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Simple Introduction into Energy Management with WinCC

WinCC

Application Description December 2011

2 Energy management with WinCC

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Industry Automation and Drive Technologies Service & Support Portal

This article is taken from the Service Portal of Siemens AG, Industry Automation and Drive Technologies. The following link takes you directly to the download page of this document.

http://support.automation.siemens.com/WW/view/en/48586219

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 Content-ID 50203404.


If you have any questions about this document, please contact us at the following e-mail address:

[email protected]

http://support.automation.siemens.com/WW/view/en/48586219�


mailto:[email protected]�

Energy management with WinCC V1.1, Entry ID: 48586219 3

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SIMATIC Energy Management with WinCC

Simple Introduction into Energy Management with WinCC

Fehler! Verweisquelle konnte nicht gefunden werden.

1

Automation Solution

2

Installation

3 Starting up the Application (own project)

4

Starting up the Application (Sample Project)

5

Operating the Application

6 Expanding the Application Example with SIMATIC Powerrate

7

Literature

8

History

9

Warranty and Liability


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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 your 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 and 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 accept no liability for 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”). However, claims arising from a breach of a condition which goes to the root of the 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 disadvantage.

It is not permissible to transfer or copy these application examples or excerpts thereof without express authorization from Siemens Industry Sector.

Preface


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Preface

Simple energy management

The first and basic step in energy management is to be aware of the energy consumption.

This is the approach of this application example. Using standard WinCC tools you are provided with an overview of your energy consumption, and on this basis, you will be able to derive further steps for increasing the energy efficiency of your plant.

Additionally, this example with WinCC faceplates shall serve as a template for the realization in your plant.

Table of Contents


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Table of Contents Warranty and Liability ................................................................................................. 4 Preface .......................................................................................................................... 5 Table of Contents......................................................................................................... 6 1 Automation Task................................................................................................ 7

1.1 Introduction........................................................................................... 7 1.2 Overview of the automation task.......................................................... 7 1.3 Description of the automation task....................................................... 7

2 Automation Solution ......................................................................................... 8 2.1 Overview of the general solution.......................................................... 8 2.2 Description of the core functionality ..................................................... 9 2.3 Hardware and software components used......................................... 10 2.4 Possible expansions of the application example ............................... 11

3 Installation........................................................................................................ 12 3.1 Hardware installation.......................................................................... 12 3.2 Installation and preparation of the operator station............................ 13

4 Starting up the Application (own project) ..................................................... 14 4.1 Preparation......................................................................................... 14 4.2 Commissioning................................................................................... 14

5 Starting up the Application (Sample Project) ............................................... 19 5.1 Preparation......................................................................................... 19 5.2 Commissioning................................................................................... 19

6 Operating the Application............................................................................... 20 6.1 Overview ............................................................................................ 20 6.2 Operating the faceplate...................................................................... 23

7 Expanding the Application Example with SIMATIC Powerrate................... 31 7.1 Connecting the SENTRON PAC via free of charge Modbus TCP block31 7.2 Connecting the SENTRON PAC via licensed TCP block by Siemens I

IS ........................................................................................................ 31 7.3 Connecting the SENTRON PAC via an additional Profinet module .. 31

8 Literature .......................................................................................................... 32 9 History............................................................................................................... 32

1 Automation Task

1.1 Introduction


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1 Automation Task

1.1 Introduction

The objective of this application example is to provide a simple introduction into energy management using “WinCC standard tools”.

1.2 Overview of the automation task

The figure below provides an overview of the automation task.

Figure 1-1

1.3 Description of the automation task

The parameters necessary for the energy management for one or several consumers shall be displayed in WinCC. In this application example several Sentron PAC are connected to WinCC via a Modbus TCP connection and the values are displayed in the WinCC faceplate.

2 Automation Solution

2.1 Overview of the general solution


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2.1 Overview of the general solution

Schematic layout

The following figure gives a schematic overview of the most important components of the solution:

Figure 2-1

Head-end station

The head-end station consists of one WinCC PC which is coupled via Ethernet cable and a Modbus TCP connection. The network branches to the SENTRON PAC stations via an Ethernet switch (e.g. SCALANCE X208).

Sentron PAC

SENTRON PAC is a multi-function measuring device for display, saving and monitoring all relevant network parameters in the low-voltage energy distribution. A detailed description of SENTRON PAC 3200 or 4200 is available in the manual.

SENTRON PAC 3200: http://support.automation.siemens.com/WW/view/26504150

SENTRON PAC 4200: https://www.automation.siemens.com/mdm/default.aspx?DocVersionId=25599329163&TopicId=

http://support.automation.siemens.com/WW/view/26504150�

https://www.automation.siemens.com/mdm/default.aspx?DocVersionId=25599329163&TopicId�

https://www.automation.siemens.com/mdm/default.aspx?DocVersionId=25599329163&TopicId�


2.2 Description of the core functionality


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2.2 Description of the core functionality

Overview and description of the user interface

Figure 2-2

2-wire copper cable (twisted pair cable) 2-wire copper cable (twisted pair cable)

Energy Appliance ApplianceEnergy

SENTRON PAC SENTRON PAC

SIMATIC WinCC

SCALANCE X208

WinCC FaceplateWinCC Faceplate

Core functionality

The application example provides WinCC faceplates with icon for the SENTRON PAC measuring devices for displaying basic measured values and visualizing them as trend curves.

The individual labels and units can be adjusted individually.

Advantages of this solution

The solution presented here offers you the following advantages:

Energy management of users without additional costs using WinCC standard tools

Option to expand the functions with SIMATIC powerrate

Monitoring the consumption values with this application enables choosing more cost-efficient contracts

Very simple and quick integration of SENTRON PACs into your own WinCC projects.

Simple adjustment to individual requirements due to plenty of options for faceplate settings.


2.3 Hardware and software components used


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2.3 Hardware and software components used

The application document was generated using the following components:

Hardware components

Table 2-1

Component Qty. MLFB / order number Note

Industrial PC 1 Industrial PC

http://www.automation.siemens.com/mcms/automation/en/pc-based-automation/Pages/Default.aspx

SCALANCE X208 1 6GK5208-0BA10-2AA3

SENTRON PAC 3200 1 7KM2112-0BA00-3AA0

SENTRON PAC 4200 1 7KM4212-0BA00-3AA0

Standard software components

Table 2-2

Component Qty. MLFB / order number Note

WinCC V7.0 SP2 1 6AV6 381-2BM07-0AX0 (128 power tags)

Version depends on the subsequent configuration. 128 tags are sufficient for the demo project.

Sample files and projects

The following list includes all files and projects used in this example.

Table 2-3

File Note

Energy.zip This zipped file contains the WinCC project as well as the Excel file for the tag import.

Einstieg_Einfaches_Energiemanagement_mit_WinCC_de.pdf

This document.

http://www.automation.siemens.com/mcms/automation/en/pc-based-automation/Pages/Default.aspx�




2.4 Possible expansions of the application example


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2.4 Possible expansions of the application example

SIMATIC powerrate

This application example, can amongst others, be expanded with SIMATIC powerrate. SIMATIC powerrate continuously records, archives and processes the energy data further. Exact knowledge of the consumer profile enables the tracing of saving potentials, makes energy procurement more efficient, and hence reduces the energy costs. Monitoring the contractually agreed power limit also helps avoiding unnecessarily high prices per kilowatt or penalties, and on the other hand actually makes full use of the defined power limit. A detailed function description with entry ID "48355131" is available in the Online Support.

WinCC/B.Data

This application example can be further expanded with the WinCC/B.Data option. WinCC/B.Data provides the basis for economic energy plant management to reduce the energy costs and increase the energy efficiency. The direct advantages for you are listed individually below:

Creates cross-company transparency through consistent energy and material accounting for the power generation and consumption plants

Enables originator-based energy cost allocation and creates a transition to the accounting system (e.g. SAP R/3 CO)

Forms characteristic values which enable founded statements on the increase of the efficiency of power generation plants and consumers

Provides planning reliability through production-related load and demand prognosis

Supports the purchasing department in cost-optimized energy procurement

Fulfills the legal requirements for monitoring and reporting of greenhouse gas emissions (CO2 emissions)

Load relief due to the automatic operation of internal and external energy reporting system.

A detailed function description is available in the Online Support under entry ID: 47521082).


http://support.automation.siemens.com/WW/llisapi.dll?aktprim=0&lang=en&referer=%2fWW%2f&func=cslib.csinfo&siteid=cseus&groupid=4000003&extranet=standard&viewreg=WW&nodeid0=41886031&objaction=csopen�

3 Installation

3.1 Hardware installation


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3 Installation

3.1 Hardware installation

The figure below shows the hardware setup of the application.

Figure 3-1

3 Installation

3.2 Installation and preparation of the operator station


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3.2 Installation and preparation of the operator station

Table 3-1

No. Action Comment

1 Start or install a computer with WinCC V7.0 SP1.

2 Open the WinCC Explorer and select “Tag Management” with the right mouse button, and select the “Add New Driver…” from the context menu.

3 In the window below you select the “Modbus TCPIP.chn” file and press the “Open” button to add the Modbus TCP channel driver.

4 Repeat step 3 with the “System Info.chn” file to add the system info channel driver.


4.1 Preparation


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4 Starting up the Application (own project) The faceplate described in this application requires you to also define the supplied start screen “@BST_MAIN_1M.pdl” (when using a monitor) or “@BST_MAIN_2M.pdl” (when using two monitors) as the start screen in your WinCC project.

4.1 Preparation

Table 4-1

No. Action Comment

1 Copy the “Energy_Files.zip” file to your hard drive and unzip it into a directory.

2 Copy the files from the folders “Block” and “Pictures” into the “GraCS” folder of your WinCC project (\project path\GraCS).

3 Copy the files from the “Library” folder into the “Library” folder of your WinCC project (\project path\Library).

4 Copy the files from the “CSV files” folder into the master directory of your WinCC project path. (These files are required to create the tags and structures.)

4.2 Commissioning

Table 4-2

No. Action Comment

1 Start the WinCC Explorer and create “@BST_MAIN_1M.pdl” or “@BST_MAIN_2M.pdl” as start screen, depending on the number of your monitors or call one of these two screens from your existing picture navigation. If you have created a new WinCC project, configure the additional properties of your WinCC project (e.g. Global Script Runtime, Graphics Runtime, etc.).

2 In the context menu of the Modbus unit you select the “New Driver Connection…” option to add a new Modbus connection.


4.2 Commissioning


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No. Action Comment

3 In the subsequent window you assign a name for the created connection and select the “Properties” interface to open the settings dialog.

4 Change the “Modbus TCPIP properties” as can be seen in the screen shot. CPU type: “Premium Micro” Server: “IP address of the Sentron PAC” Port : “502” Address of remote slave: “1“ Acknowledge the entries in both windows by pressing “OK”. Note: A detailed description of this procedure can be found in entry 37885119.

5 Open the WinCC Tool “TAG Export Import” via the Windows start menu “SIMATIC>WINCC>Tools>TAG Export Import” to create the tags and structures.

6 Check whether the correct project path or project name is displayed in the first line in the “TAG Export Import” tool. Now select the “Import overwrite” option and click the “Get from Regional Settings” button to select the correct “List separator”. Now click the “Execute” button to execute the process, in order to import the tags and structures into your project. Confirm the security query for overwriting with the “OK” button. Note: when using a different project name, the “Filename” must be changed to “Energy” in this window, since the project name will be entered here by default. This import creates the “Sentron_PAC” structure tag as well as the “Internal Tags” in the “Properties” folder. These “Internal tags” are necessary for the configuration in the “Property screen” (also see chapter 6.1).

http://support.automation.siemens.com/WW/view/de/37885119�


4.2 Commissioning


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No. Action Comment

7 Now you create the tags for the access of WinCC to SENTRON PAC. To create these tags you need to select the connection created in step 2 and 3 (“PAC4200_1” in the example) and select the “New Tag…” entry in the context menu.

8 In the “Tag properties” window you assign a name (TagPrefix) for the tag to be created (“PAC4200_1” in the example) and select the “Sentron_PAC” structure as “DataType”.

9 In the “Invalid Address Parameter” you press the “No” button, since the addresses for the individual tags are assigned in a later step. Now all required tags for the access are created and automatically supplied with the “TagPrefix”.

10 Open the WinCC Tool “TAG Export Import” again to define the “Offsets” for the structure created in step 8 and 9. Export your respective tags using the “AG Export Import” WinCC Tool. Select the “Export” option and start the export by pressing the “Execute” button. Also check whether the correct project has been selected in the tool.


4.2 Commissioning


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No. Action Comment

11 Now open the “Offsets_for_Sentron_PAC.csv” file and copy the entries to column D of the “CSV file” for all tags of structure “PAC4200_1.* ”. Then you add these entries to your just exported file “Energy_vex.csv” also into column D. Ensure that the tags are sorted in the same way as in the original file, since the “Offsets” of the tags, and hence later also the values, in WinCC do not match. Note: the “Offsets” of the individual tags can also be read from the SENTRON PAC Manual and the individual tags be addressed manually.

12 Save the changes to the “Energy_vex.csv” file and perform another import of data as described in step 6. Check whether the “Offsets” were assigned to the tags of the structure in the “Parameters” column of the “WinCC-Explorer”.

13 Open an already existing picture or create a new picture (“Overview.pdl” in the example) in the “Graphics Designer” to add the block icon of the SENTRON PAC faceplate.

14 To add the block icon you need to add the “Faceplate instance” from the “Object Palette” (“Standard” tab and “Smart Objects” folder) into your picture.

15 In the “Open” window you select the faceplate type “E_Management_ICON.ftp” and acknowledge the selection by pressing the “Open” button. Then adjust the size of the faceplate in your picture.

https://www.automation.siemens.com/mdm/default.aspx?DocVersionId=25599329163&TopicId=24569465483�


4.2 Commissioning


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16 Add a “C-Action…” with the following script to the “Mouse

Action” event: #include "BST_FPDEF.h" char *pch; char szTagName[128]; char *szTagPrefix; char szLinkName[128]; int pointer; LINKINFO linkinfo; BST_TopfieldOpen(lpszPictureName, lpszObjectName, BST_FP_Engery);

17 Go to the “Properties” tab and select the “UserDefined2” tree entry of the “Object Properties” of the block icon, to connect the tags to be displayed in the icon during runtime. Furthermore, you can connect the tags for the “units” to have them displayed accordingly.

18 In the “Faceplate_Name” attribute you enter a name to be displayed in the text box during runtime. Note: for a better allocation of picture window to block icon it is recommended to assign the TagPrefix to the structure (“PAC4200_1” in the example) in this attribute, since the TagPrefix is also automatically displayed in the picture window.

19 Open the “@BST_BOTTOM.pdl” picture and adjust the picture call of the first button for the “Overview.pdl” picture (when using your own picture to integrate the block icon, enter this picture name). The picture call is realized through a “C Action” on the “Mouse Action” event. The second button already contains the picture call for the “E_Property.Pdl” picture. The other buttons can be deleted or used for the picture navigation of additional pictures.

5 Starting up the Application (Sample Project)

5.1 Preparation


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5 Starting up the Application (Sample Project)

5.1 Preparation

Table 5-1

No. Action Comment

1 Start the computer prepared in chapter 3.

2 Unzip the “Energy.zip” file (WinCC project) onto the hard drive of your computer.

5.2 Commissioning

Table 5-2

No. Action Comment

1 Open the WinCC project and adjust the computer name according to your computer name in the sample project. For this purpose, click “Computer properties” with the right mouse button to open the dialog and enter the “Computer Name” of your computer in the input field.

2 Adjust the IP addresses of both SENTRON PAC stations in the Modbus connections. Open the properties of the respective Modbus connection as illustrated in the screenshot.

3 Start WinCC Runtime.

6 Operating the Application

6.1 Overview


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6.1 Overview

“Start screen”

The figure below displays the “start screen” of the sample project with two integrated faceplate instances as well as the respective picture window. The bottom part contains the buttons which enable you to switch from the “Start

screen” to the “Property screen” , the “Alarm screen” as well as the

“SysInfo screen” .

Figure 6-1

“Property screen”

In this screen you can change and set the properties for the various views of the faceplate (e.g. places before or after the decimal point, scale range, labeling text for the individual phases, etc.) for the entire project.


6.1 Overview


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Figure 6-2


6.1 Overview


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“SysInfo screen”

This screen shows some example data of your PC.

Note This screen is only available in the sample project, if you would like to integrate it into your own project, you have to extract it from the “zip file” of the sample project and manually create the necessary tags for the system info channel.

Figure 6-3


6.2 Operating the faceplate


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After you have integrated the faceplate as described in chapter 4, or you are using the sample project, you can operate the faceplate as described below.

Clicking on the faceplate instance opens a picture window where you can change between the various views by pressing the respective buttons. These views are described further in the following sections. There is the additional option to open a screen with 6 predefined WinCC pictures via the “Loop display” button. In the first line of the faceplate the tag prefix used for this faceplate is displayed. It was also configured in the faceplate instance to be able to generate an assignment between picture window and faceplate instance.

“Voltage PH-PH” view

Pressing the button opens the “Voltage PH-PH” view in the picture window of the faceplate. This view depicts the voltages between the three phases using the respective current values (black needle) as well as the maximum value (red needle).

Figure 6-4

“Voltage PH-N” view

Pressing the button opens the “Voltage PH-N” view in the picture window of the faceplate. This view depicts the voltages between the three phases using the respective current values (black needle) as well as the maximum value (red needle).




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Figure 6-5

“Current” view

Pressing the button opens the “Current” view in the picture window of the faceplate. This view depicts the currents between the three phases using the respective current values (black needle) as well as the maximum value (red needle).

Figure 6-6




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“Active Power” view

Pressing the button opens the “Active Power” view in the picture window of the faceplate. This view depicts the active power between the three phases using the respective current values (black needle) as well as the maximum value (red needle).

Figure 6-7

“Reactive Power” view

Pressing the button opens the “Reactive Power” view in the picture window of the faceplate. This view depicts the reactive power between the three phases using the respective current values (black needle) as well as the maximum value (red needle).




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Figure 6-8

“Apparent Power” view

Pressing the button opens the “Apparent Power” view in the picture window of the faceplate. This view depicts the apparent power between the three phases using the respective current values (black needle) as well as the maximum value (red needle).

Figure 6-9




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“Energy” view

Pressing the button opens the “Energy” view in the picture window of the faceplate. This view depicts the values for the active, reactive, and apparent power. These values are restricted by the limits of the tag (32 bit floating-point number) and need to be reset manually at the SENTRON PAC when reaching this limit.

Figure 6-10

“Frequency” view

Pressing the button opens the “Frequency” view in the picture window of the faceplate. This view displays the actual value (also symbolic representation) as well as the maximum value of the network frequency.




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Figure 6-11

“Trend” view

Pressing the button opens the “Trend” view in the picture window of the faceplate. The dropdown list in this view enables you to connect the various values (actual values) of the individual views to the “OnlineTrendControl”. These values (online tags) are then displayed in the “OnlineTrendControl” according to the selection.




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Figure 6-12




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“Loop display” view

Pressing the button opens the “Loop” display in the picture window of the faceplate. This view displays six different pictures in one overview. This view can be used to obtain a general overview over several views.

Figure 6-13



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Difference between this application example and SIMATIC powerrate

In this application example, using WinCC standard tools, a faceplate for energy management is introduced, which can be used without additional workload. Here, the SENTRON PAC stations are directly connected to WinCC and the data can be forwarded to WinCC via a Modbus channel. After the expansion with SIMATIC powerrate the SENTRON PACs are connected to WinCC via a controller. This expansion with SIMATIC powerrate gives you the function expansions below. The options for expanding this application example are discussed in the following sections. SIMATIC powerrate requires an S7 connection for connecting the SENTRON PAC stations.

Function expansion through SIMATIC powerrate:

Energy data acquisition and preparation for any PROFIBUS devices through pre-programmed S7 blocks.

Calculating the average performance values (e.g. 15 minutes) and archiving

Generating reports on the basis of Microsoft Excel (cost center report, duration curves, batch report)

Load management to avoid power peaks due to automatic connecting and disconnecting of consumers

7.1 Connecting the SENTRON PAC via free of charge Modbus TCP block

The data of the SENTRON PAC is forwarded to the WinCC application via the controller. This solution is the cheapest variant, since the block is free of charge. However, the interconnection of the WinCC application must be changed and a maximum of 8 connections is possible. The data is updated slower in this case.

7.2 Connecting the SENTRON PAC via licensed TCP block by Siemens I IS

The data of the SENTRON PAC is forwarded to the WinCC application via the controller and the Modbus TCP blocks (S7 OpenModbus/TCP). For this solution the costs depend on the number of controllers (license for each controller). However, the interconnection of the WinCC application must also be changed and a maximum of 8 connections is possible. Updating the data is faster than for the first solution.

7.3 Connecting the SENTRON PAC via an additional Profinet module

For this solution, the data connection with WinCC may be retained parallel to the S7 connection. Due to the additional Profinet module, the costs for this solution arise for each SENTRON PAC station, and it is necessary to wire both interfaces (additional Ethernet line). For this solution the interconnection of the WinCC application can remain and it is not restricted to 8 connections.

http://www.industry.siemens.com/industrysolutions/global/en/IT4Industry/products/simatic_add_ons/s7_open_modbus_tcp/Pages/default_tab.aspx�

8 Literature


V1.1, Entry ID: 48586219

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8 Literature

Internet Links

This list is by no means complete and only presents a selection of suitable information.

Table 8-1

Topic Title

\1\ SENTRON PAC and WinCC via Modbus


\2\ SENTRON PAC Manual


\3\ This entry http://support.automation.siemens.com/WW/view/en/48586219

\4\ SIMATIC powerrate delivery release


\5\ WinCC/B.Data sales and delivery release


\6\ Siemens I IS blocks

http://www.siemens.en/net/

9 History

Table 9-1

Version Date Modification

V1.0 11.05.2011 First issue

V1.1 01.12.2011 Improvements of small points in the documentation.






http://www.automation.siemens.com/mcms/automation/en/industrial-communications/Pages/Default.aspx�

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