Set24 Loadswitching v1d1 en PDF

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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
Applications & Tools

Answers for industry.
Warranty and Liability
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
Siemens AG 2013 All rights reserved
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.
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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
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Table of Contents
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
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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
Switching Loads with S7-1200 and SENTRON PAC3200

Version 1.1, Entry ID: 58856464 3
Table of Contents
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
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1 Automation Problem
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
Copyright Siemens AG 2013 All rights reserved
58856464_Set24_LoadSwitching_V1d1_en.doc
periods are to be logged over at least the accounting period to furnish proof to
the power utility.
Figure 1-1: Task
Measurement of electrical energy
Load 1 and power by power utility
(non-interruptible)
Load 2 Separate power

(non-interruptible) measurement Infeed
…
Load control
Load n
(non-interruptible)
…
Load 1
(interruptible)
Load 2
(interruptible)
…
Load n
(interruptible)

2 Automation Solution
2.1 Required Basic Knowledge
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

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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.
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2.3 Load control principle
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.

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
1
there is an imminent exceeding of the power limit is performed using relays (NC
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

Figure 2-2: Data acquisition and switching commands
Base Load,
Electric Losses
Measurement of electrical energy
PAC
Load 1 3200
and power by power utility
(non-interruptible)
PAC
Load 2 3200
(non-interruptible) Infeed
…
PAC
Load n 3200
(non-interruptible)
PM1207 S7-1200
Load 1 PAC
(interruptible) 3200
TIA-Portal
PAC DataLog
Load 2 3200
(interruptible)
…
…
Load n PAC
(interruptible) 3200
KTP600
Measured data of the SENTRON PAC3200 devices

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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
3 3
Pav-fc is the forecast of Pav 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)
P
tscan Pav_fc
Pmax
Pav(tn)
Pav(tn-1)
Pav(t)
t
tn-1 tn
tm
t0 tm
Pav (tn ) Pav (tn 1 )

Pav _ fc tm t n Pav (t n )
tn tn 1
3
Origin of indices: av=average, fc=forecast

Eov Eoff
4
Eov(tn) 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 P off
– 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

P
Pav(tn)
Eov
Pmax
Poff
Eoff
Emax
t
tn
tm
t0 tm
Eov | Pav (t n ) Pmax | (t n t0 );
Eoff ( Poff | Pav (t n ) Pmax |) (t m t n );
Poff is the power value of the load that defines its switch-off instant. The smaller
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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)
P
tscan
Pmax
Pav(tn-1)
Pav(t)
Pav(tn)
Pav_fc
t
tn-1 tn
tm
t0 tm
Pav (tn ) Pav (tn 1 )

Pav _ fc tm t n Pav (t n )
tn tn 1

Eov Eon
Figure 2-6: Energy resource of the next load to be switched on
Pon Eon
Pmax
Eov Pav(tn)
t
tn
tm
t0 tm
Eov | Pav (t n ) Pmax | (t n t0 );

Eoff ( Poff | Pav (t n ) Pmax |) (t m t n );
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
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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
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2.4 Data logging
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.

2.5 Error messages
Figure 2-7: Data logging
User program
Pav(tm)
…
DataLogCreate
.csv
Webserver
…
DataLogOpen
Load memory
…
DataLogWrite
…
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
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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.
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2.6 Hardware and programming software of the sample project
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 2 7KM2112-0BA00-3AA0
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. SIMATIC S7-1200 POWER MODULE PM1207 1 6EP1332-1SH71
STABILIZED POWER SUPPLY INPUT: 120/230 V AC
OUTPUT: 24 V DC/2.5 A
3. COMPACT SWITCH MODULE CSM 1277 CONNECTION 1 6GK7277-1AA10-0AA0
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
4. SIMATIC S7-1200, CPU 1215C, KOMPAKT CPU, 1 6ES7215-1AG31-0XB0
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
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 1 6AV6647-0AD11-3AX0
BASIC V10.5/ STEP7 BASIC V10.5, CONTAINS OPEN
SOURCE SW WHICH IS PROVIDED FREE OF CHARGE
FOR DETAILS SEE CD
6. MINIATURE POWER RELAY SCREW TERMINALS,
2NO+2NC SNAP-ON MOUNTING ON STANDARD 2 3TK2022-0BB4
MOUNTING RAIL DC SOLENOID SYSTEM DC 24V
7. Current transformer
(depending on the loads; both x/1A or also x/5A current 2 -
transformers can be used)

2.6 Hardware and programming software of the sample project
Components Qty. MLFB/order number

8. SIMATIC NET INDUSTRIAL ETHERNET TP CORD 6XV1870-3Q…
RJ45/RJ45, CAT 6, TP CABLE 4X2, PREASSEMBLED W.
2 RJ45 CONNECTORS, …
0.5M …E50
4
1M …H10
2M …H20
6M …H60
10M …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
or alternatively
STEP 7 Basic V12 6ES7822-0AA02-0YA5
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NOTICE Use always the latest software update (see /6/).
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2.7 Wiring of the sample project
2.7 Wiring of the sample project

Figure 2-8: Wiring
L1
N
PE
+
24V
-
CSM CPU1215C KTP600

PS1207
1277
IP-Adr. 192.168.0.254
IP-Adr. 192.168.0.1
SENTRON SENTRON
PAC3200 PAC3200
1 2
IP-Adr. 192.168.0.201
IP-Adr. 192.168.0.200 F
Load wiring as for PAC 1
L1
N Load 1
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.

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

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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.
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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
Rx_Real R Total Active Power Table 3-6 in /1/
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:

2.9 Program description
Figure 2-11: Serial communication
Start
n := 1
Connect to SENTRON PAC n
Receive from / send to SENTRON PAC n

n := n+1
Disconnect from SENTRON PAC n
All SENTRON PACs processed?

No
Yes
Wait until end of scan time

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:
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Table 2-5: Network addresses

Node IP address Subnet mask
Controller 192.168.0.1
Operator panel 192.168.0.254
255.255.255.0
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.

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”
Operating system
OB100 FB1084
“Startup” “MB_CLIENT”
FC502
FB501 “CALC_P_active_av”
“PowerMan”
FC161
“Event”
OB1
“MAIN”
FC501
“Load_shedding”
DB503
“PAC_data”
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).

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 Pav (t act ) of the average active power relative to the start
of the measuring period for each SENTRON PAC.
Eactive (tact ) Eactive (t0 )
Pav (tact )
tact t0
Eactive = value of the active energy meter;
t act = working hours counter value at the moment;
t0 = 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 IN/OUT Explanation
type
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
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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.
type
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.

type
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.

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
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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 Dim. Explanation
type
PAC_max UInt - Number of SENTRON PAC3200 devices
Number of measured loads.
IP. Struct IP address (octets 1-3)
octet1 USInt Octet 1
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.

Name Data Dim. Explanation

type
load_spec Array[1..n] Array of load specifications
of Struct 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
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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] Priority list
of UInt 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 A communication fault will be detected if a communication
faults 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.

Figure 2-13: State diagram
Initia
estab AC 1
No Step 1010 (NW11)
Step 1000 (NW3)
te co m ent
to P
Scan time Scan time elapsed Start of
lish
nnec
Load management (process FB Load_shedding) elapsed? measuring period
Initiate connection establishment to PAC 1 Step 10 (NW4)
Yes
tion
Yes CONNECTED & Restart
nicht BUSY
All PACs processed?
No Initiate communication job
Step 50 (NW10) Set MB_CLIENT parameter
Not CONNECTED
& not BUSY

Step 15 (NW5)
Pactive received n times and
Initiate connection termination
mean value generated
(DONE)
Initiate connection establishment
Step 40 (NW9) to the next PAC
Not BUSY Save mean value of Pactive

Set MB_CLIENT parameter
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Calculate Pav (relative to measuring period)

Complete communication job Step 20 (NW6)
Eactive received
(DONE)
Step 30 (NW8) No
Save Eactive
Working hours counter
received (DONE) Switching request?
Yes
Log load condition Set MB_CLIENT parameter

Set MB_CLIENT parameter Step 24 (NW7)
Load switched
(DONE)

28 Version 1.1, Beitrags-ID: 58856464
2.10 Visualization
2.10 Visualization
For monitoring, the KTP600 provides three screens.
Main screen (start screen)
Figure 2-14: Main screen

Energy reserve currently
provided by the next load to
be switched off or on. When
it has been used up, the
Total active power forecast for the respective load will be
end of the measuring period. switched off or on.
Sum of the current average active
power demands over all
measuring instruments relative to off: Load switch-off is
the start of the measuring period pending.
plus a specified base load. The
value is based on the measured on: Load switch-on is
values read out of the SENTRON pending.
PACs with register offset
addresses 801 (“Active Energy Name of the next load to be
Import Tariff 1”) and 213 switched off or on
(“Working Hours Counter”).
Button to release reclosing
next load to be switched on
Button to switch to the

Sum of the current active
load condition list
powers over all measuring
instruments plus a specified
base load. The value is based Button to switch to the error list.
on the measured values read If at least one error is pending,
out of the SENTRON PACs the will button flash red/white.
with register offset address 65
(“Total Active Power”).
Measuring period
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.

2.10 Visualization
“Consumer load list” screen
Figure 2-15: “Consumer load list” screen
Name of the loads
Earliest next switch-off instant if

Switching status a minimum on time has been
specified for the respective
load.
Earliest next switch-on .
instant if a minimum off time
has been specified for the
respective load.
Back to “Load
management” screen
“Error messages” screen
Figure 2-16: “Error messages” screen

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Error messages with

time stamp and
alarm status
Back to “Load
management” screen

3 Configuration
3.1 SIMATIC software installation
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 See chapter 9.2.3 in /1/
Navigate to the “LANGUAGE/REGIONAL” group and set the
desired language.
Parameter Device 1 Device 2

LANGUAGE ENGLISH
2. “Basic parameters” group See chapter 9.2.4 in /1/

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 See chapter 9.2.6 in /1/
Navigate to “DIGITAL OUTPUT” and define the action.

ACTION REMOTE OUTPUT

3 Configuration
3.3 Configuring the HMI
No. Instruction Additional note

4. “Communication” group See chapter 9.2.7 in /1/
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.
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3 Configuration
3.4 Settings on the development system (Windows)

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.

3.4.1 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.

3 Configuration

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.
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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.

3 Configuration
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
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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3 Configuration
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

P
Power limit
Base load
Switchable loads

3 Configuration
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

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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.

3 Configuration
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.

3 Configuration

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
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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

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
Define the switch-off/switch-on powers and the off/on
load_spec[n].P_switch_on
times of the added loads
load_spec[n].t_remain_off
(for the tag description, see Table 2-10).
load_spec[n].t_remain_on
prio_list[n] Enter the new loads in the priority list (for the tag
description, see Table 2-10).

3 Configuration
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 Configuration

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.
Dra
g
&D
r op
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

3 Configuration

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 neuen

Verbrauchern 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”.
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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
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 When the measuring period starts after a
is triggered using the CPU clock, you can set restart of the controller, the outputs of all
the time of day in online mode to start of SENTRON PAC3200 devices will be reset and
measuring period minus n seconds to save all switchable loads will be switched on.
time.
3. Monitor the “Load management” screen (for With the third scan after the start of the
the explanation, see Figure 2-14). 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
4.2 Error messages

Table 4-2: Live demo – error messages
1. No load available to switch-off: At the instant when the system wants to switch
In the watch table (see Table 4-1, 5) increase off a (nonexistent) third load, the “No load
the base load to such an extent that despite available to switch-off” error message marked
switching off both loads, the power limit is as “incoming” is generated and displayed in
exceeded at the end of the measuring period. 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: The “Scan interval too short” error message is
In the watch table (see Table 4-1, 5) enter a generated and displayed in the “Error
scan interval (“LoadSwitching_DB”.scan_time) messages” HMI screen.
that is shorter than the communication time for
two loads (e.g., 300ms).
The message disappears as soon as the
communication with all loads can be
completed within the scan interval.
3. Communication fault with load n: After the communication monitoring time for
Remove the RJ45 connector from one of the load n has elapsed, the “load name –
loads. 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

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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
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
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.
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5 Glossary
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
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*
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[*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
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
/2/ SIMATIC S7-1200 System Manual
/3/ STEP 7 Basic V11.0 SP2 System Manual
STEP 7 Basic V12 System Manual

/4/ S7-1200 Firmware Update to V3.0 via Web Server
/5/ STEP 7 V11 Support Packages for the hardware catalog in the TIA Portal
/6/ Updates for STEP 7 V11 SP2 and WinCC V11 SP2
/7/ GPS synchronization of system time and date of your S7-1200 PLC
/8/ Operating Instructions S7-1200 Compact Switch Module CSM 1277
/9/ Operating Instructions PM1207
/10/ Operating Instructions SIMATIC HMI HMI devices Basic Panels
12
Always use the most current software
(pay attention to “…_Vxdx” in the file name!).

8 History
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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Cover

Application Description July 2013

Applications & Tools

Warranty and Liability

Any form of duplication or distribution of these Application Examples or excerpts

2.7 Wiring of the sample project............................................................. 17

Switching Loads with S7-1200 and SENTRON PAC3200

3.4.2 Setting the PG/PC interface ............................................................. 35

Load 2 Separate power

Switching Loads with S7-1200 and SENTRON PAC3200

2.2.1 SENTRON PAC3200

The link to the multi-function measuring instrument you find in

Abbildung 2-1: SENTRON PAC3200

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

Thanks to its compact design in 96 x 96 mm format, it is an ideal replacement for

2.3 Load control principle

Switching Loads with S7-1200 and SENTRON PAC3200

Figure 2-2: Data acquisition and switching commands

Measured data of the SENTRON PAC3200 devices

The multi-function measuring instruments provide a variety of data. For this

Base quantity for load control

Base load and electrical losses

Criteria for switching off loads

Pav (tn ) Pav (tn 1 )

Switching Loads with S7-1200 and SENTRON PAC3200

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

Eov | Pav (t n ) Pmax | (t n t0 );

Eoff ( Poff | Pav (t n ) Pmax |) (t m t n );

The condition Eov Eoff of this bullet has two tasks:

Waiting time between switch-off actions was complied with

Minimum on time was complied with

Criteria for switching loads back on

Pav_fc < Pmax

Pav (tn ) Pav (tn 1 )

Switching Loads with S7-1200 and SENTRON PAC3200

Eov | Pav (t n ) Pmax | (t n t0 );

Eoff ( Poff | Pav (t n ) Pmax |) (t m t n );

reference power or low rated powers of the individual loads to be switched on

Table 2-1: Priority list

NOTICE Especially highly alternating processes require an exact adjustment with

2.4 Data logging

Switching Loads with S7-1200 and SENTRON PAC3200

Figure 2-7: Data logging

2.5 Error messages

Data log errors

2.6 Hardware and programming software of the sample

Switching Loads with S7-1200 and SENTRON PAC3200

Components Qty. MLFB/order number

Table 2-3: Programming software

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

2.7 Wiring of the sample project

CSM CPU1215C KTP600

Load wiring as for PAC 1

2.8 Communication principle

Switching Loads with S7-1200 and SENTRON PAC3200

The MB_CLIENT instruction

Figure 2-9: MB_CLIENT instruction

Access to the Modbus data register

Figure 2-10: Different data views of the Modbus data register

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

Switching Loads with S7-1200 and SENTRON PAC3200

Figure 2-11: Serial communication

Connect to SENTRON PAC n