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Cover sheet Saving Energy with SIMATIC S7 PROFIenergy with ET200S (STEP 7 V5.5) Application November 2011 Applications & Tools Answers for industry. Siemens Industry Online Support This document is taken from Siemens Industry Online Support. The following link takes you directly to the download page of this document: http://support.automation.siemens.com/WW/view/en/41986454 If you have any questions regarding this document, please send us an e-mail to the following address: online-support.automation@siemens.com By the increasing networking of industrial plants the productivity is increased. However, also IT security risks arise which it is necessary to meet with corresponding protective measures for Industrial Security. A holistic view is necessary which takes similarly into account technical measures and contains the training of employees and the definition of guidelines and processes. This is necessary to attain the highest possible level of security and to ensure the safe operation of the plant. You find further information about technical solutions and our service offer for Industrial Security on the Internet under www.siemens.com/industrialsecurity. CAUTION Copyright Siemens AG 2011 All rights reserved Industrial Security 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 at http://support.automation.siemens.com/WW/view/en/50203404. 2 PROFIenergy 1.2, Entry ID: 41986454 s 1 Automation solution 2 Basic information 3 Function mechanisms of this application 4 SIMATIC PROFIenergy Configuration and settings 5 Application of PROFINET profile "PROFIenergy" Installation 6 Commissioning the application 7 Operating the application 8 Annex 9 Copyright Siemens AG 2011 All rights reserved Automation task PROFIenergy 1.2, Entry ID: 41986454 Links & literature 10 History 11 3 Warranty and Liability Warranty and Liability Note The application examples are not binding and do not claim to be complete regarding configuration, equipment 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 sound 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 this application example and other Siemens publications – e.g. catalogs – the contents of the other documents have priority. We do not accept liability for information contained in this document. Siemens AG 2011 All rights reserved Any claims against us – based on whatever legal reason – resulting from the use of the examples, information, programs, setting 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, 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 fundamental contractual obligations. However, claims for damages arising from a breach of a duty under this contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions do not imply a change in the burden of proof to your detriment. Copyright These application examples or excerpts thereof must not be handed on or copied without express authorization from Siemens Industry Sector. 4 PROFIenergy 1.2, Entry ID: 41986454 Preface Preface This application is part of our series “Saving Energy with SIMATIC S7”. Applications realized with STEP 7 V5.5 that have already been published: PROFIenergy with ET 200S PROFIenergy with the I-Device PROFIenergy with measuring devices PAC3200 / PAC4200 or with SCOUT: PROFIenergy with SIMOTION Copyright Siemens AG 2011 All rights reserved 41986454_PROFIenergy_ET200S_DOKU_V12_en.doc The following applications have already been configured with TIA Portal: PROFIenergy with ET 200SP PROFIenergy with Comfort panel The procedure and parameterization can also be used to migrate your PROFIenergy applications from STEP 7 V5.5 to TIA Portal. Further information on the topic of energy efficiency is available on our website: Energy-efficient production Validity Valid for STEP 7 V5.5 and WinCC flexible 2008. PROFIenergy 1.2, Entry ID: 41986454 5 Table of Contents Table of Contents Warranty and Liability ..............................................................................................4 Preface......................................................................................................................5 Table of Contents.....................................................................................................6 1 Automation task .............................................................................................8 1.1 1.2 2 Automation solution.....................................................................................11 2.1 2.2 2.3 3 Preparation......................................................................................53 Commissioning................................................................................53 Operating the application............................................................................. 54 Siemens AG 2011 All rights reserved Copyright 8.1 8.2 8.3 8.4 6 Installation of the hardware .............................................................. 51 Installing the software ...................................................................... 52 Installing the application software .................................................... 52 Commisioning of the application................................................................. 53 7.1 7.2 8 Configuration of the ET 200S head module...................................... 37 Configuration of the ET 200S power module .................................... 38 Setting of the PROFIenergy program ............................................... 39 Installation ....................................................................................................51 6.1 6.2 6.3 7 Program overview............................................................................18 Functionality FB53 "DS3_Write“....................................................... 19 Program details for block FB53 "DS3_WRITE”................................. 20 Functionality FB815 "PE_START_END“ .......................................... 22 Program details for block FB815 "PE_START_END“ ....................... 23 Functionality FB816 "PE_CMD“ ....................................................... 25 Program details for block FB816 "PE_CMD“ .................................... 26 Response data ................................................................................29 PE command Start_Pause............................................................... 30 PE command End_Pause ................................................................ 30 PE command Query Modes - List of energy saving modes............... 30 PE command Query Modes - Get mode........................................... 31 PE command PEM_Status............................................................... 31 PE command PE_Identify ................................................................ 32 PE command Query Measurement – Get measurement list ............. 33 PE command Query Measurement – Get measurement values........ 34 Configuration and settings ..........................................................................37 5.1 5.2 5.3 6 PROFIenergy profile........................................................................ 16 Available hardware ..........................................................................17 Required software ...........................................................................17 Function mechanisms of this application ................................................... 18 4.1 4.2 4.2.1 4.3 4.3.1 4.4 4.4.1 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7 4.5.8 5 Overview of the overall solution ....................................................... 11 Description of the core functionality..................................................13 Hardware and software components used ....................................... 14 Basic information .........................................................................................16 3.1 3.2 3.3 4 Overview ...........................................................................................8 Scenarios ........................................................................................10 Overview .........................................................................................54 Operation with HMI..........................................................................54 Operating with a variable table (VAT)............................................... 58 Reading parameters with the FB816 "PE_CMD“ .............................. 61 PROFIenergy 1.2, Entry ID: 41986454 Table of Contents 9 Annex............................................................................................................63 9.1 9.1.1 9.1.2 9.1.3 Annex A: Measurement list .............................................................. 63 Instantaneous measurements.......................................................... 63 Demand measurements................................................................... 67 Energy measurements..................................................................... 70 Links & Literature.........................................................................................71 11 History ..........................................................................................................71 Copyright Siemens AG 2011 All rights reserved 10 PROFIenergy 1.2, Entry ID: 41986454 7 1 Automation task 1.1 Overview 1 Automation task 1.1 Overview Introduction The importance of energy management will grow in the future. To cut costs by saving energy in the production is an approach that has been used for quite some time already. Recently, short production-free times become center of the focus from short pauses up to shifts off work. Main switch turned off - the complete production stops and the lights in the hall go out. This is the common way in nearly each plant all over the world in productionfree times like weekends or during plant vacation shutdown. But what happens during shorter pauses? Here, the plant proceeds and consumes energy without delivering productive results. Is it not possible to put smaller units of the plant that are not needed over a certain period of time into an energy saving mode while the rest of the plant keeps on producing? All this might considerably improve the energy balance of a production unit. Siemens AG 2011 All rights reserved The currently used technology which isolates the production components from the mains via one or more main switches is inappropriate for that purpose as it deactivates production units in an undifferentiated way. Hard-wired switching paths for firmly defined production units are not flexible enough to make the grade concerning energy efficiency. The decision for PROFINET already lays the foundations for a new and futureoriented energy management. Copyright Future-oriented energy management means: Units are no longer switched off via the conventional method which uses the main switch, but in a better defined way via the network! In doing so, the general power supply of the components remains activated and the components enter a defined energy-saving state - initiated by a command. PROFIenergy is a profile defined by the PROFINET user organization which provides the prerequisites for a vendor-independent system that can be generally used to switch off individual consumers or complete production units in a flexible and intelligent way on a short-term base. SIEMENS already supports PROFIenergy /1/ with first implementations into the automation system SIMATIC. The following application shows step by step how such an application can be realised using the ET 200S with integrated PROFIenergy functionality. 8 PROFIenergy 1.2, Entry ID: 41986454 1 Automation task 1.1 Overview Overview of the automation task The following figure gives an overview of the automation task. Figure 1-1 This plant consists of one feeding and one discharging conveyor belt and a processing unit. The belts are connected to an ET 200S; each with an own PROFIenergy-enabled power module. For reasons of clarification the processing unit is a "black box" that is switched on/off via an own ET 200S. In terms of energy saving the PROFIenergy does not focus on the drive motors since these are switched off in case of a production stop. It rather concentrates on the numerous sensors and further electronic components. Copyright Siemens AG 2011 All rights reserved This application describes the switch-off of automation components using an example from production - here a production line with robots. PROFIenergy 1.2, Entry ID: 41986454 9 1 Automation task 1.2 Scenarios Description of the automation task During a pause the components of the automation component shall be switched off. The spontaneous or regularly planned pause can be initiated by the user via the control system. After the production has stopped parts of the decentral periphery are switched off via applicable PROFIenergy commands. Before the production is started again the necessary automation components are switched on again. A variable table and an optional control panel serve to visualize and control. 1.2 Scenarios Requirements of the automation task This application example shall present the following switch-on and switch-off scenarios. Copyright Siemens AG 2011 All rights reserved Figure 1-2 Table 1-1 Problem description Explanation Switch off the first components of the plant If no staggered switch-off is required; which means that all parts are switched off at once Switch off further components of the plant Staggered switch-off Coordinated shut-down, i.e. necessary because of the technological process 10 Switch on individual components of the plant Staggered switch-on Switch on all / remaining components of the plant Components of the plant that are not subject to a special switch-on sequence. PROFIenergy 1.2, Entry ID: 41986454