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Communication:
Performant Data Synchronization
Between Several Field and One Head
PLC
S7-1200 Set 17
Application Description June 2013
Table of Contents
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
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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.
Copyright
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
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(wesentliche Vertragspflichten). The damages for a breach of a substantial
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proof to your detriment.
Any form of duplication or distribution of these Application Examples or excerpts
hereof is prohibited without the expressed consent of Siemens Industry Sector.
Caution:
The functions and solutions described in this article confine themselves to the
realization of the automation task predominantly. Please take into account
furthermore that corresponding protective measures have to be taken up in the
context of Industrial Security when connecting your equipment to other parts of the
plant, the enterprise network or the Internet. Further information can be found
under the Entry ID 50203404.
http://support.automation.siemens.com/WW/view/en/50203404
Datasync
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Table of Contents
Table of Contents
Warranty and Liability .............................................................................................. 2
1
Task................................................................................................................. 4
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Installation .................................................................................................... 32
6.1
6.2
10
History .......................................................................................................... 42
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1 Task
Task
Introduction
For synchronization tasks and for the exchange of control and status information
among a head PLC and field PLCs, e.g. for solar trackers in solar parks, a
performant cyclic communication system is needed.
For reducing the data transfer, e.g. to an HMI or when a remote supervision is
used, the data are to be exchanged in bundles by means of a data concentrator
(here: head PLC).
The figure below provides an overview of the automation task.
Field PLC 1
Head PLC
HMI
Field PLC 2
Field PLC n
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Figure 1-1
Supply of all the field PLCs with the same or different sets of data from the
head PLC (down sync).
Updating the sets of data from all the field PLCs in the head PLC (up sync).
Requirements of the automation task
The following requirements are posed to the block:
Optimal and performant utilization of the available connection resources of the
head and field PLC.
Simple adaptation to variable quantities (data volume sent and received).
To be used with S7-1200 and S7-300/400/IPC with Win AC.
The programming is to be done mainly with SCL.
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2 Solution overview
Solution overview
Display
The following figure gives a schematic overview of the most important components
of the solution:
Figure 2-1
IPC + WinAC
S7-1200
DATASYNC_
HEAD
DATASYNC_
HEAD
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DATASYNC_
SUB
DATASYNC_
SUB
DATASYNC_
SUB
DATASYNC_
SUB
Setup
The application example is demonstrated in a concrete example - controlling solar
trackers.
The expression solar tracker means solar energy systems which can be tracked
according to the position of the sun to ensure the best possible energy yields.
For the field PLC, a CPU S7-1200 is used in this example. For the sake of a better
clarity, the number has been reduced to four.
For the head PLC, this solution uses two types of devices:
An S7-1200 controller
An S7-300/400 / IPC with WinAC
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2 Solution overview
Description
With the function block DATASYNC_X (X:= HEAD or SUB), a block has been
developed that assumes the control of the data synchronization automatically.
The head PLC sequentially establishes an ISO-on-TCP communication connection
with each field PLC and terminates it again. Data is sent to the field PLCs and data
is received from them. After all field PLCs have been operated, the process is
repeated.
The following figure summarizes the data exchanged between head PLC and field
PLCs.
Figure 2-2
Current time
Field PLC
1..4
Production data
Head PLC
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2.1
2.1.1
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Figure 2-3
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Information screen
There is a separate information screen for every field PLC. The calculated zenith
and azimuth angles and simulated weather information and production data are
displayed here.
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Figure 2-4
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2 Solution overview
2.1.2
Schematic layout
The data synchronization between the head PLC and the field PLCs is done
comfortably with the function block DATASYNC_X.
This block implements the cyclic and performant data exchange between the head
PLC and the field PLCs.
The defined data structure is sent from the head PLC to the field PLC when the
connection has been built up on both sides. The field PLC waits for reception and
then sends its own data structure to the head PLC
(see Figure 2-2).
As soon as the head PLC has received the data sent from the field PLC, the data
exchange is completed. The connection is disconnected.
The exchanged data structures and the IP addresses of the field PLCs are stored
in different global data blocks.
There is the possibility of operating several field PLCs in parallel (multiplexing). The
function block DATASYNC_HEAD can be called with a different instance data
block in the OB1 of the head PLC for every available connection. The maximum
number of calls is limited by the available connection resources of the head PLC.
In the present Application Example, these parallel connections are being used.
Note
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2 Solution overview
3
2
DATASYNC_
HEAD
DATASYNC_
HEAD
DATASYNC_
HEAD
DATASYNC_
HEAD
n available
connection
resources
FIELD PLCs
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HEAD PLC
DATASYNC_
FIELD
DATASYNC_
FIELD
DATASYNC_
FIELD
DATASYNC_
FIELD
Example:
An S7-1200 CPU is used as the head PLC, and there are 12 field PLCs. This
makes possible the following combinations:
Number of available connection resources: n = 8
Number of field PLCs: z = 12
Therefore, the DATASYNC_HEAD block can be called in eight instances. There
are eight communication channels for the 12 field PLCs.
In the dynamic multiplex mode, the 12 field PLCs are synchronized through the
eight channels.
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2 Solution overview
Communication blocks
The communication between the head PLC and the field PLCs is done by an ISOon-TOP connection.
The connecting and disconnecting process and the sending and receiving of the
data is internally carried out in the DATASYNC_X block by means of the following
standard communication blocks:
Table 2-1
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Block
2.1.3
Description
TCON
TDISCON
TSEND
TRCV
Unit
Description
Longitude
[]
Latitude
[]
In this Application Example, the astronomic algorithm is calculated with the function
block SimpleAstroAlgorithm in the cyclic program of the field PLCs.
Simulation of the weather and production data in the field PLCs
The simulation of data that are sent from the field PLCs to the head PLC is done by
time-controlled OBs and a mathematical calculation.
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2 Solution overview
2.1.4
Time synchronization
For the visualization screen the time synchronization of all the CPUs can be
synchronized with the current UTC time in the head PLC. The synchronization
takes place in two steps:
1. With a trigger command, the head PLC reads out the current time and date
head PLC with the button Activate Timesync by means of the function block
RD_SYS_T. This information is stored in the sending reports of the field PLCs
and the time synchronization bit there is set.
2. The field PLCs receive the information with the next data synchronization and
recognize the requirement to carry out a time synchronization. Then they adapt
their real time clocks to the times they received.
2.2
Hardware components
Table 2-3
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Component
No.
Order number
Note
6ES7 215-1BG31-0XB0
Head PLC
6ES7 647-8A
Head PLC
6ES7 214-1AE30-0XB0
Field PLC
Field PLC1
6ES7 212-1AE31-0XB0
Field PLCs
Field PLC2 - 4
6AV2124-0GC01-0AX0
SCALANCE X208
6GK5208-0BA10-2AA3
PG / PC
12
No.
Order number
6ES7822-0A
WinCC Professional
6AV210
Note
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2 Solution overview
Note
This zip file contains two STEP 7 V12
projects.
DATASYNC_1200 for the S7-1200
CPU as the head PLC.
DATASYNC_IPC for the IPC with
WinAC as the head PLC
39040038_DATASYNC_DOKU_v20_d.pdf
This document.
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39040038_DATASYNC_CODE_v20.zip
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3.1
3.1.1
Program structure
The following graphic shows the complete user program of the head PLC.
Figure 3-1
DATASYNC_HE iDB
iDB
DATASYNC_HE
AD
iDB
iDB
AD
DATASYNC_HE
AD
DATASYNC_
HEAD
DB_IPADDRESS
TCON
TRCV
TSEND
TDISCON
DB_MANAGE
DB_STATE
OB 1
DB_SND_
DATA
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DB_RCV_
DATA
RD_SYS_T
Description
Table 3-1
Block
14
Note
DATASYNC_HEAD
DB_IPADDRESS
DB_STATE
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Block
3.1.2
Note
DB_MANAGE
DB_RCV_DATA
DB_SND_DATA
RD_SYS_T
Function block; responsible for reading out the current and local
time for the time synchronization.
Program structure
The following graphic shows the complete user program of the field PLCs.
Figure 3-2
DATASYNC_
SUB
TCON
TRCV
TSEND
DB_SND_RCV
_DATA
OB 1
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iDB
SimpleAstro
Algorithm
WR_SYS_T
OB 30
OB 31
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Description
Table 3-2
Note
DATASYNC_SUB
DB_SND_RCV_DATA
Data block; contains sending data for and receiving data from
the head PLC.
SimpleAstroAlgorithm
WR_SYS_T
Function block; responsible for reading out the current and local
time for the time synchronization.
OB 30, OB 31
3.2
Data blocks
3.2.1
Overview
For establishing a communication connection, the data block DATASYNC_HEAD
needs more information
about the field PLC
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Block
IP addresses
storage location
All these pieces of information are stored in different global data blocks:
Table 3-3
Data block
Responsible for...
DB_IPADDRESS
DB_MANAGE
DB_RCV_DATA
DB_SND_DATA
DB_STATE
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DB_IPADDRESS
In the global data block DB_IPADDRESS, the IP addresses for every field PLC
are stored. Every IP address is defined as the data type Struct, and divided into
the segments REM_1, REM_2, REM_3 and REM_4 with the data type
USInt (S7-1200) or byte (WinAC).
Figure 3-3
The global data block DB_MANAGE serves for the communication of the
connections.
Figure 3-4
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DB_MANAGE
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DB_STATE
In this data block, the communication status of each field PLC is listed and updated
and observed while DATASYNC_HEAD is running. For every station, one byte is
provided.
Figure 3-5
A connection between the head and the field PLCs is being established.
The connection between the head and the field PLC was successfully
established.
The data exchange between the head and the field PLC is completed and the
communication connection is disconnected.
The first attempt to establish a connection between the head and the field PLC
failed.
From the second attempt onwards (the status was 4 before), the system tries to
establish a connection for a certain period of time.
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Value
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UDT_HEAD_RCV_STRUCT
As the data type of the receive data, the template UDT_HEAD_RCV_-STRUCT is
used:
Figure 3-6
With this template, one sector is defined for every field PLC in the receive data
block DB_RCV_DATA of the head PLC.
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Figure 3-7
UDT_HEAD_SND_STRUCT
As the data type of the receive data, the template UDT_HEAD_RCV_-STRUCT is
used:
Figure 3-8
With this template, one sector is defined for every field PLC in the send data block
DB_SND_DATA of the head PLC.
Figure 3-9
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3.2.2
DB_SND_RCV_DATA
Since this communication connection is always initiated by the head PLC, it is
sufficient to integrate only one data block into the user program of the field PLC.
The global data block DB_SND_RCV_DATA contains the send and receive
structure for the data exchange.
The rules for the send and receive structure are also applied here:
The structure of the send data of the field PLC must be identical with the
receive structure of the head PLC.
The structure of the receive data of the field PLC must be identical with the
send structure of the head PLC.
Here, the data block template is also created by a template.
UDT_SUB_SND_STRUCT
As the data type of the receive data, the template UDT_SUB_SND_-STRUCT is
used:
UDT_SUB_RCV_STRUCT
As the data type of the receive data, the template UDT_HEAD_RCV_-STRUCT is
used:
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Figure 3-10
Figure 3-11
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With these templates, the data block of the field PLC is defined.
Figure 3-12
Since the send and receive structures must be identical for all field PLCs, these
templates can be reused for the other field PLCs.
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Note
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3.3
Description
The function block DATASYNC_X controls the data synchronization between the
head and the field PLC.
For the head and the field PLC, there are different DATASYNC_X blocks which
differ as far as their functionalities scope and therefore their interface configuration
are concerned.
Interfaces for the head PLC
Calling the block has been described as follows:
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Figure 3-13
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Parameters
The parameters have the following meaning:
Table 3-5
Parameters
Type
Data
type
ID
WORD
REQ
BOOL
NR_SUBSTATIONS
INT
DB_NR_IPADDRESS
DB_NR_STATE
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Meaning
DB_NR_SND_DATA
LEN_SND_DATA
DB_NR_RCV_DATA
LEN_RCV_DATA
IDB_NR_LOC
ACT_SUBNET_NUM
BER
IN/
OUT
INT
RSC_FREE
OUT
BOOL
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Figure 3-14
Parameters
The parameters have the following meaning:
Table 3-6
Parameters
Type
ID
Data type
WORD
REM_IP1
REM_IP2
USINT
REM_IP4
RCV_DATA
24
INPUT
REM_IP3
SND_DATA
Meaning
IN/ OUT
VARIANT
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4.1
Figure 4-1
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Establish connection
Establish connection
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4.2
The block receives the required information through the input parameters in the
DATASYNC_X block.
Receive data
The command TRCV sends data through an existing communication connection.
TRCV is carried out in several cycles.
The received data are buffered in a receive area, and then they are transmitted to
the receive area.
The receive area is defined by the following two dimensions:
pointer at the beginning of the area
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Copy data
The transmission of the data (IP address, send and receive structure) between a
global data block and an instance data block is done by MOVE commands.
The storage address where the information of the current field PLC is located, is
determined by an Offset calculation.
The following graphic shows the principle with the example of an IP address.
The global data block DB_IPADDRESS contains the IP address for all the field
PLCs. The block DATASYNC-HEAD calculates the Offset for the storage area of
the IP address of the field PLC to be edited on the basis of the IN/OUT variables
ACT_SUBNET_Number.
Figure 4-2
Global DB
DB_IPADDRESS
IP address
Field PLC 1
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IP addresse
Field PLC 2
Instance DB
DATASYNC-HEAD
ACT_SUBNET_NUMBER:=3
4- Bytes
Offset: 2 * 4-Bytes
IP address
Field PLC 3
IP address
Field PLC z
4.3
IP address
Field PLC 3
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5 Performance Measurement
Performance Measurement
Objective
In order to be able to describe the performance of the program, a performance
measurement is carried out.
The following chapter describes:
the concept of the performance measurement.
the measurement results.
an analysis of the values.
5.1
Structure
The following hardware constellation was used for the measurement:
Constellation 1:
Constellation 2:
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S7-1200
DATASYNC_
HEAD
DATASYNC_
DATASYNC_
HEAD
HEAD
DATASYNC_
HEAD
DATASYNC_
SUB
DATASYNC_
HEAD
DATASYNC_
DATASYNC_
HEAD
HEAD
DATASYNC_
HEAD
DATASYNC_
SUB
DATASYNC_
SUB
...
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5 Performance Measurement
Measuring scenarios
For the performance measurement, several variants were measured that differ in
the following aspects:
type of head PLC
number of substations
data load
program load.
The following table shows the values:
Table 5-1
Parameters
Settings
Number of substations
1, 4, 8, 16, 32
6, 50
The measuring clock is started before the connection to the first substation is built
up. The end of a measure cycle is the point in time when all the substations have
been synchronized once.
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Measure cycle
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5 Performance Measurement
5.2
Data conditioning
To avoid systematic errors, the measuring parameters are determined by repeated
measurement.
100 subsequent measurements are determined and processed as representative
measuring data. All the values and the maximum and the minimum synchronization
time of a measure of a series of measurements are listed in the Annex (see
chapter 11).
Diagrams
The following diagrams show the time for a synchronization cycle the S7-1200
(gray line) needs as compared to the WinAC (blue line) for two measuring
scenarios.
Figure 5-2
Time in ms
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Number of substations
Figure 5-3
Time in ms
Number of substations
Detailed values
The detailed values of the performance measurement are listed in chapter 11
Appendix A: Measured Data.
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5 Performance Measurement
5.3
Result
Overview
These are the results of the individual measurements:
The WinAC always synchronizes the data fields quicker than the S7-1200.
The higher the number of substations, the higher is the time difference
between the synchronization for the S7-1200 and the Win AC.
The synchronization time increases clearly when more than 8 substations are
being used.
The synchronization time increases with the number of substations and the
volume of the data to be synchronized.
Analysis
The measured values allow the following conclusions:
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6 Installation
Installation
6.1
Hardware installation
The figure below shows the hardware setup of the application.
Figure 6-1
CPU 1215C
IPC 277D
PG
192.168.0.50
24V
192.168.0.45
192.168.0.55
24V
24V
X208
24V
CPU 1212C
CPU 1212C
CPU 1212C
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CPU 1214C
192.168.0.1
24V
192.168.0.2
24V
192.168.0.3
24V
192.168.0.4
24V
Connect one head PLC (a CPU 1215C or an IPC277D), the field PLCs, the
SCALANCE X208 and the panel to one 24V power supply each. Connect all the
devices with a SCALANCE X208 by means of a standard Ethernet cable.
Note
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6 Installation
6.2
Software installation
Development software
Install the TIA V12 on your configuration computer.
Follow the instructions of the installation program.
Application software
For each head PLC, a sample program is available.
Unpack the zipped code folder 39040038_DATASYNC_CODE_v20.zip from the
download area into a folder you chose.
In this folder, there are the STEP 7 V12 project folders:
DATASYNC_1200 for the S7-1200 CPU as the head PLC.
DATASYNC_IPC for the IPC with WinAC as the head PLC
Navigate to the project folder you need and open the TIA project Datasync.ap12
with a double click.
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Figure 6-2
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7.1
Component
192.168.0.45
192.168.0.55
192.168.0.50
HMI panel
192.168.0.100
PG / PC
192.168.0.1
Field PLC 1
192.168.0.2
Field PLC 2
192.168.0.3
Field PLC 3
192.168.0.4
Field PLC 4
PG / PC
Change the IP addresses of the PG / PC as follows:
Table 7-2
No.
1.
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Action
Note
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SIMATIC components
The SIMATIC components are addressed in the TIA portal by means of the online
function Assign IP address.
Table 7-3
Action
1.
2.
3.
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No.
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Note
35
Action
4.
5.
6.
Note
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No.
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7.2
Note
Please find a detailed instruction in the FAQ How is a project downloaded in the
CPU in STEP 7 (TIA portal) V11? in the Entry ID: 59728694.
Table 7-4
No.
1.
Action
Note
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2.
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No.
Action
Activate Start all to start the
block.
Exit the download with Finish.
4.
5.
3.
Note
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No.
Note
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6.
Action
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Note
weather data
production data
Table 8-1
No.
Action
In the HMI screen HEAD PLC,
enter the coordinates of every
field PLC. With these data, the
field PLCs calculate the current
position of the sun.
2.
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1.
Note
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No.
Action
Change to the visualization of
the field PLCs with the
navigation.
Here, the information is
displayed which the field PLCs
transmit to the head PLC.
4.
5.
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3.
Note
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9 Related literature
Related literature
This list is not complete and only represents a selection of relevant literature.
Bibliography
Table 9-1
Subject
Title
/1/
STEP7
SIMATIC S7-300/400
/2/
STEP7
SIMATIC S7-1200
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Table 9-2
Subject
Title
/1/
Reference to the
document
http://support.automation.siemens.com/WW/view/en/39040038
/2/
Siemens Industry
Online Support
http://support.automation.siemens.com
/3/
10
History
Table 10-1
Version
42
Date
Modifications
V1.0
10/2009
First version
V2.0
05/2013
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11.1
Number of bytes
10
1
in ms
4
in ms
8
in ms
16
in ms
32
in ms
min
234min
443min
500min
987min
1912
max
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3522max
3539max
3009max
5155
average
280average
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1752average
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min
357min
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min
300min
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7819
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351average
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100
200
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Number of bytes
10
100
200
1000
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in ms
8
in ms
16
in ms
32
in ms
1
in ms
min
1637min
1486min
1739min
3313min
6944
max
1834max
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8053max
12347
average
1740average
2781average
3775average
5131average
8490
min
1867min
1740min
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7202
max
2009max
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6799max
12598
average
1975average
2805average
3230average
4977average
8854
min
1657min
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3417min
7157
max
1857max
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12065
average
1721average
2777average
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min
1672min
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7000
max
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10
1
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max
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max
average
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200
1000
Copyright
11.4
in ms
4
198 min
219 max
209 average
203 min
221 max
215 average
204 min
222 max
213 average
202 min
221 max
211 average
in ms
8
187 min
362 max
257 average
187 min
590 max
277 average
186 min
792 max
287 average
193 min
795 max
444 average
in ms
16
192 min
536 max
304 average
192 min
402 max
280 average
200 min
2188 max
463 average
202 min
1833 max
475 average
in ms
32
385 min
643 max
479 average
457 min
576 max
523 average
378 min
1144 max
667 average
178 min
987 max
785 average
in ms
3108
803
1187
785
2617
1189
4441
789
1850
799
3062
1834
Number of bytes
10
100
200
1000
44
1
in ms
4
in ms
8
in ms
16
in ms
32
in ms
min
1694min
1550min
1538min
3124min
6223
max
1750max
3260max
2982max
4377max
10534
average
1704average
1812average
1972average
3353average
7537
min
1681min
1543min
1749min
3130min
6154
max
1741max
2344max
2649max
4321max
10668
average
1704average
2070average
2286average
3355average
7416
min
1681min
1532min
1538min
3128min
6256
max
1740max
3077max
3082max
7341max
11114
average
1703average
2178average
2428average
4182average
7502
min
1678min
1533min
1541min
3134min
6010
max
1790max
3659max
4126max
6807max
10124
average
1707average
2172average
2566average
4065average
7700
Datasync
V21, Entry ID: 39040038