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Application description

10/2013

Realization of a Fault-

Tolerant Tunnel Lighting

System With S7-400HSIMATIC H-System S7-400H



Warranty and liability

Tunnel Lightning SystemItem-ID: 81066268, Version 1.0, 10/2013 2

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2 0 1 3 A l l r i g h t s r e s e r v e d

Warranty and l iability

Note The Application Examples are not binding and do not claim to be completeregarding the circuits shown, equipping and any eventuality. The ApplicationExamples do not represent customer-specific solutions. They are only intendedto provide support for typical applications. You are responsible for ensuring thatthe described products are used correctly. These application examples do notrelieve you of the responsibility to use safe practices in application, installation,operation and maintenance. When using these Application Examples, yourecognize that we cannot be made liable for any damage/claims beyond theliability 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 theseapplication examples and other Siemens publications – e.g. Catalogs – thecontents 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 shallnot 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 adeficiency or breach of a condition which goes to the root of the contract(“wesentliche Vertragspflichten”). The damages for a breach of a substantialcontractual 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.

Any form of duplication or distribution of these Application Examples or excerptshereof is prohibited without the expressed consent of Siemens Industry Sector.

CautionThe functions and solutions described in this article confine themselves to therealization of the automation task predominantly. Please take into accountfurthermore that corresponding protective measures have to be taken up in thecontext of Industrial Security when connecting your equipment to other parts of theplant, 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







1 Task



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1 Task

Introduction

The safe operation of a tunnel not only requires security systems (e.g. fireprotection systems), but also systems for ventilation, lighting and traffic signcontrol.

For this reason, these systems should also be integrated in the tunnel securityconcept and protected against damage.

Today, the use of redundant systems for tunnel operation is a mandatoryrequirement, so as to ensure a high level of security and availability. Thecomplexity of fault-tolerant systems is alleviated through the use of modular structures.The individual modules – in this example the systems for safe tunnel operation – can be easily separated from each other.

The example presented here focuses on the “tunnel lighting system” as a separate

module.

The lighting system is not merely important for traffic safety, it is also closelyconnected with the smooth flow of traffic. A high degree of illumination qualityincreases the driving safety and driving pleasure and thus conduces to a harmonictraffic flow.

Overview of the automation task

The following figure provides an overview of the automation task.

Figure 1-1

Control room 1

Control room 2

Light intensity areas

Entrance ligh t Interior light Exit light

Light sensor

level 1

level 2

level 3

Choose Intensity level

Descripti on of the automation task

The abrupt light changes when entering and leaving the tunnel shall be smoothedby a tunnel lighting system which meets the adaptability of the human eye. Theoperator control and monitoring functions shall be realized with the help of a localHMI panel.



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The following requirements shall be fulfilled by the automation system:

· Light intensity measurement outside the tunnel by means of a light sensor.

· Light intensity control:

– The entrance and exit lights depend on the values measured (three-step

control). The function and the values of the light at the entrance and exitremain always the same.

– The interior light depends on the time of day.

· Plausibility check of the outside sensor measurement: A defect sensor or external influences (e.g. fog) may lead to values that would not be measuredunder normal conditions (e.g. correctly working light sensor, no unusualexternal influences). This might lead to the measurement of a night situationduring daytime, for example.

· Realization of the tunnel lighting task using the fault-tolerant S7-400H systemon the basis of a function block.

The following points shall be realized with a local HMI panel:

· Changeover between automatic and manual mode.

· Control of the tunnel lighting levels.

· Specification of the light intensity limit values for the outside light sensor.

· Indication of group information about the status of the fault-tolerant system.

· Display of the result from the sensor plausibility check.

· Password protection for the HMI panel to prevent unauthorized manipulation.



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2 Solution

2.1 Overview

Schematic layout

The following figure provides a schematic overview of the solution and its mostimportant components:

Figure 2-1

Control room 1 Control room 2

ET 200M

HMI-PanelS7-400H

ET 200M

HMI-Panel S7-400H

Industrial Ethernet

PROFIBUS DP

synchronisation

FB 100

Tunnel_Lighting_

System

FB 100

Tunnel_Lighting_

System

Structure

Each control room is equipped with a fault-tolerant system (CPU 416-5H) includinga distributed I/O system (ET200M) and an HMI panel.The ET 200M is a redundant system (two head modules) which is additionallyprovided with an analog input module and a digital output module.The HMI panel (MP 370 Touch) is used for visualization and operator control.

Network integration is laid out as follows:

· The S7-400H stations and the HMI panel are connected via Industrial Ethernet

· In control room 1: Connection of the CPU with always the first head module of the ET 200M stations via PROFIBUS DP.

· In control room 2: Connection of the CPU with always the second head moduleof the ET 200M stations via PROFIBUS DP.

Note In our test setup, the use of an analog module for connection with the outsidesensor has been omitted, as the light intensity is entered manually in thisexample application.

Advantages

The solution presented here offers the following advantages:



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· Configuration and programming of the H-systems is identical to that of standard systems; only a few additional hardware components are required.

· No further configuration of the redundancy-specific functions andconfigurations. This is effected by the optional package “S7-H-Systems”

(integrated in STEP 7 Version 5.3 or higher).

· Integrated self-diagnosis function of the H-system (besides the standarddiagnosis functions) for advance error identification and indication, beforethese errors affect the process.

· Replacement of components (hot swapping) and performance of program andconfiguration changes while the system remains running.

· The use of two control rooms enables the local distribution of redundantsystems. If a fire breaks out in one control room, the redundant system willtake over and vital functions such as ventilation, lighting and traffic signalingwill remain operative.

· Realization with the function block FB 100 makes the system for tunnel lighting

control transparent to the user so that it can be easily modified or expanded.

Assumed knowledge

The following knowledge is assumed:

· Basic experience with STEP 7

· Basic experience with fault-tolerant systems, S7-400H

· Basic experience with WinCC flexible



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2.2 Descr iption of the core functionali ty

2.2.1 Function block FB 100 “ Tunnel_Lighting_System”.

Overview

The core element of the automation task is the function block“Tunnel_Lighting_System”.

This block is used to control the tunnel lighting for the entrance, interior and exitzones in automatic or manual mode.

The function principle of the block depends on the selected mode of operation.

Function princip le in automatic mode

In automatic mode, a light sensor measures the light intensity outside the tunnel.Depending on the result, the light intensity level of the entrance and exit light willbe adapted accordingly.

The table below shows the sensor limit values and the associated light levels for the entrance and exit zones.

Table 2-1

Light intensity measured by the outside sensor in Cd (lm/ser)

Level

Set_Val_Lev1 - Set_Val_Lev2 Level 1


Set_Val_Lev3 - Set_Sensor_MAX_VAL Level 3

The sensor intensity limits (Set_Val_LevX) are defined via the local HMI panel.

The interior light is also broken down into three levels and depends on the relevant

time of day.

Table 2-2

Time of day Level

Nighttime: 00:00 to 06:00 and 20:00 to 23:59 Nightlight

Sunrise or sunset time: 6:00 to 8:00;

18:00 to 20:00

Morning and evening twilight

Daytime: 08:00 to 18:00 Daylight

The functional interaction of the required light levels between entrance, exit andinterior light are listed in the following table:

Table 2-3

Time of day Expected light intensity Level

00:00 to 06:00

20:00 to 23:59

Set_Val_Lev1 - Set_VAL_Lev2 Level 1 or nightlight,respectively

6:00 to 8:00

18:00 to 20:00

Set_Val_Lev2 - Set_VAL_Lev3 Level 2 or evening andmorning twilight,respectively

08:00 to 18:00 Set_Val_Lev3 -Set_Sensor_MAX_VAL Level 3 or daylight,respectively



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The function block FB 100 “Tunnel_Lighting_System” performs a plausibility checkof the light intensity values measured by the sensor.If this check is negative, e.g. resulting from a defect or incorrect light sensor values(weather conditions: fog or rain), the required light levels for the entrance, exit or

passing zones will be activated automatically. In addition, a message will appear on the local HMI panel.

The light control system can be explained by the following example:

If a light intensity between “Set_Val_Lev3” and “Set_Sensor_MAX_VAL” ismeasured during daytime, light level 3 will be activated automatically for theentrance and exit zone. The interior light will be set to “daylight” in accordance withthe time of day.

.

Function princ iple in manual mode

In this mode of operation, the lighting of the entrance, exit and interior zones iscontrolled with the help of three manually controlled light levels. The light levels areactivated via the local HMI panel. The table below shows the relation between themanually controlled light levels and the associated light levels in the entrance, exitand interior zones.

Table 2-4

Desired light level Entrance and exit zones Interior zone

Entrance_Exit_Level1_Man Entrance_Exit_Level1 Nightlight

Entrance_Exit_Level2_Man Entrance_Exit_Level2 Morning and eveningtwilight

Entrance_Exit_Level3_Man Entrance_Exit_Level3 Daylight



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2.2.2 User interface for visualization on the local HMI panel

Each control room is equipped with a local HMI panel. The user interface for

visualization on the panels is identical.Visualization on the local HMI panels

Figure 2-2

Note Visualization can also be effected with WinCC flexible Runtime.







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2.3 Hardware and software components

The function example was reproduced using the following components.

Hardware components

Table 2-6

Component Qty. Order number Note

Power SupplyAC120/230V/10A 2 6ES7 407-0KA01-0AA0 Standard power supplymodule

Power Supply AC120/230V/5A 2 6ES7 307-1EA00-0AA0 Standard power supplymodule

CPU 416-5H 2 6ES7 416-5HS06-0AB0 Firmware V6.0 or later

IM153-2 HF 4 6ES7 153-2BA02-0XB0 Redundant structure

DO SM 322 for ET 200M 2 6ES7322-8BH00-0AB0 Digital output module

MP 370 Touch 2 6AV6 545-0DA10-0AX0 12’’ HMI panel

PC 1 For engineering purposes

SCALANCE X208 2 6GK5208-0BA10-2AA3

Note You may also use similar products which deviate from the list above. In thiscase, please note that changes to the sample code (e.g. different addresses)

may become necessary.

NotePlease also note that a pairwise and redundant installation requires the use of modules of the same product and firmware versions.

Software components

Table 2-7

Component Qty. Order number Note

SIMATIC STEP7 V5.5 +SP3 1 6ES7810-5CC11-0YC5..

Floating license for 1user

SIMATIC WinCCFlexible+ RUNTIME2008 SP3

1 6AV6612-0AA51-3CA5 Floating license for 1user



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Block library " Functional I/O Redundancy"

The block library “Functional I/O Redundancy” supplied with the S7-400 H optionspackage contains the following blocks supporting the redundant inputs andoutputs.

Table 2-8

Functional I/O redundancy blocks Applied Used in

FC 450 "RED_INIT": Initialization function X OB72, OB100 and OB102

FC 451 "RED_DEPA": Triggers re-enable function - -

FB 450 "RED_IN": Function block to read in redundantinputs

X OB1

FB 451 "RED_OUT": Function block to controlredundant outputs

X OB1

FB 452 "RED_DIAG": Function block for the diagnosisof redundant I/Os

X OB72, OB82,OB83 and OB85

FB 453 "RED_STATUS": Function block for redundancystatus information.

X OB1

Note Functionality and application of the blocks are described in the associated onlinehelp.

Further libraries

In addition, the following libraries from the SIMATIC library are required for thisexample:

·

“Redundant IO CGP V5.X“: Blocks for channel group granular redundancy· “Redundant IO CGP V4.X”: Blocks for channel granular redundancy

· “Redundant IO MGP V3.X”: Blocks for module granular redundancy

These libraries can be opened in the SIMATIC Manager by selecting "File > Open> Libraries"

Note For supplementary information on the subject of “Functional I/O Redundancy”,please refer to the manual: “SIMATIC Fault-Tolerant Systems S7-400H”, see \3\.

Sample files and projects

The following list shows all files and projects used in this application example.Table 2-9

Component Note

81066268_Tunnel_Lighting_System_v10.zip This zip file includes the

STEP 7- and WinCC flexible project.

81066268_Tunnel_Lighting_System _v10_de.pdf This document.



3 Realization of “Fault Tolerance”



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3 Realization of “ Fault Tolerance”

3.1 The automation system S7–400H

3.1.1 Description

The requirements on tunnel lighting control are fulfilled with the help of afault-tolerant system.

The automation system S7–400H satisfies the high demands on availability,intelligence and decentralization placed on modern automation systems.Furthermore, it also provides all functions required for the acquisition andpreparation of process data, including functions for the control, management andmonitoring of plants and aggregates.

3.1.2 Struc ture of the H-Systems

Overview

In order to ensure the reliable availability of the S7–400H system even if an error occurs, it is laid out in a redundant structure (master and standby station). Allessential components, such as the central processing unit (CPU), the power supplymodule and the hardware for connection between the two CPUs are doublypresent.

Usually, the master and standby stations are arranged in a centralized structure.

Figure 3-1








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3.1.3 Function principle

The H-system is suitable to establish a redundant system environment with two

CPUs and so ensures switchover to the standby system, if the master system fails.The event-controlled synchronization enables a fast and bumpless switchover between the two stations in case of a failure. The redundant CPU steps in andcontinues operation at the point of failure, so that no information or alarm will belost.

Under the aspect of user program processing, the S7-400H follows the sameprinciple as a standard system. The synchronization functions are integrated in theoperating system and run automatically and entirely in the background. Thesefunctions need not be considered in the user program.

In a redundant operating mode, the user programs in the two CPUs are completelyidentical and processing is performed in an event-controlled approach.

3.2 Distributed I/Os3.2.1 Description

One decentralized I/O module ET200M is connected as DP slave to the fault-tolerant automation system via PROFIBUS DP. The redundant structure isobtained by means of an additional ET 200M and an additional PROFIBUS DPconnection.

3.2.2 Redundant I/O structure

The add-on modules in the distributed I/O device ET200M, also referred to asinterface modules (IM), are used as a PROFIBUS DP interface. In a redundant I/O

structure, two interface modules (IMs) per ET 200M station are required and bothmust be set to the same bus address.This is to ensure bumpless continuation by the passive module, if the active add-onmodule fails during operation. The active interface is indicated by the LED ACT of the corresponding add-on module.

Connection of the redundant I/Os to the H-system is effected in the connected DPslave mode. This means that both the master station and the stand-by station areconnected with the two ET200M stations.

Figure 3-3

Redundant module pair






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The use of redundant I/O modules ensures that the connected I/Os remainavailable for the process, even if the following situations arise:

· Failure of a signal module

·

Failure of an interface module· Failure of the ET200M station

· Failure of an H-CPU

· Failure of a PROFIBUS-DP segment

3.3 Redundant connections

The demand for highest availability also includes the communication. Dependingon the specific network topology, redundant connections with automatic switchover in case of failure can be realized. If a failure occurs, the fault-tolerantcommunication will be continued automatically and entirely in the background.

Note In this application example, fault-tolerant communication has not beenconfigured.



4 Program Blocks for Tunnel Lighting Control



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4.1 General overview

Graphical illu stration

The graphic below shows the program structure of the entire STEP 7 project.

Figure 4-1

OB 1

FB 1„H-SYS_STATUS“

FB 100„Tunnel_Lighting_System“

DB 101„SYS_DATA_HMI“

DB 102„HMI_CONTROLLER“

SFC 1,

SFC 51

SFC 2, 3,4

FC 6, 8, 105

Meaning of the blocksThe blocks fulfill the following functions:

Table 4-1

Block Function

OB 1 Organization block; called at cyclic intervals.

FB 1 “H-SYS_STATUS” Provides information on the current status of the H-system.

FB 100“Tunnel_Lighting_System”

Tunnel lighting control system.

DB 101 “SYS_DATA_HMI” Display interface between HMI panel and CPU.

DB102 “HMI_Controller” Control interface between HMI panel and CPU.






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Overview of s tandard functions

The following table shows the functions from the S7 standard library required for the realization of the tunnel lighting control system.

Table 4-2

S7-Functions

Description Used in

SFC 1 SFC 1 "READ_CLK" (read system clock) is used to readthe clock time and date from the CPU.

FB1 “H-SYS_STATUS“

SFC 2 With SFC 2 "SET_RTM" (set runtime meter) , theelapsed-time counter of the CPU can be set to aspecified value.

FB100“Tunnel_Lighting_System“

SFC 3 SFC 3 "CTRL_RTM" (control runtime meter) is used tostart or stop the elapsed-time counter.


SFC 4 SFC 4 "READ_RTM" (read runtime meter) is used to

read out the elapsed-time counter.

FB100

“Tunnel_Lighting_System“SFC 51 SFC 51 "RDSYSST" (read system status) is used to read

an SZL sub-list or an excerpt from an SZL sub-list.FB1 “H-SYS_STATUS“

FC 6 The function FC 6 is used to extract the data formatDATE from the DATE_AND_TIME format. The DATE islocated between the limits DATE#1990-1-1 andDATE#2089-12-31.


FC 8 The function FC 8 is used to extract the data formatTIME_OF_DAY from the DATE_AND_TIME format.


FC 105 The “Scale Values” function is used to convert integralvalues into real numeric values.







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4.2 Function block “ H-SYS_STATUS” (FB 1)

4.2.1 Description

The function block “H-SYS_STATUS” (FB 1) is called in OB1 at cyclic intervals.

When the system function “RSYSST” (SFC 51) with the SZL-ID (system status listID) W#16#0071 is called within this function block, information on the current statusof the H-system will be read out.This information will then be buffered in the global data block “SYS_DATA_HMI”(DB101) for visualization of the H-system status on the local HMI panels.

For supplementary information on the individual system functions, please refer tothe manual: “System and Standard Functions for S7-300/400 Volume1/2“, see\5\.

4.2.2 Structure of the system status list W#16#0071

The sub-list identified by the SZL-ID (system status list ID) W#16#0071 providesinformation on the current status of the H-system. 16 bytes can be read out in total.

The data record is structured as follows:

Table 4-3

Content Length Description

redinf 2 bytes Information on redundancy

mwstat1 1 byte Status byte 1

Bits 0-3: Reserved

Bit 4: H-status of CPU in rack 0

=0: standby CPU

=1: master CPUBit 5: H-status of CPU in rack 1

=0: standby CPU

=1: master CPU

Bits 6/7: Reserved

mwstat2 1 byte Status byte 2

Bit 0: Synchronization between CPU 0 and CPU 1

=0: not possible

=1: possible

Bits 1/2: 0

Bit 3: Reserved

Bit 4:

=0: CPU not inserted in rack 0 =1: CPU inserted in rack 0 (in redundant mode: bit 4 = 0)

Bit 5: =0: CPU not inserted in rack 1

=1: CPU inserted in rack 1 (in redundant mode: bit 5 = 0)

Bit 6: Reserved

Bit 7: Standby-master switchover since last re-enable

=0: no

=1: yes

hsfcinfo 2 bytes Info word to SFC 90 "H_CTRL"

Bit 0:

=0: re-enable inactive






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Content Length Description

=1: re-enable active

Bit 1: =0: updating of standby enabled

=1: updating of standby disabled

Bit 2: =0: link-up to standby enabled

=1: link-up to standby disabled

Bit 3-8: Reserved

samfehl 2 bytes Reserved

bz_cpu_0 2 bytes Mode of CPU in rack 0

W#16#0001: STOP (update)

W#16#0002: STOP (memory reset)

W#16#0003: STOP (self-initialization)

W#16#0004: STOP (internal)

W#16#0005: STARTUP (cold restart)

W#16#0006: STARTUP (warm restart)

W#16#0007: STARTUP (hot restart)

W#16#0008: RUN (solo mode)

W#16#0009: RUN-R (redundant mode)

W#16#000A: HOLD

W#16#000B: LINK-UP

W#16#000C: UPDATE

W#16#000D: DEFECTIVE

W#16#000E: SELFTEST

W#16#000F: NO POWER

bz_cpu_1 2 bytes Mode of CPU in rack 1

(see values for bz_cpu_0)bz_cpu_2 2 bytes Reserved

cpu_valid 1 byte Validity of variables bz_cpu_0 and bz_cpu_1

B#16#01: bz_cpu_0 valid

B#16#02: bz_cpu_1 valid

B#16#03: bz_cpu_0 and bz_cpu_1 valid

hsync_f 1 byte Status of connection quality(valid only, if b bit 0 is set in mwstat2)

Bit 0: Fiber optics connection quality of the synchronization modules in the upper receptacle is limited

Bit 1: Fiber optics connection quality of the synchronization modules in the lower receptacle is limited

Bit 2-7: 0








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Parameter Data type Note

=1: possible

(Bit 0 from mwstat2 of SZL data record)

bz_cpu_0 WORD Operating status of CPU in rack 0(bz_cpu_0 of SZL data record)

bz_cpu_1 WORD Operating status of CPU in rack 1(bz_cpu_1 of SZL data record)

Output parameters

The output parameters have the following meanings:

Table 4-5


PLC_Rack_0_Master BOOL H-status of CPU in rack 0

=0: standby CPU=1: master CPU

PLC_Rack_1_Master BOOL H-status of CPU in rack 1

=0: standby CPU

=1: master CPU

Syn_Link_UP_01 BOOL Status of synchronization connection 01:Synchronization between CPU 0 and CPU 1

=0: not possible

=1: possible

Fiber_optic_Con_0 BOOL =0: faultless

=1: Fiber optics connection quality of thesynchronization modules in the upper

receptacle is limitedFiber_optic_Con_1 BOOL =0: faultless

=1: Fiber optics connection quality of thesynchronization modules in the lower receptacle is limited

PLC_Rack_0_Stop BOOL CPU rack 0 in STOP mode


PLC_Rack_0_RUN_S BOOL CPU rack 0 in solo mode


PLC_Rack_0_RUN_R BOOL CPU rack 0 in redundant mode

PLC_Rack_1_RUN_R BOOL CPU rack 1 in redundant mode






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4.3 Function block “ Tunnel_Light ing_System” (FB 100)

4.3.1 Description

The function block “Tunnel_Lighting_System” is used to control the tunnel lightingsystem for the tunnel entrance and exit zones.

A light sensor measures the light intensity outside the tunnel and via an analoginput the measuring signal is transmitted to the controller.Depending on the measured value, the light intensity in the entrance and exitzones is regulated in three levels (see chapter 2.2.1).

The interior light is also broken down into three levels according to the relevanttime of day (also refer to chapter 2.2.1). In performing these tasks, the functionblock uses the standard functions from the S7 standard library (see chapter 4.1).

The correlation between the individual light levels as required in the entrance, exitand interior zones is shown in the following table:

Table 4-6

Time of day Expected light intensity Level

00:00 to 06:00

20:00 to 23:59

Set_Val_Lev1 - Set_VAL_Lev2 Level 1 or nightlight

6:00 to 8:00

18:00 to 20:00

Set_Val_Lev2 - Set_VAL_Lev3 Level 2 or morning/evening twilight

08:00 to 18:00 Set_Val_Lev3 - Set_Sensor_MAX_VAL Level 3 or daylight

The plausibility check of the light intensity measurement by the sensor is performedwithin the function block on the basis of defined real light intensity values over thecourse of the day. If this plausibility check shows a negative result, e.g. due to

incorrect values supplied by the light sensor (weather conditions: fog or rain), or adefect, either daylight, nightlight or evening/morning twilight will be activated,depending on the clock time.

Note The light intensity measured by the outside sensor is defined manually at the“Tunnel_Lighting_System” block (FB 100).






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4.3.2 Avoiding light f lickering between activat ion levels

The selection of the light level for the entrance and exit zones depends on the light

intensity measured outside the tunnel by the light sensor.Table 4-7

Light intensity measured by the outside sensor in Cd (lm/ser)

Level



Set_Val_Lev3 - Set_Sensor_MAX_VAL Level 3

Weather-induced influences or similar reasons may cause variations in the resultsof light intensity measurement. If this occurs at the defined transitions to adjacentlight levels, fast changes in the light levels cannot be avoided.

Light intensity

Time00:00 06:00 08:00 18:00 20:00 23:59

Set_Value_Lev1

Set_Value_Lev2

Set_Value_Lev3

Set_Sensor_Max_

Value

Level 1

Level 2

Level 3

Nightlight NightlightDaylightTwilight Twilight

In order to avoid light flickering at least for minor variations, a hysteresis is used.

This hysteresis represents sort of an “environment” around the setpoint valuewithin the range of which the actual value may vary. The control system will reactonly, if the actual value exceeds the maximum value or falls below the minimumvalue of this range.

In this application, the hysteresis is controlled with the help of a timer. If the valuemeasured by the sensor exceeds a defined limit to the next light level, a timer willbe started (time value: 1 minute). If the sensor value levels out to the previousrange within this period, the timing element will be reset.

If the sensor value remains within the new range even after the period haselapsed, the relevant light level will be activated.

This reduction of light flickering is effective only in automatic mode.






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4.3.3 Descr iption of the interface

The figure and table below show the call interface of the user function block“Tunnel_Lighting_System” (FB 100).

Figure4-3

Input parameters

The input parameters have the following meanings:

Table 4-8


LIGHT_SENSOR_OUTSIDE INT Analog value measured in Cd (lm/ser)

AUTO_MODE_ON BOOL Automatic mode

MANUAL_MODE_ON BOOL Manual mode

ACTUAL_SYS_DATE_TIME DATE_ AND_TIME

Current system date and time

Entry_EXIT_LIGHTLEV_1_MAN BOOL Entrance and exit light at level 1 inmanual mode



SET_ELAPSED_T_COUNTER_PV BOOL Reset of elapsed-time counter to 0

Set_VAL_Level_1 REAL Sensor limit value for level 1 in Cd(lm/ser)

Set_VAL_Level_2 REAL Sensor limit value for level 2 in Cd

(lm/ser)






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Set_VAL_Level_3 REAL Sensor limit value for level 3 in Cd(lm/ser)

Set_Sensor_MAX_VAL REAL Maximum sensor value in Cd (lm/ser)

Output parameters

The output parameters have the following meanings:

Table 4-9

Name of the variable Data type Note

ENTRY_LIGHT_1 BOOL Entrance light, level 1



EXIT_LIGHT_1 BOOL Exit light, level 1EXIT_LIGHT_2 BOOL Exit light, level 2

EXIT_LIGHT_3 BOOL Exit light, level 3

TUNNEL_INSIDE_DAYLIGHT BOOL Interior light for the period08:00-18:00

TUNNEL_INSIDE_SUNUP_DOWN BOOL Interior light for the period06:00-08:00 and 18:00-20:00

TUNNEL_INSIDE_NIGHTLIGHT BOOL Interior light for the period20:00-06:00

ACTUAL_SYS_DATE DATE Current system date for visualizationon the local HMI panel

ACTUAL_SYS_TIME TIME_OF_DAY Current system time for visualizationon the local HMI panel

ENTRY_EXIT_DAY_ON BOOL Daylight for entrance and exit zone

ENTRY_EXIT_SUNUP_DOWN_ON BOOL Evening and morning twilight for entrance and exit zone

ENTRY_EXIT_NIGHT_ON BOOL Nightlight for the entrance and exitzone

ELAPSED_TIME_COUNTER_VAL INT Current value of the elapsed-timecounter

AUTO_MODE BOOL Automatic mode activated

MANUAL_MODE BOOL Manual mode activated

SEN_PLAUSIBILITIY_CHECK BOOL Sensor plausibility check

=0: no fault, sensor OK

=1: failed

LIGHT_INTENSITY_SENSOR REAL Current light intensity value

measured by outside sensor in Cd(lm/ser)






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4.4 Data block “ SYS_DATA_HMI” (DB 101)

Description

The data block “SYS_DATA_HMI” is used to collect and store all informationrequired for visualization from the two function blocks.

Descripti on of variables

The figure and table below show the variables of data block “SYS_DATA_HMI”(DB 101).

Figure 4-4






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The meaning of the variables is as follows:

Table 4-10

Variable Data type Note

Elapsed_Time_CounterVAL INT

SYS_Time TIME_OF_DAY Internal system time

SYS_DATE DATE Internal system date

AUTO_Mode BOOL Automatic mode activated

MANUAL_MODE BOOL Manual mode activated

Sen_Plausibility_Check BOOL Sensor plausibility check

=0: no fault, sensor OK

=1: failed

Entry_Light_1 BOOL Entrance light, level 1

Entry_Light_2 BOOL Entrance light, level 2

Entry_Light_3 BOOL Entrance light, level 3EXIT_Light_1 BOOL Exit light, level 1

EXIT_Light_2 BOOL Exit light, level 2

EXIT_Light_3 BOOL Exit light, level 3

T_Inside_Day_Light BOOL Interior light for the period08:00-18:00

EXIT_ENTRY_DAYLIGHT_ON

BOOL Daylight for entrance and exit zone

EXIT_ENTRY_NIGHTLIGHT _ON

BOOL Nightlight for entrance and exit zone

PLC_Rack_0_RUN_P BOOL CPU rack 0 in redundant mode

PLC_Rack_1_RUN_P BOOL CPU rack 1 in redundant modePLC_Rack_0_RUN_S BOOL CPU rack 0 in solo mode




SYNC_Link_UP_01 BOOL Status of synchronization link-up 01:Synchronization between CPU 0 andCPU 1

=0: not possible

=1: possible

Fiber_Optic_Con_0 BOOL =0: no fault

=1: Fiber optics connection quality of the synchronization modules in theupper receptacle is limited

Fiber_Optic_Con_1 BOOL =0: no fault

=1: Fiber optics connection quality of the synchronization modules in thelower receptacle is limited

T_Inside_Night_Light BOOL Interior light for the period 20:00-06:00

T_Inside_SunUP_Dw_ON BOOL Interior light for the periods06:00-08:00 and 18:00-20:00

EXIT_ENTRY_SunUP_Dw_ON

BOOL Evening and morning twilight for theentrance and exit zone






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Variable Data type Note

RACK_0_MSTR BYTE H-status of CPU in rack 0

=0: standby CPU

=1: master CPURACK_1_MSTR BYTE H-status of CPU in rack 1

=0: standby CPU

=1: master CPU

Light_Intensity_Sensor REAL Current light intensity value

measured by the outside sensor in Cd(lm/ser)

DT_date_and_time DATE_AND_TIME

Read system time and date

Reserve1 WORD

Reserve2 WORD



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5 Configuration

5.1 Address overview

The following figure illustrates the structure of the S7 project for the tunnel lightingcontrol system.

Figure 5-1


S7-400H„T_Control_Room1_PLC1“

ET 200M

HMI panel„Control_Room1_HMI1“

ET 200M

S7-400H„T_Control_Room2_PLC2“

HMI panel„Control_Room2_HMI2“

IP addresses

The modules are addressed as follows:

Table 5-1

Hardware Address Subnet mask

H-CPU_1

“T_Control_Room_1_PLC1”

192.168.0.130 255.255.255.0

H-CPU_2

“T_Control_Room_1_PLC2”

192.168.0.131 255.255.255.0

HMI Multipanel

“Control_Room_HMI_1”

192.168.0.3 255.255.255.0

HMI Multipanel“Control_Room_HMI_2”

192.168.0.4 255.255.255.0



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Connection ID

Communication between the modules is realized by means of S7 connections. Thefollowing table provides an overview:

Table 5-2

H-CPU_1 Control Center/T_Control_Room_1_PLC1

Local ID Partner ID Partner Type Active connection buildup

1 S7-connection_1 Control_Room_1_HMI S7 connection no


H-CPU_2 Control Center/T_Control_Room_2_PLC2




Table5-3

Control_Room_1_HMI


S7-connection_1 1 T_Control_Room_1_PLC1 S7 connection yes


Control_Room_2_HMI






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5.2 Informat ion on the hardware configurat ion

The STEP 7 project supplied with the functional example of a tunnel lighting control

system as presented in this document also includes the hardware configurationand the sample code.

For a better overview, the following chapter goes into some important STEP 7hardware settings. Basically, these settings can be modified (e.g. to adapt thesystem to individual requirements).

5.2.1 Settings for the H-CPUs

Table 5-4

No. Action Notes

1. Open a STEP 7 project in the SIMATIC

Manager. Select the H-system Tunnel andopen the hardware configuration dialog.

2. In the Properties dialog for the H-CPU youcan define the following properties:

· Definition of monitoring times:

– Max. scan cycle time extension

– Max. communication delay

– Max. disabling time for priority classes

– Min. I/O retention time

You may also click the “Calculate” button to initiate automatic calculation of the monitoring times.

· Allocation of the data block no. for theredundant I/O. These two data blocksare generated by the library“Redundant IO” at runtime.

3. Select “Properties> PN-IO Interface” toopen a dialog where you can define the IPaddresses of the two CPUs:

CPU1: IP address:192.168.0.130,subnet mask:225.225.225.0.

CPU2: IP address:192.168.0.131,

subnet mask:225.225.225.0.



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Note The data block number for the redundant I/Os should not be used somewhereelse in the user program. Previous data blocks will be deleted and generatedanew.

Note For further information on H-system configuration, please refer to the followingmanual: “SIMATIC Fault-tolerant systems S7-400H”, see \3\.

5.2.2 Conf iguration of the HMI panels

Table 5-5

No. Action Notes

1. Select the HMI station“Control_Room_1_HMI” and

open the hardware configurationdialog.

Select “Properties HMI IE>General> InterfaceProperties>Parameters” to opena dialog where you can definethe IP address and the network:

Control_Room_1_HMI:

IP address:192.168.0.3

Subnet mask:225.225.225.0

Control_Room_2_HMI:

IP address:192.168.0.4

Subnet mask:225.225.225.0



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5.2.3 Defining the I/O redundancy

The term ‘redundant I/Os” refers to input/output modules which are available in

twofold and redundantly configured and operated in pairs. The redundancy mode isdefined in the Properties dialog of the signal modules.

Table 5-6

No. Action Notes

1. Open the Properties dialog for the signal module “SM322 DO1624 V / 0.5 A” and select the“Redundancy tab” where youcan define the redundant modesettings.

If “2 modules” is selected in the

redundancy settings, all possibleredundant modules in other ET200M stations of the sametype will be listed automatically.

Click the “Find” button to displayall modules of the same type inthe redundant Profibusnetworks.

Note A current list of modules suitable for redundant operation can be found in thefollowing system manual:

“Fault-tolerant system S7-400H“, chapter “Signal modules for redundancy”,see \3\.



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5.2.4 Conf igurat ion of the S7 connect ion

To enable communication between the HMI panel and the H-CPUs, the relevant

S7 connections are to be created in NetPro.Table 5-7

No. Action Notes

2. To add a new connection, firstselect CPU 1. Use your rightmouse button or the shortcutCtrl+N to add a new connection.Now select the connection type"S7 connection” and confirmyour selection with OK.

3. The Properties dialog for the S7connection shows the local andthe partner address.

After a click on the OK button,the configured connection will beshown in the table.



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No. Action Notes

4. After having configured allconnections, click “Ethernet(1)”so that all connections will be

shown in the lower connectiontable.

Compile the networkconfiguration and download it tothe controller.

5.3 Configurat ion inst ruct ions for the HMI panel

5.3.1 Connection to the H station

An HMI panel can be connected directly to a SIMATIC H station only, if the H-CPUs have different IP addresses. As this requirement is met in this applicationexample, the HMI panel can be used for visualization and control.

Each control room is provided with its own HMI panel which shall always beavailable for operator control and monitoring even after a switchover betweenmaster and standby station.

This is effected by the internal system function “WechseleVerbindung” incombination with the status analysis of the H-CPUs.

If the SIMATIC H-station identifies the failure of an H-CPU, the“WechseleVerbindung” function will build up a connection to the other H-CPU.

The “WechseleVerbindung” function terminates the connection to the PLC currentlyin use and establishes a new connection with the specified controller.



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5.3.2 Connections in WinCC f lex ible

Configuration of connections

The HMI panels are connected with the two H-CPUs via Industrial Ethernet. Toenable the exchange of variables between these components, the relevantconnections must be specified in WinCC flexible.

· S7-connect ion_1 or S7-connection_3 is connected to the first H-CPU(T_Control_Room_1_PLC1) via Industrial Ethernet.

· S7-connect ion_2 or S7-connection_4 is connected to the second H-CPU

(T_Control_Room_2_PLC2) via Industrial Ethernet.

· Control_Raum_1_PLC_Changer_12 and/or Control_Raum_2_PLC_Changer_12 has been connected “manually” to anS7-300/400 unit via Industrial Ethernet and provides an auxiliary connectionfor the “WechseleVerbindung” function.

Figure 5-2

Note Please make sure to enter the receptacle and slot numbers correctly.

5.3.3 The system function “ WechseleVerbindung”

With the help of the internal system function “WechseleVerbindung” and the statusanalysis of the H-CPUs, a connection to the active H-CPU will be established,depending on the operating mode of the CPU.

Creation of variables

For the status analysis of the H-CPUs, one variable for each H-CPU must becreated in WinCC flexible (“Rack_x_PLC_x_Master”) and referenced to thecorresponding status variable in the data block "SYS_DATA_HMI". In concreteterms, this means:

· “Rack_0_PLC_1_Master”è Tag “RACK_0_MSTR” in DB 101 (DB101.DBB11)

· “Rack_1_PLC_2_Master”è Tag “RACK_1_MSTR” in DB 101 (DB101.DBB12)

These data block variables may show the following values:

· =0: CPU presently used as standby station

· =1: CPU defined as master.

In WinCC flexible, the acquisition type “cyclic continuous” is selected.

Figure 5-3



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Configuration of variables

In the Properties dialog for the WinCC tag “Rack_x_PLC_x_Master”, an upper limitvalue of “0” is defined in combination with the event parameter “High limit

exceeded” and the function “ChangeConnection”. As “Connection” partner, theauxiliary connection “Control_Room_x_PLC_Changer_12” is selected.

The addresses, slots and racks correspond to the connection parameters.

Figure 5-4

Function principle

Initial situation: The first CPU (T_Control_Room_1_PLC_1) is the master CPU; theassociated H-status in DB101.DB11 shows the value "1".

In WinCC flexible, the upper limit value of the variable “DB101.DBB11” is analyzed(limit value “0”). The “limit value” is exceeded (Master = “1”) and the"ChangeConnection" function is executed.

The panel terminates the connection “Control_Room_1_PLC_Change_12” andchanges over to the configured connection parameters of S7-connection_1.

Connection to the CPU is built up.

Initial situation: The second CPU (T_Control_Room_2_PLC_2) is the master CPU;the associated H-status in DB101.DB12 shows the value “1”.

In WinCC flexible, the upper limit value of the variable “DB101.DBB12” is analyzed(limit value “0”). The “limit value” is exceeded and the “ChangeConnection” functionis executed.

The panel terminates the connection “Control_Room_2_PLC_Change_12” andchanges over to the configured connection parameters of S7-connection_2.Connection to the CPU is built up.

Note A detailed description of how to connect a panel with a SIMATIC H-station isavailable under the entry ID: 23842653, see \6\



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6 InstallationThe following chapter describes all steps required to put the sample project intoservice on the basis of this application example and the hardware list.

6.1 Hardware and software instal lat ion

Hardware structu re of the H-stations

The figure below shows the hardware structure of the application.

Figure 6-1


S7-400H

ET 200M

HMI panel

S7-400H

ET 200M

HMI panel

SCALANCE

X208

SCALANCE

X208

Both control rooms are equipped with identical hardware components:

· H-CPU 416-5H

· PS 407

· HMI panel

· SCALANCE X208

· ET 200M (for redundant operation) with two IMs and one DO.



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Proceed as follows for hardware installation and connection in the control rooms:

Table6-1

No. Action Notes

1. Mount the individual modules to a suitablemodule rack.

See HW configuration

2. Connect the PS307 for ET 200M and the PS 407for the H-CPUs to power (230 V AC).

Take note of correct polarity.

3. Use the power supply modules to supply theother modules with 24V DC.

4. Connect the following devices with theSCALANCE X208:

· PROFINET interface of the CPU

· PROFINET interface of the HMI panels

· PROFINET interface of the Engineering PG

The Engineering-PG is used to load thecontroller and the HMI panel in the controlroom.

Depending on the controller or HMI panel tobe loaded, the PC will be connected with therelevant X208 of the control room.

5. Connect an IM of the ET200M with the CPU via

PROFIBUS. The following assignments apply:· Control room 1: IM1 with H-CPU1

· Control room 2: IM2 with H-CPU2

Interconnect the two control rooms as follows:

Table6-2

Nor. Action Notes

1. Connect the two SCALANCE X208 units.

2. Produce further connections to the IMs of theET 200M via PROFIBUS.The following assignments apply:



Connection of the redundant I/Os to the H-system is effected in the defined DP slavemode. This means that both master andstandby station are connected with the two

ET 200M stations.

3. Interconnect the H-CPUs via fiber optics cables.

Note The guidelines for the installation and setup of components are to be observed.Please refer to the corresponding device manuals.

NOTICE Connect the system to power only after having completed and checked allinstallation and setup work!

Software installation

The Engineering station is used as a configuration calculator for the S7 station. Thefollowing software components must be installed.

Table 6-3

No. Action Notes

1.. Install STEP 7 Follow the instructions of the installationprogram.

2. Install WinCC Flexible Follow the instructions of the installationprogram.





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Change the IP address

The figure below shows the network settings to be changed for the PG/PC.

Table 6-6No. Action Display

1. Select “Start > Settings >NetworkConnection >Local Connections” to open the Propertiesdialog for the Internet Protocol (TCP/IP).

In this dialog, select the internet protocol(TCP/IP) and open the Properties dialog.

Activate the radio button “Use following IP-address” and fill in the field as shown in thescreenshot. Click “OK” to close the dialogagain.

2. If your PG is provided with an IWLANinterface, it must be disabled.



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Change the IP address of the CPU

Before you can download the STEP 7 project to your CPU, the IP address of theH-CPU must be changed as shown in Table 4-1.Connect the Engineering PC with the corresponding SCALANCE X208.

Table 6-7

No. Action Display

1. Open the SIMATIC Manager and select theSTEP 7 project.

2. Select “Edit Ethernet Node…” from the “PLC”menu list.

3. Click the “Browse…“ button.



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No. Action Display

4. Select the desired module and confirm your selection with “OK”.

5. In the “Set IP configurations” field in the nextdialog, enter the IP address as described inthe chapter on H-CPU configuration.

Click the button “Assign IP Configuration”.Then click the “Close” button to close thedialog window.



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Set the clock time

When using the tunnel application it is important that the controller knows thecurrent clock time. Proceed as follows to set the clock in the CPU:

Table 6-8

No. Action Display

1. Open the SIMATIC Manager and select theSTEP 7 project.

2. Select the first CPU(T_Control_Room_1_PLC_1). Select the CPUmenu commands “PLC > Set Time of Day” toopen a dialog where the clock time can bedefined.

You can either use the clock time from thePG/PC or enter another value manually. Clickthe “ Apply” button to transfer the clock time

information to the PLC.





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Download the WinCC flexible project

To enable operation of the project via the operator control devices(Control_Room_1_HMI and Control_Room_2_HMI), the project data must betransmitted. Connect the Engineering PC with the corresponding SCALANCE

X208.

Proceed as follows to download the WinCC project to the operator control device(in this example to the HMI panels in control room 1; download to the other HMIpanel is performed analogously):

Table 6-10

No. Action Display

1. Open the SIMATIC Manager and select“Control_Room_1_HMI > WinCC flexible RT”using the “Open object” command or with adouble-click.

2. Select “Project > Transfer > Transfer…” todefine the settings for data transfer.Select Ethernet mode and enter the IPaddress of the HMI panel. Use the Transfer button to start the transmission of the projectto the operator control device.



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Overview

Prerequisite for the operation of the sample project is that the H-system, as well asthe HMI panels and the sample project have been loaded.

The sample project is operated via the HMI panel. Only the light intensity values for sensor simulation are entered directly into the variables table “VAT_1”.

This interaction is illustrated in the following figure:

Figure 7-1

or

Note The light intensity value is entered via the variables table VAT_1:0 – 27648 corresponds to a light intensity of 0 – 100.000 Cd (lm/ser).






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Log in and log out at the panel

Table 7-1

No. Action Display

1. Before you start operating the HMI panel, youmust first log in with the following access data:

User: “ Admin”

Password: “siemens”

After successful registration, the name of thelogged-in user will be shown.

Use the “Log out” button, if you wish to quit.

With the “Runtime OFF” button you can closethe Runtime program.

Define the sensor limit values via the HMI

Table 7-2

No. Action Display

1. Click the button SENSOR SET VALUES toopen a dialog where the sensor limit valuescan be defined.

Enter the following limit values:

Set Sensor Maximum Value = 100.000,00 Cd.

Set Value Level 3= 66666,67Cd.

Set Value Level 2 = 33333,34Cd.

Set Value Level 1 = 0,00 Cd.






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Switchover between operating modes

Table 7-3

No. Action Display1. Click the button AUTO-MODE to activate the

automatic mode.

The automatic mode will be reset, as soon asmanual mode (MAN-Mode) is selected andone of the following inputs is activated:

ENTRY_EXIT_LIGHTLEV1_MAN;ENTRY_EXIT_LIGHTLEV2_MAN;

ENTRY_EXIT_LIGHTLEV3_MAN.

Reset the elapsed-time coun ter of the CPU

Table 7-4

No. Action Display

1. Here you can set the elapsed-time counter of the CPU to 0.

You may also define a CPU-specific number for the elapsed-time counter.

The output field shows the current value of theCPU’s elapsed-time counter.

Note If the elapsed-time counter exceeds 32767 hours, it will stop and the SFC 4“READ_RTM” will show the error message “Overflow”.






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Define the light in tensity value

Table 7-5

No. Action Displays

1. Open the variables table “VAT_1” and activate

the monitoring mode (Strg+F7 or ).

Change this value in a range between0..27648 which corresponds to a light intensityof 0..100.000Cd (lm/ser).

The specified value can then be transferred tothe PLC by pressing the shortcut keys Ctrl+F9

or clicking the icon .

Simulate reaction to an error

For the period between 8:00 and 18:00 the light sensor shall show a value betweenSet_Val_Lev3 (66666,67) and Set_Sensor_Max_Val (100000), as expected.If a defect or environmental influences (e.g. fog) lead to an incorrect measuringresult, e.g. a value smaller than Set_Val_Lev3, an error reaction will be simulatedon the HMI.

Table 7-6

No. Action Display

1. We assume that the current CPU time is

14:00. Light level 3 is activated and theplausibility check does not show any problems(i.e. the measured light intensity complies withthe time of day).

Enter a light intensity value of 65104,17 Cd(integer number 18000) in the variables tableVAT_1 and transfer this value to the PLC.

The light intensity value of 65104,17 Cd is nolonger within the expected range betweenSet_Val_Lev3 (66666,67) andSet_Sensor_Max_Val (100000), but in a rangefor light level 2.

Since a plausibility check indicates an

incorrect measuring result (time of day andmeasured light intensity do not match), thefollowing message will appear on the HMI after a time T=1min (hysteresis time to avoid lightflickering):

“Sensor plausibility check failed, please checkthe outside sensor”.

Daylight illumination and light level 3 will beactivated for the entrance and exit zones.






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H-system status: H-system in solo mode

Table 7-7

No. Action Display

1. The HMI shows the status of the fault-tolerantsystem.

If a hardware error occurs, one H-CPUchanges over to STOP mode and the H-system is no longer in redundant mode.

Set the master H-CPU to STOP mode.

The system will switchover from the master tothe standby CPU. The previous master H-CPUbecomes the standby CPU and remains inSTOP mode, whereas the new master H-CPUtakes over the control functions.

H-system status: Synchronization cable disconnection

Table 7-8

No. Action Display

1. Any disconnection of the synchronization cablebetween the two H-CPUs is indicated on theHMI. The standby H-CPU will turn into a faultlocating mode (RUN and STOP LEDs startflashing at a frequency of 0,5 Hz) and the H-system is no longer in redundant mode.



8 Related literature


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8 Related literatureTable 8-1

Topic Title / Link\1\ Siemens Industry

Online Support

http://support.automation.siemens.com

\2\ Download page of this entry


\3\ Fault-tolerantsystems S7-400H


\4\ WinCC flexible2008

WinCC flexible 2008 Communication Part 1http://support.automation.siemens.com/WW/view/en/18797552

\5\ System andStandardFunctions for S7-300/400 Volume1/2.


\6\ How do youconnect a panelto a SIMATIC Hstation?


/7/ Step 7 Automating with STEP7 in STL and SCL

Author: Hans Berger

Publicis Publishing

ISBN 3895783242

/8/ SPC automation Automatisieren mit SPS – Theorie und Praxis

[Automating with PLC – Theory and Practice]

Authors: Günter Wellenreuther \ Dieter Zastrow

Publicis Publishing

ISBN 9783834802316

9 HistoryTable 9-1

Version Date Modifications

V1.0 10/2013 First version

http://support.automation.siemens.com/











http://support.automation.siemens.com/

Documents

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