Siemens Industry Online Support: Communication: Performant Data Synchronization Between Several Field and One Head PLC
Siemens Industry Online Support: Communication: Performant Data Synchronization Between Several Field and One Head PLC
S7-1200 Set 17
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Datasync
Entry-ID: 39040038, V3.1, 21.03.2016 2
Table of contents
Datasync 39040038
Table of contents
Warranty and liability ................................................................................................... 2
1 Task ..................................................................................................................... 4
2 Solution overview .............................................................................................. 5
2.1 Description of the core functionality ..................................................... 7
2.1.1 Overview and description of the user interface .................................... 7
2.1.2 Synchronization of the data .................................................................. 9
2.1.3 Simulation of the data in the field PLCs ............................................. 11
2.1.4 Time synchronization ......................................................................... 12
2.2 Hardware and software components used......................................... 12
3 The blocks of the data synchronization ........................................................ 14
3.1 Complete overview of the program blocks ......................................... 14
3.1.1 Program overview of the head PLC ................................................... 14
3.1.2 Program sequence in the field PLC ................................................... 15
3.2 Data blocks ......................................................................................... 16
3.2.1 The data block of the head PLC ......................................................... 16
3.2.2 The data block of the field PLC .......................................................... 20
39040038_DATASYNC_DOKU_V31_en.docx
1 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.
Figure 1-1
2 Solution overview
Display
The following figure gives a schematic overview of the most important components
of the solution:
Figure 2-1
DATASYNC_ DATASYNC_
HEAD HEAD
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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
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
Field PLC
Head PLC
1..4
Data structure of the Field PLCs:
• Zenith / azimuth angle
• Current weather data (temperature / wind)
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• Production data
It is always the head PLC which takes the initiative.
Since the field PLCs are only passive and wait for the request from the head PLC,
there is a separate “DATASYNC_SUB” block for the field PLC. Its task is the
supply and disposal of the send and receive data.
The data communication among the PLCs is displayed in images by the HMI panel.
For displaying and updating the images, the panel uses the send and receive data
of the head PLC.
Delimitation
This application does not include any
information concerning the programming language SCL.
basic information on industrial Ethernet.
information on astronomic algorithm or solar tracking.
Basic knowledge of these topics is assumed.
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.
Figure 2-4
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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.
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 The maximum admissible number of parallel connections varies depending in the
head PLC.
3
Multiplex z field PLCs
2 …
via several channels
1 z
n available
connection
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resources
1 2 3 z
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.
Communication blocks
The communication between the head PLC and the field PLCs is done by an ISO-
on-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
Block Description
TCON The TCON command establishes the communication
connection.
TDISCON TDISCON establishes the connection to the partner station.
TSEND TSEND sends data through an existing communication
connection.
TRCV The counterpart to TSEND is TRCV. With this command, data
can be received through an existing communication
connection.
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.
Hardware components
Table 2-3
Component No. Order number Note
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Program structure
The following graphic shows the complete user program of the head PLC.
Figure 3-1
DATASYNC_HE iDB
iDB TCON
DATASYNC_HE
AD iDB TRCV
AD
DATASYNC_HE iDB
AD
DATASYNC_ TSEND
HEAD TDISCON
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DB_RCV_ DB_SND_
DATA DATA
RD_SYS_T
Description
Table 3-1
Block Note
DATASYNC_HEAD Function block for data synchronization; to enable a parallel
data synchronization with all the other field PLCs (solar tracker),
the block is called several times - each time with a different
instance data block - cyclically in the application program.
Per field PLC, there is one call of the FB in the OB1 in this
Application Example (4 field PLCs 4 calls).
TCON, TRCV, TSEND Function blocks for the communication (see also chapter 2.1.2);
and TDISCON the enable the data communication.
DB_IPADDRESS Data block; contains the IP addresses of all the field PLCs.
DB_STATE Data block; contains status information of every field PLC.
Block Note
DB_MANAGE Data block; contains information setting up the communication
channels.
DB_RCV_DATA Data block; contains the receive data of the field PLC in
separate structures.
DB_SND_DATA Data block; contains the receive data of the field PLC in
separate structures.
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
iDB TCON
DATASYNC_ TRCV
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SUB
TSEND
DB_SND_RCV
_DATA
OB 1
SimpleAstro
Algorithm
WR_SYS_T
OB 30
OB 31
Description
Table 3-2
Block Note
DATASYNC_SUB Function block for data synchronization
TCON, TRCV, TSEND Function blocks for the communication (see also chapter 2.1.2);
the enable the data communication.
DB_SND_RCV_DATA Data block; contains sending data for and receiving data from
the head PLC.
SimpleAstroAlgorithm Function block; calculates the position of the sun on the basis of
the position data (longitude and latitude) sent.
WR_SYS_T Function block; responsible for reading out the current and local
time for the time synchronization.
OB 30, OB 31 Time-controlled organization block for the simulation of the
weather and production data
Overview
For establishing a communication connection, the data block “DATASYNC_HEAD”
needs more information
about the field PLC
– IP addresses
– number of project engineers
– feedback concerning the status of the connection
the maximum number of possible parallel connections
– with an S7-1200 as head PLC: eight connections
– with an S7-300/400 / WinAC as head PLC: 32 connections
about the sending and receive structure
– size of each structure
– storage location
All these pieces of information are stored in different global data blocks:
Table 3-3
Data block Responsible for...
DB_IPADDRESS IP addresses of the field PLCs used
DB_MANAGE Number of field PLCs, length of the structures, global trigger for
starting the data synchronization
DB_RCV_DATA Storage location for the received data of every field PLCs
DB_SND_DATA Storage for the data to be sent
DB_STATE Communication status of every field PLC
These data blocks are described in the following:
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
DB_MANAGE
The global data block “DB_MANAGE” serves for the communication of the
connections.
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Figure 3-4
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
4 The first attempt to establish a connection between the head and the field PLC
failed.
5 From the second attempt onwards (the status was “4” before), the system tries to
establish a connection for a certain period of time.
0 Field PLC available for access.
Since the send and receive structure must be identical for all field PLCs, we
recommend the use of templates (PLC data types).
PLC data types are defined data structures which can be opened several times in
the program. The structure of a PLC data type is composed of several components
which can have different data types. There are the following possibilities of using
PLC data types:
PLC data types can be used as data types for variables in a variable
declaration of code blocks or in data blocks
PLC data types can be used as templates for creating global data blocks with
the same data structure.
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.
Figure 3-7
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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
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:
Figure 3-10
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UDT_SUB_RCV_STRUCT
As the data type of the receive data, the template “UDT_HEAD_RCV_-STRUCT” is
used:
Figure 3-11
With these templates, the data block of the field PLC is defined.
Figure 3-12
Note 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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Parameters
The parameters have the following meaning:
Table 3-5
Parameters Type Data Meaning
type
ID WORD A unique number for the communication connection. If
the “DATASYNC_HEAD” is called several times, a
different number must be selected.
REQ BOOL With “True” the data synchronization is triggered and a
supply resource is assigned.
With “False”" the synchronization process is stopped and
the approval of the communication is initiated
NR_SUBSTATIONS INT Number of project field PLCs
DB_NR_IPADDRESS Number of the data block
“DB_IPADDRESS”.
DB_NR_STATE INPUT Number of the data block
“DB_STATE”.
DB_NR_SND_DATA Number of the data block
“DB_SND_DATA”.
LEN_SND_DATA Length of the send structure
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Parameters
The parameters have the following meaning:
Table 3-6
Parameters Type Data type Meaning
ID WORD A unique number for the communication connection.
REM_IP1 First part of the IP address of the head PLC
REM_IP2 INPUT Second part of the IP address of the head PLC
USINT
REM_IP3 Third part of the IP address of the head PLC
REM_IP4 Fourth part of the IP address of the head PLC
SND_DATA Pointer to the send section
IN/ OUT VARIANT
RCV_DATA Pointer to the receive section
Send data
The command “TSEND” sends data through an existing communication
connection. “TSEND” is carried out in several cycles.
The block receives the required information through the input parameters in the
“DATASYNC_X” block.
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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
length of the area in number of bytes.
This information is transmitted by the parameters at the “DATASYNC_X” block.
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 Instance DB
DB_IPADDRESS DATASYNC-HEAD
ACT_SUBNET_NUMBER:=3
IP address
4- Bytes
Field PLC 1
IP addresse
Field PLC 2
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Offset: 2 * 4-Bytes
IP address
Field PLC 3
IP address
IP address Field PLC 3
Field PLC z
5 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.
DATASYNC_ DATASYNC_
DATASYNC_
HEAD DATASYNC_
HEAD
DATASYNC_
HEAD DATASYNC_
HEAD
DATASYNC_
HEAD DATASYNC_
HEAD
HEAD HEAD
...
1, 4, 8, 16, 32 Field-PLCs S7-1200 with function
block DATASYNC_SUB
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
Type of head PLC S7-1200 (CPU 1215), WinAC (IPC 227D)
Number of substations 1, 4, 8, 16, 32
Size of the area to be synchronized (in 10, 100, 200, 1000
bytes)
Program load (in ms) 6, 50
Measure cycle
The measuring clock is started before the connection to the first substation is built
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up. The end of a measure cycle is the point in time when all the substations have
been synchronized once.
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
4000
200 Byte,6 ms
200 byte, 6 ms Programmlast
program load
3000
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Zeit in ms
Time in ms
2000
S7-1200
1000 WinAC
0
1 4 8 16 32
Anzahl
NumberSubstationen
of substations
Figure 5-3
10000
1000
1000 Byte,
byte, 5050
msms Programmlast
program load
8000
in ms
Time in ms
6000
S7-1200
Zeit
4000
WinAC
2000
0
1 4 8 16 32
Anzahl
NumberSubstationen
of substations
Detailed values
The detailed values of the performance measurement are listed in chapter 11
“Appendix A: Measured Data”.
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:
The first two observations can be attributed to the increased performance of
the current Intel atomic chip of the IPC as compared to the processor of the
S7-1200 CPU.
Up to a number of 8 substations there is a call of the FB “DATASYNC_HEAD”
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per substation in the OB1. Accordingly, the computing time increases, but the
synchronization time does not increase proportionally to the number of
substations, since the connection resources can be used in parallel.
From a number of 8 substations or more, the maximum number of connection
resources of the two head PLC is used up, so that the parallel processing is
completed by a serial processing. For more details about the behavior of the
program, please refer to Figure 2-5.
6 Installation
PG
192.168.0.50 192.168.0.45 192.168.0.55
24V 24V 24V
X208
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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 The installation guidelines for these components must always be observed.
Application software
For each head PLC, a sample program is available.
Unpack the zipped code folder 39040038_DATASYNC_CODE_v22.zip from the
download area into a folder you chose.
In this folder, there are the STEP 7 V13 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.ap13
with a double click.
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PG / PC
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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
No. Action Note
1. Open the portal view of the TIA
portal project.
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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. Action Note
1. At first, select the first field PLC.
Table 8-1
No. Action Note
1. In the HMI screen HEAD PLC,
enter the coordinates of every
field PLC. With these data, the
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Datasync 39040038
9 Related literature
This list is not complete and only represents a selection of relevant literature.
Bibliography
Table 9-1
Subject Title
/1/ STEP7 Automating with STEP7 in STL and SCL
SIMATIC S7-300/400 Author: Hans Berger
Publicis MCD Verlag
ISBN: 978-3-89578-397-5
/2/ STEP7 Automating with SIMATIC S7-1200
SIMATIC S7-1200 Author: Hans Berger
Publicis MCD Verlag
ISBN: 978-3-89578-355-5
This list is not complete and only represents a selection of relevant information
Siemens AG 2016 All rights reserved
Table 9-2
Subject Title
/1/ Reference to the http://support.automation.siemens.com/WW/view/en/39040038
document
/2/ Siemens Industry http://support.automation.siemens.com
Online Support
/3/
10 History
Table 10-1
Version Date Modifications
V1.0 10/2009 First version
V2.0 05/2013 Complete review of code and document.
V3.1 03/2016 New warranty, Change V12 to V13 SP1
Datasync 39040038
Number of bytes 1 in ms 4 in ms 8 in ms 16 in ms 32 in ms
10 min 234 min 443 min 500 min 987 min 1912
max 323 max 3522max 3539max 3009 max 5155
average 280 average 741 average 1752average 2047 average 2334
100 min 357 min 376 min 507 min 1111 min 1923
max 459 max 2673max 3570max 4002 max 4413
average 399 average 725 average 982 average 2100 average 2417
200 min 342 min 411 min 449 min 956 min 2134
max 430 max 3467max 3446max 4052 max 6077
average 392 average 823 average 939 average 1356 average 3526
1000 min 300 min 387 min 470 min 1116 min 2860
max 393 max 3484max 3066max 4004 max 7819
average 351 average 772 average 924 average 2115 average 3395
39040038_DATASYNC_DOKU_V31_en.docx
Siemens AG 2016 All rights reserved
Number of bytes 1 in ms 4 in ms 8 in ms 16 in ms 32 in ms
10 min 1637 min 1486min 1739min 3313 min 6944
max 1834 max 4710max 6899max 8053 max 12347
average 1740 average 2781average 3775average 5131 average 8490
100 min 1867 min 1740min 1724min 3494 min 7202
max 2009 max 4793max 6601max 6799 max 12598
average 1975 average 2805average 3230average 4977 average 8854
200 min 1657 min 1611min 1661min 3417 min 7157
max 1857 max 4757max 5743max 7205 max 12065
average 1721 average 2777average 3158average 4726 average 9226
1000 min 1672 min 1484min 1558min 3468 min 7000
max 1952 max 4645max 5010max 8668 max 12709
average 1853 average 2698average 3149average 5168 average 8830
Datasync 39040038
Number of bytes 1 in ms 4 in ms 8 in ms 16 in ms 32 in ms
10 min 198 min 187 min 192 min 385 min 3108
max 219 max 362 max 536 max 643 max 803
average 209 average 257 average 304 average 479 average 1187
100 min 203 min 187 min 192 min 457 min 785
max 221 max 590 max 402 max 576 max 2617
average 215 average 277 average 280 average 523 average 1189
200 min 204 min 186 min 200 min 378 min 4441
max 222 max 792 max 2188 max 1144 max 789
average 213 average 287 average 463 average 667 average 1850
1000 min 202 min 193 min 202 min 178 min 799
max 221 max 795 max 1833 max 987 max 3062
average 211 average 444 average 475 average 785 average 1834
Number of
substations
Number of bytes 1 in ms 4 in ms 8 in ms 16 in ms 32 in ms
10 min 1694min 1550min 1538min 3124min 6223
max 1750max 3260max 2982max 4377max 10534
average 1704average 1812average 1972average 3353average 7537
100 min 1681min 1543min 1749min 3130min 6154
max 1741max 2344max 2649max 4321max 10668
average 1704average 2070average 2286average 3355average 7416
200 min 1681min 1532min 1538min 3128min 6256
max 1740max 3077max 3082max 7341max 11114
average 1703average 2178average 2428average 4182average 7502
1000 min 1678min 1533min 1541min 3134min 6010
max 1790max 3659max 4126max 6807max 10124
average 1707average 2172average 2566average 4065average 7700