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Warranty and Liability
Note The Application Examples are not binding and do not claim to be complete with
regard to configuration, equipment or any contingencies. The Application
Examples do not represent customer-specific solutions. They are only intended
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Table of contents
Warranty and Liability ................................................................................................. 2
Preface .......................................................................................................................... 4
1 Task ..................................................................................................................... 5
2 Solution............................................................................................................... 6
2.1 Solution overview ................................................................................. 6
2.2 Description of the overall solution ........................................................ 7
3 Basics ................................................................................................................. 9
4 Selecting the correct Measuring Device ....................................................... 13
4.1 Measuring devices ............................................................................. 15
4.1.1 7KM PAC3200/ 7KM PAC4200 .......................................................... 15
Application area .................................................................................. 15
More information ................................................................................ 15
4.1.2 ET 200SP Energy Meter (module) ..................................................... 16
Application area .................................................................................. 16
More information ................................................................................ 16
4.1.3 SIMOCODE pro V .............................................................................. 17
Application area .................................................................................. 17
More information ................................................................................ 17
4.1.4 SIRIUS monitoring relay 3RR24 and 3UG4841 ................................. 18
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Preface
Objective of this application
In this application, you learn about the basics of energy data acquisition as well as
the setup of an integrated and logic measuring concept.
The application example is divided into three topic areas.
Documentation is available for each topic area.
The following table shows what topics are described in the respective document.
The document you are currently reading is written in bold letters.
Table 1-1
Document Content
Part 1 Basic Knowledge In this document you learn about the basic
setup of a measuring system for energy
data with SIMATIC components.
Part 2 Programming the Data Acquisition This document mainly discusses
programming the PLC for connecting it to
the visualization.
Furthermore, commissioning the supplied
demo application is described.
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Part 3 Visualizing the Energy Data This document mainly discusses the
configuration of the visualization. Operating
the supplied faceplates and demo
applications is also explained in this
document.
1 Task
Introduction
Globally rising energy costs make more and more companies focus on energy
management, hence, energy data acquisition.
Energy data acquisition represents a part of the complete energy management
process. Further steps are the visualization of the energy data as well as the
further processing of the data with higher-level systems.
2 Solution
2.1 Solution overview
Schematic layout
The following diagram gives a schematic setup overview of the introduced solution:
Figure 2-1
Management level
Control level
Data flow
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Field level
Advantages
This application offers the following advantages:
Integrated acquisition concept
Flexible quantity framework
Independent of the used measuring device
Cost reduction through reduced configuration workload
Scope
This application does not include a description of
programming SIMATIC, SIMOCODE and SIRIUS components
creating HMI configurations
installation and wiring of measurement instrumentation
Basic knowledge of these topics is assumed.
Field level
The field level contains the sensors, switching and measuring devices for acquiring
the energy data and later controlling the energy-efficient plant.
The data is read and processed by a controller of the SIMATIC S7 product family in
real time. Subsequently, these data are automatically forwarded to the visualization
system.
For these automation tasks we supply you with program blocks which are
described in greater detail in a further document.
These blocks provide a uniform way of processing the energy data in order to
prepare and standardize them optimally for the visualization irrespective of the
measuring device.
Additionally, we supply you with the driver blocks required for the measuring device
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Control level
On the control level, the acquired energy data is displayed live and available to the
operator or energy manager in real time. For your staff this creates an awareness
for the energetic status of the plant.
When using SIMATIC WinCC V7.x or SIMATIC PCS7, you can use the SIMATIC
powerrate option for automated engagement in the plant and for load
management. This reliably prevents expensive load peaks in your plant.
On the control level, a first activation and compaction of the energy data can
already be performed. For this task, SIMATIC powerrate offers an intelligent
archiving mechanism which buffers the data in the controller and then stores it in
SIMATIC WinCC tag archives.
For visualizing the energy data we provide you with preprogrammed faceplates
which can display all of the online data relevant for the operator and energy
manager.
Your task only consists of connecting the data points from the controller with the
faceplate for your visualization system.
Management level
Long-term archiving of the energy data is performed on management level using
the SIMATIC B.Data energy data management system.
The management level deals with preparing the energy data to enable statements
based on this energy data (e.g. energy consumption per production day or
produced product).
KPIs are formed, the energy data is assigned to specific cost centers, and then the
data is represented as a report or dashboard in a defined cycle.
On this level, the requirements of ISO50001 play a major role.
Legal tax reductions can only be expected when complying with this standard.
An automated and low staff solution for meeting these requirements requires using
specific software for energy data management which also enables long-term
archiving of the energy data.
For further information on the products for this task, please refer to the following
link: www.siemens.de/simatic/energy-management.
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3 Basics
Current situation
Globally rising energy demands and the continually decreasing resources make
energy prices rise worldwide.
Where previously the intention was to produce as much as possible, it is now
becoming more and more important to produce as efficiently as possible.
Energy efficiency is increasingly developing into a success factor in production
industry.
The enormous saving potential in industry needs to be uncovered and used for
increasing the efficiency.
It is no longer a matter of cost reduction only, but also of preserving and protecting
our climate. For, energy efficiency is a matter of image.
Today, it can hardly be accounted for if a plant requires 60% of the normal energy
consumption during non-production times.
Energy prices
Surveys have revealed that in some European countries the price for electrical
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The following figure shows the electricity tariffs (without duties and taxes) for
average-sized industrial consumers in 2012 compared with other countries:
Figure 3-1
11.93 11.55
10.97
10.28
9.05 8.95
8.31 8.09
As apparent in Figure 3-2, the decisive part for calculating the demand rate is the
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average power intake of the last 96 hours or 15 minutes. This interval is given by
the energy provider and is fixed in the energy supply contract.
The figure below shows the 96 hours demand measurement principle as a graph.
Figure 3-3
kW
Power value
.
1h 1h 1h 1h
Table 3-1
Calculation
kW Power value
.
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15min
For this method of measuring the demand, the average power consumption is
calculated and saved every 15 minutes.
The demand rate is calculated as follows:
Table 3-2
Calculation
Depending on the payment model agreed with your energy supplier, it is sufficient
to adopt the hourly or quarter-hourly average values from the electrical energy data
into the energy data management system.
Only the online visualization requires measured data in shorter intervals.
Transparency
To find out the demand of your plant, you need to know what sort of energy is
required when and where at any time. This does not only apply for electrical
energy, but also for all other energy types, such as water, gas or pressed air.
This transparency is reached by measuring the energy data.
Intelligent measuring and switching-components by Siemens help you acquire the
energy data at any location in the production process and even visualize them
locally.
Should your energy management requirements change in the course of time, you
can simply switch over to a higher-level system using the integrated solutions by
Siemens and migrate all previously collected data.
It is important to know that the quality of the measured energy data is directly
related to the location of the measuring points in a plant.
The closer the energy data is recorded to individual consumers in the plant, the
more precise the later analysis of the location and type of energy flows produced
as well as the resulting costs.
Example
If in a plant, energy data is only recorded at the energy feed of the production lines,
it is impossible to determine which consumer has an unusually high energy
demand.
However, if the energy data is measured down to the individual consumer, it is
possible to analyze the development of the energy demand of this consumer.
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The figure below shows the measuring devices introduced in this documentation in
the intended area of production. The deeper the measuring depth of a plant, the
higher the transparency regarding the energy flow within the plant.
Figure 4-1
7KM PAC3200/
Measuring depth
Transparency
Note The devices SIMOCODE Pro V, SIRIUS 3RR24 and SIRIUS 3UG4841 are not
measuring devices in the classical sense.
These devices primarily fulfill a technological function. Acquisition of energy data
is an additional functionality which saves using an additional measuring device at
this measuring point.
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General
Figure 4-2
Application area
The display and the high number of measured values makes the 7KM PAC3200, or
the 7KM PAC4200 respectively, perfect for application at the energy feed of plant
or production line.
The 7KM PAC4200 additionally allows you to record and evaluate the network
quality directly on the level of the energy feed.
More information
Table 4-1
Document Link
General product www.siemens.de/sentron
information
Device manual 7KM http://support.automation.siemens.com/DE/view/en/26504150
PAC3200
Operating instructions http://support.automation.siemens.com/DE/view/en/26504261
7KM PAC3200
System manual 7KM http://support.automation.siemens.com/DE/view/en/34261595
PAC4200
Operating instructions http://support.automation.siemens.com/DE/view/en/34261817
7KM PAC4200
General
Figure 4-3
The analog input module Energy Meter is a compact and cost-efficient module for
the SIMATIC ET 200SP. Communication is performed with the PROFINET or
PROFIBUS protocol via the head module of the ET 200SP.
The configuration of the module can be changed during operation without
interrupting the data acquisition process. The actually supplied measured values of
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Application area
The ET 200SP Energy Meter is perfect for the application on the level of the
product lines or machines. The modular concept of the ET 200 SP enables a
scalable setup with up to 42 Energy Meter modules per head module and, at the
same time, makes efficient use of the space.
The module convinces due to its low procurement costs and high number of
available measuring devices.
More information
Table 4-2
Document Link
General product http://w3.siemens.com/mcms/distributed-io/en/ip20-
information systems/et-200sp/Pages/default.aspx
Analog input module http://support.automation.siemens.com/WW/view/en/73098696
Energy Meter manual
General
Figure 4-4
Additionally, the device offers the most important energetic process parameters
such as motor current, voltage, output and power factor.
The device measures currents of up to 820 A and records voltages of up to 690 V.
Furthermore, PROFIenergy is integrated in the SIMOCODE pro V basic device with
PROFINET. The motors centrally controlled via PROFINET can, for example, be
switched off during idle times. Additionally, measured values and status information
can be polled and further used via the PROFIenergy protocol.
Application area
The motor management system SIMOCODE pro V is used directly on consumer
level as a switching device. Due to the intelligent acquisition of energy data when
using the SIMOCODE pro V, an additional measuring device for energy data is not
required.
More information
Table 4-3
Document Link
General product www.siemens.de/simocode
information
Energy-efficient industrial www.siemens.de/sirius/energy-efficiency
controls
System Manual http://support.automation.siemens.com/WW/view/en/61896631
SIMOCODE pro
PROFINET
Manual SIMOCODE pro http://support.automation.siemens.com/WW/view/en/21463088
operator control block
General
Figure 4-5
The SIRIUS monitoring relay offers maximum protection for machines and systems
and, thanks to the IO link, you also communicate with the control level.
The 3RR24 relay (left in the picture) enables three-phase monitoring for upper and
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lower electrical current limits, phase failure, phase sequence and fault current.
Apparent and active current monitoring is possible for a range from 1.6 to 40A, or 4
to 40A (direct connection without transformer) at a voltage of up to 690V.
Apart from phase failure, phase sequence and ground fault detection, the relay
also offers an operating hours count and monitoring for active and apparent current
as well as current asymmetry.
The 3UG4841 relay (right in the picture) enables monitoring the power factor and
the active current of power consumers from 0.2 to 10A (direct connection without
transformer) from 90 to 690V (AC).
The relay is supplied via IO link or with an external auxiliary voltage of DC 24V and
is used for monitoring for under-current, over-current, as well as upper and lower
power factor limits, as selected.
For both devices, the error information is also transferred via IO link.
Application area
The SIRIUS monitoring relay provides the option of recording the energy data
directly at the consumer.
Due to the intelligent acquisition of energy data when using 3UG481 or 3RR24, an
additional measuring device for energy data is not required.
More information
Table 4-4
Document Link
General product www.siemens.de/sirius
information
General information on www.siemens.de/io-link
the IO link
Energy-efficient industrial www.siemens.de/sirius/energy-efficiency
controls
Device Manual http://support.automation.siemens.com/WW/view/en/54375430
3UG48/3RR24
Monitoring Relay
SIMATIC IO Link System http://support.automation.siemens.com/WW/view/en/65949252
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General
Figure 4-6
The SIRIUS 3RW44 soft starter is employed where ever the respective application
of the motor-driven machine requires soft starting and/or stopping
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The innovative inertia control makes 3RW44 suitable for 710 kW drives in standard
configuration or 1200 kW drives in root 3 circuit.
The integrated power management of the soft starter actively contributes to
avoiding current peaks.
The integrated bypass contacts leading to a lower internal power loss of the device
reduces the heating in the control cabinet.
The energy data provided by the device can be read via the optional PROFIBUS or
PROFINET communication module.
Application area
The SIRIUS soft starter 3RW44 provides the option of recording the energy data
directly at the consumer.
More information
Table 4-5
Document Link
General product www.siemens.de/soft-starter
information
Energy-efficient industrial www.siemens.de/sirius/energy-efficiency
controls
Manual Communication http://support.automation.siemens.com/WW/view/en/85261694
module PROFINET for
soft starter 3RW44
Reactive power X X
Energy counter X X X
Frequency X X
Conclusion
As you can see, the measuring devices 7KM PAC3200, 7KMPAC4200 as well as
the ET 200SP Energy Meter are perfectly suitable for application at the energy feed
of the plant, the production line or the machine. All three devices supply all relevant
measured values for these measuring points and offer a large range of values.
The motor management system SIMOCODE pro V and the monitoring relays
SIRIUS 3UG4841 and SIRIUS 3RR24 as well as soft starter 3RW44 on the other
hand, are perfectly suitable for the acquisition of the energy data directly at the
(motor-driven) consumer.
Using these devices enables a simple realization of energy data acquisition, not
only for new plants.
For existing plants, energy data acquisition can be realized at low expenses by
replacing the old control devices with intelligent SIRIUS monitoring relays.
Figure 6-1
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In many cases, controllers of the SIMATIC S7 product family provide the option of
storing data in CSV or text format on the controller and supply them, amongst
others, via the integrated web server.
This enables downloading the data from the controller in regular intervals or on
request at any time and then import them into the energy data management
system for permanent archiving.
The advantage of short-term archiving of energy data on control level is that data
can be compressed prior to the transfer to the SCADA or energy data management
system (e.g.: to the 15 minutes average relevant for payment).
SIMATIC powerrate takes on precisely this functionality and facilitates the
engineering, for example, due to the automatic generation of data points in
SIMATIC WinCC from the control program.
When using archiving on control level, any measured data is available to the
operator for online visualization. However, for long-term archiving only the data
relevant for the evaluation and accounting of energy data is transferred to the
energy management system.
On top of relieving the local network, you also save storage space on the server of
the energy data management system.
8 Related Literature
Table 8-1
Topic Title
\1\ Siemens Industry http://support.industry.siemens.com
Online Support
\2\ Download page of https://support.industry.siemens.com/cs/ww/en/view/86299299
the entry
\3\ Energy www.siemens.de/simatic/energy-management
management with
SIMATIC
\4\ Energy https://support.industry.siemens.com/cs/de/en/view/68043160
management in
the Industry
Online Support
9 History
Table 9-1
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