Error messages

The following errors that do not require acknowledgement are written to a message buffer with a time stamp and displayed in a message display on the KTP600. The error texts can be edited in the TIA Portal: Communication fault

The communication is implemented as a sequencer. If one step of the communication (e.g., wait for “connection established”, wait for “data reception complete”, etc.) exceeds a parameterized time, an error will be reported for the respective SENTRON PAC.

No load available to switch-off If loads are no longer available for switching off in the priority list as all switchable loads have already been switched off by the system or load shedding is currently not permitted due to a running minimum on time, an error message will be generated.

Scan interval too short When adding the individual power/energy measured per SENTRON PAC to the total power/energy over all loads, it is assumed that the individual power/energy values were determined at exactly the same time. The finite communication time required for polling a SENTRON PAC3200 device causes skews that eventually influence the accuracy of the cumulative values. As long as the scan time tscan (= parameterizable time after which polling restarts with the first SENTRON PAC) is long compared to the sum of the communication time requirements of all connected SENTRON PAC3200 devices, the issue can be ignored. If, however, the number of SENTRON PAC3200 devices is so large that the communication with them lasts longer than tscan, tscan will no longer take effect and the summation will no longer be determined. In this case, an error message will be displayed to inform the user of the problem. However, please consider that an extension of tscan results in a decrease of the number of measured values within the measuring period and thereby also adversely affects the accuracy.

2 Automation Solution 2.6 Hardware and programming software of the sample project


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Data log errors An error message is configured for each of the DataLogCreate, DataLogOpen and DataLogWrite data log instructions used. If the respective instruction sets its error bit, an error message will be generated and the status word of the instruction will be saved to a DB for evaluation by the user.

2.6 Hardware and programming software of the sample project

In the sample project, two loads are configured that are measured using SENTRON PAC3200 devices. For information on how to extend the application to more loads, please refer to chapter 3.6.

Products………. Table 2-2: Products

Components Qty. MLFB/order number

1. SENTRON PAC3200; LCD; 96X96MM POWER MONITORING DEVICE PANEL MOUNT TYPE FOR MEASUREMENT OF ELECTR. VALUES VAUX: 110-340VDC / 95-240VAC VIN: MAX.690/400V; 45-65HZ AMPIN: X/1A OR X/5A AC COMPRESSION TYPE TERMINALS

2 7KM2112-0BA00-3AA0

2. SIMATIC S7-1200 POWER MODULE PM1207 STABILIZED POWER SUPPLY INPUT: 120/230 V AC OUTPUT: 24 V DC/2.5 A

1 6EP1332-1SH71

3. COMPACT SWITCH MODULE CSM 1277 CONNECTION SIMATIC S7-1200 AND UP TO 3 FURTHER IND. ETHERNET USERS WITH 10/100 MBIT/S UNMANAGED SWITCH, 4 RJ45 PORTS, EXT. 24V DC POWER SUPPLY, LED DIAGNOSTICS, S7-1200 MODULE INCL. ELECTRONIC MANUAL ON CD

1 6GK7277-1AA10-0AA0

4. SIMATIC S7-1200, CPU 1215C, KOMPAKT CPU, DC/DC/DC, 2 PROFINET PORT, ONBOARD I/O: 14 DI 24VDC; 10 DO 24VDC; 0,5A; 2 AI 0-10V DC, 2 AO 0-20MA DC, STROMVERSORGUNG: DC 20,4 -28,8 V DC, PROGRAMM/DATENSPEICHER 100 KB

1 6ES7215-1AG31-0XB0

5. SIMATIC HMI KTP600 BASIC COLOR PN, BASIC PANEL, KEY AND TOUCH OPERATION, 6" TFT DISPLAY, 256 COLORS, PROFINET INTERFACE, CONFIGURATION FROM WINCC FLEXIBLE 2008 SP2 COMPACT/ WINCC BASIC V10.5/ STEP7 BASIC V10.5, CONTAINS OPEN SOURCE SW WHICH IS PROVIDED FREE OF CHARGE FOR DETAILS SEE CD

1 6AV6647-0AD11-3AX0

6. MINIATURE POWER RELAY SCREW TERMINALS, 2NO+2NC SNAP-ON MOUNTING ON STANDARD MOUNTING RAIL DC SOLENOID SYSTEM DC 24V

2 3TK2022-0BB4

7. Current transformer (depending on the loads; both x/1A or also x/5A current transformers can be used)

2 -

2 Automation Solution 2.6 Hardware and programming software of the sample project


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Components Qty. MLFB/order number

8. SIMATIC NET INDUSTRIAL ETHERNET TP CORD RJ45/RJ45, CAT 6, TP CABLE 4X2, PREASSEMBLED W. 2 RJ45 CONNECTORS, … 0.5M 1M 2M 6M 10M

4

6XV1870-3Q… …E50 …H10 …H20 …H60 …N10

Note In deviation from Table 2-2 you can use each type of S7-1200 CPU from firmware V2.1.

Should the S7-1200 CPU you are going to use not be included in the hardware catalogue, actualize it with the latest HSP (hardware Support Package). See /5/.

A KTP600 operator panel is not mandatory. In the TIA Portal, you can work with the simulation ( icon in the toolbar).

Programming package Table 2-3: Programming software

Komponente Bestellnummer oder Link

STEP 7 Basic V11 SP2 6ES7822-0AA01-0YA0 Update to zu STEP 7 Basic V11 SP2 http://support.automation.siemens.com/WW/view/en/58112582

or alternatively STEP 7 Basic V12 6ES7822-0AA02-0YA5

NOTICE Use always the latest software update (see /6/).


https://eb.automation.siemens.com/mall/de/de/Catalog/Product/6ES7822-0AA02-0YE5

2 Automation Solution 2.7 Wiring of the sample project


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2.7 Wiring of the sample project

Figure 2-8: Wiring L1N

PE

PS1207CSM1277

CPU1215C

+24V

-

KTP600

SENTRONPAC3200

1

L1

N

F

Load 1

SENTRONPAC3200

2

Load wiring as for PAC 1

IP-Adr. 192.168.0.254IP-Adr. 192.168.0.1

IP-Adr. 192.168.0.200IP-Adr. 192.168.0.201

The load-side wiring of the SENTRON PAC3200 devices depends on the load types. The sample wiring shows the connection of a single-phase load. For detailed information and other examples of how to connect different loads, please refer in particular to chapter 6.4 “Connection examples” and chapter 9.2.4 “Basic parameters” in /1/.

2.8 Communication principle

Client-server relationship As a server, the SENTRON PAC3200 devices provide “MODBUS on TCP” communication. Using the MB_CLIENT instruction, the SIMATIC S7-1200 CPU can communicate as a Modbus TCP client via its PROFINET interface. Additional communication hardware – e.g., a communications processor – is not necessary.

2 Automation Solution 2.8 Communication principle


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The MB_CLIENT instruction The MB_CLIENT instruction can be found on the “Instructions” task card in “Communication > Communications processor > MODBUS TCP”. When it is dragged to the program using the mouse, a respective system FB will be created whose data will be stored in a system DB or as a multi-instance in the instance DB of the calling FB. In the program, the MB_CLIENT instruction is called only once per CPU cycle. It satisfies the requirements of its different communication partners and tasks by the fact that its parameters are variably set for the respective partners and tasks.

Figure 2-9: MB_CLIENT instruction

For the parameter description of MB_CLIENT, please refer, for example, to the online help of the TIA Portal.

NOTICE To communicate with the SENTRON PAC3200, in the static data of the MB_CLIENT record, the TCON_PARAM.MB_UNIT_ID parameter must have a value between 16#0001 and 16#00F7. As the default value when creating the data record is 16#00FF, it must be changed later. In the associated application example, the change has already been made and the parameter has been set to 16#0001.

2 Automation Solution 2.8 Communication principle


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Access to the Modbus data register The register is a buffer for the data received from the Modbus server or to be sent to the Modbus server. It is accessed via the MB_DATA_PTR InOut parameter of the MB_CLIENT instruction. MB_DATA_PTR is a pointer of the VARIANT type. This means that only the address information of the actual parameter on MB_DATA_PTR is transferred, whereas the data type of the actual parameter is irrelevant. Therefore, it is possible to interpret the Modbus register to be addressed by means of the symbolic addressing in the correct data view.

Figure 2-10: Different data views of the Modbus data register (FB LoadSwitching [FB501], static tags))

As can be seen in Figure 2-10, the Modbus data register is eight bytes wide and assigned to the static tag Rx_LReal. With Rx_Real, Rx_UDInt and Tx_Uint, three more data views are defined whose data widths can be less than eight bytes. In this application, the different data views are used to access the following data of the SENTRON PAC device:

Table 2-4: Reference: Data view – measured value/action

Data view Read/Write Measured value/action Reference

Rx_LReal R Active Energy Import Tariff 1 Table 3-6 in /1/ Rx_Real R Total Active Power

Rx_UDInt R Working Hours Counter Tx_UInt W Switching outputs Table 3-26 in /1/

Serial communication To allow operation of more than eight SENTRON PAC3200 devices, the communication is serial communication:

2 Automation Solution 2.9 Program description


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Figure 2-11: Serial communication

Connect to SENTRON PAC n

Receive from / send to SENTRON PAC n

Disconnect from SENTRON PAC n

Wait until end of scan time

n := 1

n := n+1

All SENTRON PACs processed?

YesNo

Start

The application needs 200-300ms to process a SENTRON PAC3200 device. The max. possible number of SENTRON PAC3200 devices is determined by the relation between the total communication time requirement, the scan time and the length of the measuring period. The issue has already been touched on in chapter 2.5, third bullet.

Network addresses In the application, the following addresses are assigned:

Table 2-5: Network addresses

Node IP address Subnet mask

Controller 192.168.0.1

255.255.255.0 Operator panel 192.168.0.254 SENTRON PAC 1 192.168.0.200 SENTRON PAC 2 192.168.0.201

The application assumes that all SENTRON PAC3200 devices belong to one subnet. Therefore, the first three bytes are identical for all measuring instruments and must be specified only 1 x in the relevant parameter DB. The fourth byte is crucial for the discrimination of the devices. In this case, the addresses 2-252 5 can be assigned to the SENTRON PAC3200 devices.

2.9 Program description

This chapter describes the program structure of the example at the function and data block level of the automation system.

5 On condition that the IP device address of the development system is 253.



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2.9.1 Block structure

Figure 2-12 shows the call hierarchy of the program blocks and the access to the data blocks.

Figure 2-12: Block structure

DB501“PowerMan_DB”

FB501“PowerMan”

OB1“MAIN”

DB503“PAC_data”

Ope

ratin

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stem

FC502“CALC_P_active_av”

FC161“Event”

FC501“Load_shedding”

OB100“Startup”

FB1084“MB_CLIENT”

OB100 – “Startup” In this block, constants are calculated that are derived from input parameters and do not change during runtime.

NOTICE During runtime, do not change input parameters that are accessed in “Startup”. These are the following parameters in LoadSwitching_DB:

P_average_limit P_active_sample_max monitoring_time offset_P_active offset_E_active offset_h offset_DQ

(see Table 2-9)

OB1 – “Main” The block contains only the call of FB501 “LoadSwitching”.

FB501 – “LoadSwitching”, DB501 – “LoadSwitching_DB” The FB provides the main functionality of this application. It does not have any parameters. The tags marked with “!” in the comment of the associated instance DB represent load-independent, general data that must be parameterized by the user (see Table 2-9).



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FB1084 – “MB_CLIENT“ When the instruction of the same name is inserted into the user program in “System blocks > Program resources”, this system FB will be created in the project tree. The associated static data was created as a multi-instance and is located in DB501 “LoadSwitching_DB” under the name “MB_CLIENT_Instance”.

FC502 – “CALC_P_active_av” The FC is used as an auxiliary function and, once in the scan interval, calculates the instantaneous value )( actav tP of the average active power relative to the start of the measuring period for each SENTRON PAC.

0

0 )()()(tt

tEtEtPact

activeactactiveactav

activeE = value of the active energy meter;

actt = working hours counter value at the moment;

0t = working hours counter value at the start of the measuring period. Active energy meter and working hours counter can overflow in the SENTRON PAC and after an overflow, restart at zero. As the overflow limits are known, the overflow can be considered. FC502 takes this into account.

Table 2-6: FC502 – block parameters

Parameter Data type

IN/OUT Explanation

E_active LReal IN Value of the active energy meter (Wh) at the moment

E_active_0 LReal IN Value of the active energy meter (Wh) at the start of the measuring period

E_active_overflow LReal IN Overflow value of the active energy meter (Wh) (from /1/) h UDInt IN Value of the working hours counter (s)

at the moment h_0 UDInt IN Value of the working hours counter (s)

at the start of the measuring period h_overflow UDInt IN Overflow value of the working hours counter (s) (from /1/)

FC161 – “Event” The FC facilitates entering and removing error bits in alarm words from which the HMI generates the error messages. Table 2-7: FC161 – block parameters

Parameter Data type

IN/OUT Explanation

Trigger Bool IN TRUE: Error bit is set FALSE: Error bit is reset

Event_Bit UInt IN Significance in the error word (0…15) Alarm_Word Word INOUT Error word accessed by the HMI Global_fault Bool OUT = TRUE if at least 1 bit is set in the error word



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FC501 – “Load_shedding” In accordance with the explanations in chapter 2.2.1, the block decides if a load is to be switched off or on. If a load is no longer available for load switching, the block initiates a relevant error message.

Table 2-8: FC501 – block parameters

Parameter Data type

IN/OUT Explanation

Reset Bool IN At the start of the new measuring period, the block is executed once with Reset=TRUE. This results in an initialization for the new measuring process.

switch_load SInt OUT Switching command: -0 = no action -1 = switch off load +1 = switch on load

PAC_index UInt OUT Number of the load to be switched (corresponds to the array index of the load_spec array tag in the PAC_data DB.)

SUM_P_active_av_log Real OUT Average of the total active power at the end of the measuring period that is written to the data log.

DB503 – “PAC_data” While the data concerning the overall functionality is stored in LoadSwitching_DB, DB503 includes all necessary load-specific data records. The tags marked with “!” in the comment of the DB have to be parameterized by the user (see Table 2-10).

2.9.2 User parameters

The following section provides a description of the tags that have to be parameterized by the user. In the comment, the respective tags are marked with “!”.

Load-independent parameters in LoadSwitching_DB Table 2-9: Load-independent parameters in LoadSwitching_DB

Name Data type Dim. Explanation

P_average_limit Real W Power limit Pmax Limit Pmax specified by the power utility for the average total active power relative to the measuring period. If exceeded, a higher kilowatthour rate will be charged for the entire accounting period.

P_base_load Real W Base load Pb Base load assumed to be constant that is not measured.

P_active_sample_max USInt - Active power measured value – sample no. The active power can be averaged from several measured values. The measurements are performed in direct succession with regard to time.



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Name Data type Dim. Explanation

ext_trigger Bool - Trigger for measuring period FALSE = CPU clock TRUE = pos. edge at E0.0 When triggering using the CPU clock, it is recommended that it be synchronized at regular intervals, e.g. by means of an NTP server or a GPS receiver.

ON_ack_required Bool - Acknowledgement for reclosing FALSE = By load control switched-off loads are

reclosed automatically. TRUE = Each reclosing demand from the load contol

has to be released manually. (default value = FALSE)

monitoring_time Time Time Duration of the measuring period tm Permitted values in minutes: 2, 3, 4, 5, 6, 10, 12, 15, 20, 30, 60; When triggering using the CPU clock, the measuring periods within an hour always start with the first minute and the multiples of the minute value that corresponds to the length of the selected measuring period.

scan_time Time Time Scan time tscan Interval at which one and the same SENTRON PAC is periodically polled.

comm_error_time Time Time Detection time for communication faults

The communication flow is organized in a sequencer. If a step exceeds a specific time, a relevant error message will be generated and the transition from the faulty to the next SENTRON PAC will take place.

switch_delay USInt - Switching delay In terms of software, load switching can be performed max. at the interval specified by the scan_time. To avoid avalanches when there are significant load changes, the switching interval can be extended to multiples of the scan time.

P_OnOff. Struct OFFfactor Real - Factor for switch-off power

The measured active power of the load reduced by a factor (P_OFFfactor < 1.0)6is used as the switch-off power (see chapter 2.2.1).

ONfactor Real - Factor for switch-on power The measured active power of the load increased by a factor (P_ONfactor > 1.0)6 is used as the switch-on power (see chapter 2.2.1).

6 Switch-off and switch-on power can also be specified as absolute values (see Table 2-10). When doing so, the P_OFFfactor, P_ONfactor and threshold parameters are irrelevant.



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threshold Real W Zero threshold for active power The switch-off and switch-on powers of the loads are only permanently derived from the currently measured active powers when they are above a parameterizable zero threshold. If this is not the case, a stored value will be used as a substitute7.

DataLog_1. Struct Data log Data area in the load memory or on the memory card to which process values are saved.

records UDInt - Total number of data records The number of data records to be archived. In this application, a data record consists of only one value, i.e. the average of the total active power relative to the measuring period. At the end of each measuring period, it is written to the load memory or memory card.

filename String File name Name of the csv file located in the load memory or on the memory card that can be downloaded from the Web server to the PC.

header String Column headers Comma-separated column headers. In this application, however, there is only one column (aside from the data record number and time stamp).

offset. Struct Offset addresses of the Modbus registers used P_active UInt - Total Active Power (65), see Table 3-6 in /1/

E_active UInt - Active Energy Import Tariff 1 (801), see Table 3-6 in /1/ h UInt - Working Hours Counter (213), see Table 3-6 in /1/ DQ UInt - Switching outputs (60008), see Table 3-26 in /1/

Load-dependent parameters in DB “PAC_data” Table 2-10: Load-dependent parameters in DB PAC_data

Name Data type

Dim. Explanation

PAC_max UInt - Number of SENTRON PAC3200 devices Number of measured loads.

IP. Struct IP address (octets 1-3) octet1 USInt Octet 1 octet2 USInt Octet 2 octet3 USInt Octet 3

7 This requires that a value above the zero threshold has been measured at least 1 x after the CPU start. Ensure this if you determine switch-off and switch-on power via the P_OFFfactor and P_ONfactor parameters.



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Name Data type

Dim. Explanation

load_spec Array[1..n] of Struct

Array of load specifications Maximum number of possible loads

load_spec [ ]. Struct Load specification index UInt - Index

The value must always be identical to the array element number. It is necessary to be able to access the individual loads in the HMI using a text list with names.

IP_octet4 USInt - IP address (octet 4) Must be in the range from 2 to 253.

P_switch_off Real W Switch-off power8 Poff The active power of the load used for the calculation of the switch-off instant. A value less than or equal to the rated power is usually used. The smaller the value compared to the rated power, the sooner the load will be switched off at a switch-off request within the measuring period if the software has defined it as the next load to be switched off. When you parameterize P_switch_off with 0, the system uses the measured active power multiplied by the OFFfactor parameter (see Table 2-9).

P_switch_on Real W Switch-on power8 Pon The active power of the load used for the calculation of the switch-on instant. A value greater than or equal to the rated power is usually used. The greater the value compared to the rated power, the later the load will be switched on at a switch-on request within the measuring period if the software has defined it as the next load to be switched on. When you parameterize P_switch_on with 0, the system uses the measured active power multiplied by the ONfactor parameter (see Table 2-9).

t_remain_off Time Time Off time Time a load must remain switched off after it was switched off by the system. It will only be available for switching on after this time has elapsed.

t_remain_on Time Time On time Time a load must remain switched on after it was switched on by the system. It will only be available for switching off after this time has elapsed.

prio_list Array[1..n] of UInt

Priority list The first list element has the highest priority, the last one has the lowest priority with regard to switching off loads. When loads are switched off, the priority list is processed from top to bottom (from 1 to n). When loads are switched back on, it is processed from bottom to top (from n to 1).

prio_list [ ] UInt - In the priority list, the array element numbers of the loads have to be entered in load_spec according to the desired priority. If the load is not available or if it is not to be switched at all, 0 has to be entered.

8 Different switch-on and switch-off power of a load force hysteresis.



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Note This application includes data records for 20 loads. If necessary, modify the number of data records to save disk space or cover more loads. To do so, reduce or increase the size of load_spec, prio_list and consumer_load arrays accordingly. PAC_max must never be greater than the number of elements of these arrays.

2.9.3 Program flow in FB501 “LoadSwitching”

Networks…………….

Table 2-11: Networks of FB501

NW no. Title Description

1 Monitoring interval Definition of the trigger times for the measuring period Time definition of the end of the measuring period

2 Call MB_CLIENT Call of the MB_CLIENT instruction 3-11 Waiting for… Sequencer (see below for the explanation) 12 Recognize communication

faults A communication fault will be detected if a communication step exceeds the comm_error_time specified in DB501. Communication steps are characterized by step number <1000.

13 Process scan interval timer Process scan interval as a switch-on delay. The time is started in step 1000 and reset in steps 50 and 1010.

14 Data Log Data logging handling. 15-18 For HMI [..] - … Data conditioning for display on the HMI.

NW16-NW18 are used to generate a global error bit.

Sequencer The state diagram (Figure 2-13) below shows the program flow implemented by the sequencer. In the diagram’s yellow ellipses (states) the program waits for the events which are displayed by the blue texts. With the arriving event, the current state is left and the program executes the task which follows the yellow ellipse in direction of the arrow. Subsequently the program leads – where required via a branching (decision) - to a successor state. The task or branching directly following a state is always programmed in the same network than the state definition itself.


28 Switching Loads with S7-1200 and SENTRON PAC3200

Version 1.1, Beitrags-ID: 58856464

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Figure 2-13: State diagram

No

Step 1010 (NW11)

Step 50 (NW10)

Step 40 (NW9)

Step 30 (NW8)

Step 24 (NW7)

Step 20 (NW6)

Step 15 (NW5)

Step 10 (NW4)

Step 1000 (NW3)

Restart

Load switched(DONE)

Start ofmeasuring period

CONNECTED &nicht BUSY

Pactive received n times andmean value generated

(DONE)

Eactive received(DONE)

Yes

Switching request?Working hours counter

received (DONE)

Not BUSY

Not CONNECTED& not BUSY

Scan time elapsed?

Initiate communication jobSet MB_CLIENT parameter

Scan time elapsed

Initiate connection

establishment

to PAC 1

Save mean value of Pactive Set MB_CLIENT parameter

Save Eactive

Log load conditionSet MB_CLIENT parameter

Set MB_CLIENT parameter

Calculate Pav (relative to measuring period) Complete communication job

Initiate connection termination

All PACs processed?

No

No

Initiate connection establishmentto the next PAC

Load management (process FB Load_shedding)Initiate connection establishment to PAC 1

YesYes

2 Automation Solution 2.10 Visualization


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2.10 Visualization

For monitoring, the KTP600 provides three screens.

Main screen (start screen)

Figure 2-14: Main screen

Sum of the current activepowers over all measuring instruments plus a specifiedbase load. The value is based on the measured values readout of the SENTRON PACs with register offset address 65 (“Total Active Power”).

Sum of the current average active power demands over all measuring instruments relative to the start of the measuring periodplus a specified base load. The value is based on the measured values read out of the SENTRON PACs with register offset addresses 801 (“Active Energy Import Tariff 1”) and 213 (“Working Hours Counter”).

Total active power forecast for theend of the measuring period.

Energy reserve currently provided by the next load to be switched off or on. Whenit has been used up, the respective load will beswitched off or on.

off:

on:

Load switch-off ispending.

Load switch-on is pending.

Name of the next load to be switched off or on

Measuring period

Button to switch to the error list. If at least one error is pending, the will button flash red/white.

Button to switch to the load condition list

Button to release reclosing next load to be switched on

The bar charts of the power displays are normalized to the specified power limit (in the example: 8 kW). They display values in the range between 80% and 120% of the power limit. The number representations allow the display of values less than 10MW. The bar chart of the energy reserve is also normalized. It displays values in the range between 0 and 10% of the active energy limit relative to the measuring period. The bar chart of the measuring period is normalized to its duration. The button to release reclosing the next consumer load to be switched on is only visible, if… „LoadSwitching“.ON_ack_required is parameterized to TRUE9 and the load control schedules reclosing a consumer load due to the power regime.

To confirm pressing the “ON” button, its color becomes light yellow until the relevant SENTRON PAC3200 device has got the switch-on command for the load.

9 In the project code of the application example bit „LoadSwitching“.ON_ack_required = FALSE (default value). Therefore button „ON“ is invisible and consumer loads get reclosed automatically without any manually release.

2 Automation Solution 2.10 Visualization



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“Consumer load list” screen

Figure 2-15: “Consumer load list” screen

Name of the loads

Switching status

Earliest next switch-on instant if a minimum off time has been specified for the respective load.

Earliest next switch-off instant ifa minimum on time has been specified for the respective load..

Back to “Load management” screen

“Error messages” screen

Figure 2-16: “Error messages” screen

Back to “Load management” screen

Error messages withtime stamp and alarm status

3 Configuration 3.1 SIMATIC software installation


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3 Configuration Once you have properly installed and wired all components and connected them to the supply voltage as shown in Figure 2-8, the following configurations and parameter settings have to be made.

3.1 SIMATIC software installation

The project was created with TIA Portal Version V11 SP2 Update 5 and Version V12. The firmware version of the CPU 1215C used was V3.0.2. If necessary, update your software. see also chap. 2.6 Hardware and programming software of the sample project

3.2 Parameterizing the SENTRON PAC3200 devices

Starting from the default configuration of the devices, the following settings have to be made. They are made in the user interface of the devices. For the general operation of the SENTRON PAC3200 devices, please refer to chapter 8 “Operator control” in /1/. At this point of commissioning, neither measuring voltage nor measuring current are applied to the measuring instruments.

Table 3-1: Parameterizing the SENTRON PAC3200 devices

No. Instruction Additional note

1. “Language, regional settings” group Navigate to the “LANGUAGE/REGIONAL” group and set the desired language.

Parameter Device 1 Device 2

LANGUAGE ENGLISH

See chapter 9.2.3 in /1/

2. “Basic parameters” group Basic parameters are all settings for the measuring inputs. Define the connection type (number of phases, conductors), if you are measuring with or without voltage transformer and your required current transformer ratio. Adjust the parameters to your loads. To test the application in a useful way, the two configured loads should be in a range where load switching can be properly monitored in the “Load management” HMI screen (Figure 2-14). In the laboratory test, loads were used that were interpreted by the SENTRON PAC3200 devices as loads with approx. 200W to 1000W. To reach values in that range, you can – if loads of that magnitude are not available to you – manipulate the SENTRON PAC3200 devices with regard to voltage or current conversion by means of reconfiguring.


3. “Integrated I/O” group Navigate to “DIGITAL OUTPUT” and define the action.


ACTION REMOTE OUTPUT


3 Configuration 3.3 Configuring the HMI



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No. Instruction Additional note

4. “Communication” group Set the following parameters.


IP-ADDR 192.168.0.200 192.168.0.201 SUBNET 255.255.255.0 GATEWAY 0.0.0.0 PROTOCOL MODBUS TCP


After the above parameterization, the measuring voltage and the measuring current have to be applied to the SENTRON PAC3200 devices and the displayed measured values have to be checked.

3.3 Configuring the HMI

If the real KTP600 (not simulated) is used as the operator panel, the project-specific IP address 192.168.0.254 must be set.

Table 3-2: Assigning the IP address to the KTP600

No. Operator action Picture / result / additional note

1. Select the “Control Panel” button to open the control panel of the Loader.

3 Configuration 3.4 Settings on the development system (Windows)


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2. 1. Select the “Profinet” button to open the “Profinet Settings” dialog box.

2. Select “Specify an IP address”. 3. Make the following entries:

– IP address = 192.168.0.254 – Subnet mask = 255.255.255.0

4. Select “OK” to close the dialog box and apply the entries.

3.4 Settings on the development system (Windows)

3.4.1 Assigning the IP address to the development system

Your PG/PC must be assigned an IP address in the same subnet as the other network components involved. The IP addresses of the individual nodes are shown in Table 2-5. To assign the IP address for your network card, proceed as follows in the Windows XP operating system:

Table 3-3: Assigning the IP address to the development system


1. In the Windows Control Panel, open Network Connections.




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2. Select the network card to be used and right-click to open the properties.

3. Select the “Internet Protocol (TCP/IP)” item

and open its properties.

4. Select “Use the following IP address”.

In IP address, enter an available address in the relevant subnet10.

In Subnet mask, enter “255.255.255.0”. Select “OK” to confirm the settings.

10 When using IP device address 253 for the development system, the entire address range from 2-252 will be available to you for the SENTRON PAC3200 devices.



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3.4.2 Setting the PG/PC interface

To simulate the KTP600 on the development system, the PG/PC interface must be set accordingly.

Table 3-4: Setting the PG/PC interface


1. In the Windows Control Panel, open Set PG/PC Interface.

2. In “Access Point of the Application”, select

“S7ONLINE (STEP 7)” in conjunction with the interface parameter assignment of your network card (“… -->TCP/IP(Auto) -> …”).

Select “OK” to confirm the settings.

3 Configuration 3.5 Parameter assignments in the TIA Portal and project download



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3.5 Parameter assignments in the TIA Portal and project download

Opening the project

Table 3-5: Opening the project


1. Unzip the sample project to any directory on your hard drive and double-click on the file with the “.ap11” extension.

2. If the TIA Portal has opened in the portal view,

select the project view.



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Setting the country-specific local time Make sure that the date and time of day setting in the CPU is correct. This is necessary for the following reasons: The measuring period for the mean-value generation of the power is

synchronized with the local time. The controller synchronizes the KTP600 system time every minute. This

ensures that the time stamps of the alarm messages are correct. Table 3-6: Setting the country-specific local time

No. Instruction Picture / result / additional note

1. Select the CPU.

2. Navigate to the Time of day settings and, if

necessary, adjust the time zone and the daylight-saving time/standard time settings.

Load settings for the live demo If, after configuring, you want to perform a live demo as described in chapter 4, it is recommended at this point to set a power limit and base load so that loads are switched on and off. Select the load relationships as shown in Figure 3-1.

Figure 3-1: Recommended power relationships for the live demo

Base loadPower limit

Switchable loads

P

t




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Downloading the control program to the CPU

Table 3-7: Downloading the control program to the CPU


1. Connect your development system to the CPU either directly or using the CSM1277 switch.

2. Select the “PLC_1 [CPU 1214C DC/DC/DC]” PLC folder.

Select the “Download to device” button to download the PLC project part to the CPU.

3. Select the PG/PC interface used and the

subnet. Check Show all accessible devices. Identify your controller from the list of

accessible devices using the MAC address or via “Flash LED”.

Select the selected controller and use the “Load” button.

4. Enable consistent downloading of the

program blocks. Select the “Load” button.

5. After transferring all program blocks to the

controllers, a “download result” window appears. Check “Start all” to set the controller to

“Run” mode. Select the “Finish” button to finish the

entire download.

Setting the CPU clock The CPU clock can be set by directly entering the date and time of day (local time) or applying the time of day from the development system.



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Table 3-8: Setting the CPU clock

No. Instruction

1. In the project tree, select the “PLC_1” controller. 2. Select the “Go online” button. 3. Select the “Online and diagnostics” option. 4. Open the “Set time of day” function. 5. Set the date and time of day or apply the local time of the development system.

Note You can conveniently synchronize the CPU clock in the following two ways:

Synchronization via NTP server (chapter 5.6.7 in /2/). Synchronization via GPS receiver (/7/).

Downloading the HMI project part to the KTP600 If a real KTP600 (not simulated) is used as the operator panel, the HMI project part must be downloaded to the KTP600. For the transfer, connect your PG/PC to the HMI either directly or using the CSM1277 switch.

Table 3-9: Downloading the HMI project part to the KTP600


1. Select the “HMI_1 [KTP600 Basic PN]” operator panel folder.

Select the “Download to device” button to download the HMI project part to the CPU.




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2. If necessary, check the “Overwrite all” option.

Select the “Load” button.

3. Depending on the operator panel setting,

you have to trigger the transfer in the Loader menu of the KTP600 using the “Transfer” button.

4. Once the successful result message is

displayed, select the “Finish” button to finish downloading.

If necessary, reconnect the HMI to the CSM1277 switch using the patch cable.

Simulating the KTP600 If you want to run the KTP600 as a simulation on your development system, proceed as follows:

Table 3-10: Simulating the KTP600


1. Select the “HMI_1 [KTP600 PN]” operator panel folder.

Select the “Simulation” button.

3 Configuration 3.6 Expanding the number of SENTRON PAC3200 devices


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3.6 Expanding the number of SENTRON PAC3200 devices

In order to operate the program example with more than two SENTRON PAC3200 devices, you have to provide more Ethernet ports. Use multiple switches or switches with more ports. Assign each SENTRON PAC3200 device a unique IP address 192.168.0.2…252 (see chapter 9.2.7 in /1/).

3.6.1 Expansions in data blocks

LoadSwitching_DB [DB501]

Table 3-11: Increasing the number of measuring instruments – expansions in DB501

Tag Additional note

P_base_load If necessary, reduce the base load that is not measured if you now (partially) measure it using additional SENTRON PAC3200 devices.

PAC_data [DB503]

With regard to the memory, 20 SENTRON PAC3200 devices are considered in the example. If you want to configure more devices, you have to increase the size of the “load_spec”, “prio_list” and “consumer_load” arrays accordingly.

Table 3-12: Increasing the number of measuring instruments – expansions in DB503

Tag Additional note

PAC_max New number of SENTRON PAC3200 devices load_spec[n].P_switch_off load_spec[n].P_switch_on load_spec[n].t_remain_off load_spec[n].t_remain_on

Define the switch-off/switch-on powers and the off/on times of the added loads (for the tag description, see Table 2-10).

prio_list[n] Enter the new loads in the priority list (for the tag description, see Table 2-10).




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3.6.2 Expansions in the “Load list” HMI screen

Table 3-13: Expansions in the “Load list” HMI screen


1. In the project tree, go to the “Load_list” screen and double-click to open the editor.

2. Put a border around all elements of a row and

copy them as often as necessary for your number of switchable loads.



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3. Open the “PAC_data” DB. Open the properties of the new row

elements. Use drag and drop to move the new tags

that have already been created in the “PAC_data” DB to the respective process tags in the properties fields of the new HMI screen elements. Drag & Drop

The following tags have to be created in the operator panel configuration as shown above:

DB “PAC_data” “Load_list” screen “Load name” column

load_spec[ ].index Properties >General

“OFF“ column consumer_load[ ].OFF >Animations

>View >Visibility

“earliest turn-on instant” column (hour) consumer_load[ ].time_control.turn_on_instant.HOUR >Properties

>General consumer_load[ ].time_control.turn_on_disabled >Animations

>View >Visibility

“earliest turn-on instant” column (minute) consumer_load[ ].time_control.turn_on_instant.MINUTE >Properties

>General consumer_load[ ].time_control.turn_on_disabled >Animations

>View >Visibility

“earliest turn-off instant” column (hour) consumer_load[ ].time_control.turn_off_instant.HOUR >Properties

>General consumer_load[ ].time_control.turn_off_disabled >Animations

>View >Visibility

“earliest turn-off instant” column (minute) consumer_load[ ].time_control.turn_off_instant.MINUTE >Properties

>General consumer_load[ ].time_control.turn_off_disabled >Animations

>View >Visibility




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4. In the project tree, go to the text list and enter the names of the new loads in the “Load name” list. The name to be entered corresponds to the name of the “PAC_data”.load_spec[ ].index tag.

Liste mit neuenVerbrauchern erweitern

3.6.3 Expansions in the “Error messages” HMI screen

Table 3-14: Expansions in the “Error messages” HMI screen


1. In the project tree, double-click on “HMI alarms”.

2. Add the communication fault messages of the

newly added loads to the alarm list. In the alarm text, specify the relevant load name and select the trigger tag with the associated array index.

4 Live demo 4.1 Switching behavior


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4 Live demo 4.1 Switching behavior

Initial load relationships as shown in Figure 3-1 are assumed.

Table 4-1: Live demo – switching behavior


1. Cause the controller to restart and then go online.

2. Wait for the start of the measuring period. If it

is triggered using the CPU clock, you can set the time of day in online mode to start of measuring period minus n seconds to save time.

When the measuring period starts after a restart of the controller, the outputs of all SENTRON PAC3200 devices will be reset and all switchable loads will be switched on.

3. Monitor the “Load management” screen (for the explanation, see Figure 2-14).

With the third scan after the start of the measuring period (scan time has elapsed 3 x), valid data is available that is displayed in the “Load management” screen.

The switching behavior will be as follows: The two loads are successively switched off. In the next measuring period, initially one load is switched back on (which one depends on the priority list). If the second load is also switched back on temporarily depends on the relationship between the power values of the loads, base load and power limit. Over time, the two loads are constantly switched on and off. The core task of this application is to ensure that the average total power – relative to the measuring period – never exceeds the specified power limit at the end of the measuring period. You check this by evaluating the data log (see chapter 4.2).

4. Go to the “Live Demo” watch table.

5. In the watch table, modify the following

boundary conditions and monitor the effects of the modifications. Load on/off time Load switch-on/switch-off power Power limit Base load

4 Live demo 4.2 Error messages



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4.2 Error messages Table 4-2: Live demo – error messages


1. No load available to switch-off: In the watch table (see Table 4-1, 5) increase the base load to such an extent that despite switching off both loads, the power limit is exceeded at the end of the measuring period.

At the instant when the system wants to switch off a (nonexistent) third load, the “No load available to switch-off” error message marked as “incoming” is generated and displayed in the “Error messages” HMI screen (see Figure 2-16). The message disappears as soon as a load is available for switching off and is switched off.

2. Scan interval too short: In the watch table (see Table 4-1, 5) enter a scan interval (“LoadSwitching_DB”.scan_time) that is shorter than the communication time for two loads (e.g., 300ms).

The “Scan interval too short” error message is generated and displayed in the “Error messages” HMI screen.

The message disappears as soon as the communication with all loads can be completed within the scan interval.

3. Communication fault with load n: Remove the RJ45 connector from one of the loads.

After the communication monitoring time for load n has elapsed, the “load name – communication fault” error message is generated and displayed in the “Error messages” HMI screen (see Figure 2-16). The message disappears as soon as communication with load n is possible.

4.3 Data log

At the end of each measuring period, the average total power (relative to the measuring period) is written to a csv file in the load memory as a data log. Wait until several measuring periods are over before you download the file.

4 Live demo 4.3 Data log


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Table 4-3: Live demo – data log

No. Instruction Additional note / picture

1. Open the browser on your development system and enter the following IP address as the Web address: 192.168.0.1. The Intro page of the controller opens.

If this has not yet been done, download and install the security certificate to ensure that the browser does not inform you of the missing certificate every time you open the PLC pages. If the certificate has already been installed, continue with 5.

2. Install the certificate.

An installation wizard guides you through the installation. Let Windows automatically select the certificate store.

3. After finishing the certificate installation, select

ENTER on the Intro page.

4. In Name, enter the user name “admin”.

It is not necessary to enter a password.

4 Live demo 4.3 Data log



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No. Instruction Additional note / picture

5. Then navigate to “Data Logs” and download the SUM_P_active_av.csv file (the file name is defined in the “DataLog_1” structure in LoadSwitching_DB).

6. Open the csv file with Microsoft Excel.

Then you can rename, for example, the csv file to xls, arrange the text in columns and format the resulting table as required or create a graphic.

5 Glossary


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5 Glossary Tabelle 5-1: Glossary

Begriff Erläuterung

CPU Central Processing Unit – in this context the complete controls S7-1200.

CSV-Format CSV means „Comma-Separated Values“ und describes the format of a text file used for storing or interchanging simple data structures.

Data Log A data log is a data area in the load memory or on the memory card to which process values can be written. With den webserver of the SIMATIC S7-1200 data can be written into an Excel file.

tm Duration of the measuring period, wherein the power utility calculates the total average power demand to compare it with a reference value (power limit). (Tag in STEP 7 program: „LoadSwitching_DB“.monitoring_time)

tscan Scan cycle in which the SENTRON PAC3200 readings are transmitted periodically. (Tag in STEP 7 program: „LoadSwitching_DB“.scan_time)

Emax(tn) Total energy consumption from the start of the measuring period to the current instant of time tn in case of permanently keeping the power limit. (Tag in STEP 7 program: no direct equvalent)

Eoff(tn) Energy that is available for shedding by the next load to be switched off according to the priority list from the current time until the end of the measuring period. (Tag in STEP 7 program: „LoadSwitching_DB“.E_switch11)

Eon(tn) Energy that is available for switch-on by the next load to be switched on according to the priority list from the current time until the end of the measuring period. (Tag in STEP 7 program: „LoadSwitching_DB“.E_switch11)

HMI Human Machine Interface Operator panel as a user interface

IP-Adresse Address if a network participant (CPU, SENTRON PAC3200, HMI, Engineering system) based on the internet protocol.

MODBUS Serial Communication protocol for use with PLCs, based on a Master/Slave architecture or a Client/Server relation.

MODBUS on TCP Modbus variant used for communications over TCP/IP networks, connecting over port 502.

NC-Kontakt Normally closed contact Relay contact, which is closed if the coil is currentless.

PLC Programmable Logic Controler – in this context SIMATIC S7-1200 Pav(tn) Individual average power demand of one load. It permanently

results from the active energy provided by the SENTRON PAC relative to the interval “start of the measuring period – current time”. (Tag in STEP 7 program: „PAC_data“.consumer_load[#PAC_index].P_active_av)

Pb Not measured base load, which can be entered into the program and which is added to the loads’ single power demands. (Tag in STEP 7 program: „LoadSwitching_DB“.P_base_load)

11 The program does not differentiate between loads to switch off or on. The distinction is done by the sign of the overload.

5 Glossary



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Begriff Erläuterung

Pmax Power limit specified by the power utility, i.e. the average power demand, relative to the measuring period, whose exceeding would result in a higher kilowatthour rate. (Tag in STEP 7 program: „LoadSwitching_DB“.P_average_limit)

Poff Active power of the load used for the calculation of the switch-off instant. A value less than or equal to the rated power is usually used. The smaller the value compared to the rated power, the sooner the load will be switched off at a switch-off request within the measuring period if the software has defined it as the next load to be switched off. (Tag in STEP 7 program: „PAC_data“.load_spec[n].P_switch_off)

Pon Active power of the load used for the calculation of the switch-on instant. A value greater than or equal to the rated power is usually used. The greater the value compared to the rated power, the later the load will be switched on at a switch-on request within the measuring period if the software has defined it as the next load to be switched on. (Tag in STEP 7 program: „PAC_data“.load_spec[n].P_switch_on)

PROFINET Process Field Network is the open Industrial Ethernet standard of PROFIBUS & PROFINET International (PI) for automation. PROFINET uses TCP/IP and IT standards

Eov(tn) Consumed energy of all loads from the start of the measuring period until the current time that exceeds the energy Emax(tn) max. permissible until that time. (Tag in STEP 7 program: „LoadSwitching_DB“.E_overload)

Pav(tn) Instantaneous total average power demand of all loads that is continually calculated from the start of each power utility’s measuring period. (Tag in STEP 7 program: SUM_P_active_av* [*Temp variable in FC „Load_shedding“])

Pav_fc Forecast of Pav for the end of the measuring period. (Tag in STEP 7 program: „LoadSwitching_DB“.SUM_P_active_av_fc)

tn Currently regarded moment within the power utility’s measuring period.

6 Code Elements


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6 Code Elements The software examples are available on the HTML page from which you downloaded this document. Table 6-1: Code elements

File name12 Contents

58856464_Set24_LoadSwitching_V11_SP2_Vxdx.zip STEP 7 V11 project 58856464_Set24_LoadSwitching_V12_Vxdx.zip STEP 7 V12 project

7 References Table 7-1: References

No. Document/link

/1/ Manual SENTRON Power Monitoring Device PAC3200 http://support.automation.siemens.com/WW/view/en/26504150

/2/ SIMATIC S7-1200 System Manual http://support.automation.siemens.com/WW/view/en/36932465

/3/ STEP 7 Basic V11.0 SP2 System Manual http://support.automation.siemens.com/WW/view/en/57199536 STEP 7 Basic V12 System Manual http://support.automation.siemens.com/WW/view/en/68113678

/4/ S7-1200 Firmware Update to V3.0 via Web Server http://support.automation.siemens.com/WW/view/en/67190848

/5/ STEP 7 V11 Support Packages for the hardware catalog in the TIA Portal http://support.automation.siemens.com/WW/view/en/54164095

/6/ Updates for STEP 7 V11 SP2 and WinCC V11 SP2 http://support.automation.siemens.com/WW/view/en/58112582

/7/ GPS synchronization of system time and date of your S7-1200 PLC http://support.automation.siemens.com/WW/view/en/45057335

/8/ Operating Instructions S7-1200 Compact Switch Module CSM 1277 http://support.automation.siemens.com/WW/view/en/36087313

/9/ Operating Instructions PM1207 http://support.automation.siemens.com/WW/view/en/37316256

/10/ Operating Instructions SIMATIC HMI HMI devices Basic Panels http://support.automation.siemens.com/WW/view/en/31032678

12 Always use the most current software (pay attention to “…_Vxdx” in the file name!).












8 History



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8 History Table 8-1: History

Version Date Modification

V1.0 03/2012 First edition V1.1 01/2013 You can select wether reclosing consumer loads is

accomplished manually or automatically Editorial revision

V1.1 05/2013 Supplemented by TIA Portal V12 project. V1.1 07/2013 Minimal text modification in chap.1

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