Simple Introduction into Energy Management with WinCC WinCC Application Description December 2011 Applications & Tools Answers for industry.

Transcription

1 Cover Simple Introduction into Energy Management with WinCC WinCC Application Description December 2011 Applications & Tools Answers for industry.

2 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. 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 If you have any questions about this document, please contact us at the following address: 2 V1.1, Entry ID:

3 s Fehler! Verweisquelle konnte nicht gefunden werden. 1 Automation Solution 2 Installation 3 SIMATIC Energy Management with WinCC Simple Introduction into Energy Management with WinCC 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 V1.1, Entry ID:

4 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 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. 4 V1.1, Entry ID:

5 Preface 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 _Energymanagement_en.doc V1.1, Entry ID:

6 Table of Contents Table of Contents Warranty and Liability... 4 Preface... 5 Table of Contents Automation Task Introduction Overview of the automation task Description of the automation task Automation Solution Overview of the general solution Description of the core functionality Hardware and software components used Possible expansions of the application example Installation Hardware installation Installation and preparation of the operator station Starting up the Application (own project) Preparation Commissioning Starting up the Application (Sample Project) Preparation Commissioning Operating the Application Overview Operating the faceplate Expanding the Application Example with SIMATIC Powerrate Connecting the SENTRON PAC via free of charge Modbus TCP block Connecting the SENTRON PAC via licensed TCP block by Siemens I IS Connecting the SENTRON PAC via an additional Profinet module Literature History V1.1, Entry ID:

7 1 Automation Task 1.1 Introduction 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 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. V1.1, Entry ID:

8 2 Automation Solution 2.1 Overview of the general solution 2 Automation Solution 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 Copyright Siemens AG Copyright 2011 All rights reserved 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: SENTRON PAC 4200: &TopicId= 8 V1.1, Entry ID:

9 2.2 Description of the core functionality Overview and description of the user interface Figure Automation Solution 2.2 Description of the core functionality WinCC Faceplate WinCC Faceplate SIMATIC WinCC 2-wire copper cable (twisted pair cable) 2-wire copper cable (twisted pair cable) Energy Appliance Energy Appliance SCALANCE X208 SENTRON PAC SENTRON PAC 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. V1.1, Entry ID:

10 2 Automation Solution 2.3 Hardware and software components used 2.3 Hardware and software components used Hardware components Table 2-1 The application document was generated using the following components: Component Qty. MLFB / order number Note Industrial PC 1 Industrial PC mation/en/pc-basedautomation/pages/default.aspx SCALANCE X GK5208-0BA10-2AA3 SENTRON PAC KM2112-0BA00-3AA0 SENTRON PAC KM4212-0BA00-3AA0 Standard software components Table 2-2 Copyright Siemens AG Copyright 2011 All rights reserved Component Qty. MLFB / order number Note WinCC V7.0 SP2 1 6AV BM07-0AX0 (128 power tags) Sample files and projects The following list includes all files and projects used in this example. Table 2-3 Energy.zip File Einstieg_Einfaches_Energiemanagement_mit_WinC C_de.pdf Version depends on the subsequent configuration. 128 tags are sufficient for the demo project. Note This zipped file contains the WinCC project as well as the Excel file for the tag import. This document. 10 V1.1, Entry ID:

11 2 Automation Solution 2.4 Possible expansions of the application example 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 " " 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: ). V1.1, Entry ID:

12 3 Installation 3.1 Hardware installation 3 Installation 3.1 Hardware installation The figure below shows the hardware setup of the application. Figure 3-1 Copyright Siemens AG Copyright 2011 All rights reserved 12 V1.1, Entry ID:

13 3 Installation 3.2 Installation and preparation of the operator station 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. V1.1, Entry ID:

14 4 Starting up the Application (own project) 4.1 Preparation 4 Starting up the Application (own project) The faceplate described in this application requires you to also define the supplied start (when using a monitor) (when using two monitors) as the start screen in your WinCC project. 4.1 Preparation Table 4-1 No. Action Comment Copyright Siemens AG Copyright 2011 All rights reserved 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 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. 14 V1.1, Entry ID:

15 4 Starting up the Application (own project) 4.2 Commissioning 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 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). V1.1, Entry ID:

16 4 Starting up the Application (own project) 4.2 Commissioning 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. Copyright Siemens AG Copyright 2011 All rights reserved 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. 16 V1.1, Entry ID:

17 4 Starting up the Application (own project) 4.2 Commissioning 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. V1.1, Entry ID:

18 4 Starting up the Application (own project) 4.2 Commissioning 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. Copyright Siemens AG Copyright 2011 All rights reserved 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 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. 18 V1.1, Entry ID:

19 5 Starting up the Application (Sample Project) 5.1 Preparation 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. V1.1, Entry ID:

20 6 Operating the Application 6.1 Overview 6 Operating the Application 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 Copyright Siemens AG Copyright 2011 All rights reserved 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. 20 V1.1, Entry ID:

21 6 Operating the Application 6.1 Overview Figure 6-2 V1.1, Entry ID:

22 6 Operating the Application 6.1 Overview 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 Copyright Siemens AG Copyright 2011 All rights reserved 22 V1.1, Entry ID:

23 6 Operating the Application 6.2 Operating the faceplate 6.2 Operating the faceplate Voltage PH-PH view 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. 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). V1.1, Entry ID:

24 6 Operating the Application 6.2 Operating the faceplate Figure 6-5 Copyright Siemens AG Copyright 2011 All rights reserved 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 V1.1, Entry ID:

25 6 Operating the Application 6.2 Operating the faceplate 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). V1.1, Entry ID:

26 6 Operating the Application 6.2 Operating the faceplate Figure 6-8 Copyright Siemens AG Copyright 2011 All rights reserved 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 V1.1, Entry ID:

27 6 Operating the Application 6.2 Operating the faceplate 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. V1.1, Entry ID:

28 6 Operating the Application 6.2 Operating the faceplate Figure 6-11 Copyright Siemens AG Copyright 2011 All rights reserved 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. 28 V1.1, Entry ID:

29 6 Operating the Application 6.2 Operating the faceplate Figure 6-12 V1.1, Entry ID:

30 6 Operating the Application 6.2 Operating the faceplate Loop display view Figure 6-13 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. Copyright Siemens AG Copyright 2011 All rights reserved 30 V1.1, Entry ID:

31 7 Expanding the Application Example with SIMATIC Powerrate 7 Expanding the Application Example with SIMATIC Powerrate 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. V1.1, Entry ID:

32 8 Literature 8 Literature Internet Links This list is by no means complete and only presents a selection of suitable information. Table History Topic Title \1\ SENTRON PAC and WinCC via Modbus \2\ SENTRON PAC Manual \3\ This entry \4\ SIMATIC powerrate delivery release \5\ WinCC/B.Data sales and delivery release \6\ Siemens I IS blocks Table 9-1 Version Date Modification V First issue V Improvements of small points in the documentation. 32 V1.1, Entry ID: