ConfigurationExample x8 S7 1200 USS v1d0 en 1

Cover sheet
Simple networking and cascading of drives

with S7-1200, SINAMICS G110 and KTP600
Configuration Example X8 y May 2009
Applications & Tools

Answers for industry.
Warranty, liability and support
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Configuration Example X8
V1.0, ID number: 37604154
1 Automation Task
Copyright Siemens AG 2009 All rights reserved

ConfigurationExample_x8_S7-1200_USS_v1d0_en.doc
Table of Contents
1
1.1
1.2
1.3
Automation Task............................................................................................. 4
Application automation task.............................................................................. 4
Control components.......................................................................................... 4
Component list.................................................................................................. 5
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Automation Solution ...................................................................................... 7

Connection diagram.......................................................................................... 7
Addressing of bus stations and terminating a RS485 bus with USS protocol... 8
Controlling bus stations via RS 485 bus ........................................................... 9
Technological Features .................................................................................. 11
Controlling the pumped amount...................................................................... 12
Balancing of operating hours .......................................................................... 13
Maintenance ................................................................................................... 14
3
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.2
3.3
3.4
3.5
3.6
3.7
Configuration ................................................................................................ 16
Installing and wiring the hardware .................................................................. 16
Connect S7-1200 with PG/PC ........................................................................ 17
Load project in the S7-1200 CPU1214C ........................................................ 18
Load project into the SIMATIC Panel KTP600 ............................................... 19
Connect SIMATIC Panel KTP600 and S7-1200 CPU 1214C ......................... 20
Close off RS 485 bus with terminating resistors ............................................. 20
Parameterization of frequency converters ...................................................... 20
Enabling the pumps ........................................................................................ 25
Change language settings .............................................................................. 26
Moving pump P1 manually ............................................................................. 26
Move pump P1 to P4 automatically on demand ............................................. 28
Procedure with balancing of operating hours ................................................. 30
Procedure for excluding pump P3 due to servicing ........................................ 31
4
4.1
4.2
Code Elements.............................................................................................. 34
Preliminary remarks........................................................................................ 34
Download........................................................................................................ 34
History ........................................................................................................... 35
V1.0, ID number: 37604154
1 Automation Task
Automation Task
1.1
Application automation task

A water user shall be supplied with water on demand via four pumps.
Assuming an output of 100% for each pump, an output of 400% is to be
generated by cascading all four pumps.
By switching pumps on and off an equal load for all pumps shall be ensured
taking into consideration the operating times. The pumping output of a
pump which has been released for maintenance shall be automatically
taken over by a pump with free capacity.
Apart from the above described automatic operation, it shall also be
possible to operate each pump manually.
In order to take into consideration the various pump types, it shall be
possible to operate all pumps in positive and negative direction.

Figure 1-1
Service
Pump 1
Pump 2
Pump 3
Pump 4
Consumer
Water reservoir
1.2
Control components
Four asynchronous motors are each connected via the communication
module CM1241 (RS485) with the frequency converter SINAMICS G110
and are to be controlled by a S7-1200 controller (CPU1214C).
Communication between control and frequency converter will be performed
by USS protocol.
Operation and visualization takes place via a KTP600 touch panel which is
connected via an Ethernet connection to the S7-1200 controller.
V1.0, ID number: 37604154
1 Automation Task
STEP7 Basic v10.5 is used as configuration tool for the control program
and the HMI.
Figure 1-2
3
Ethernet
USS Protokoll via RS485

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Power module PM1207
Communication module CM 1241
Basic Panel KTP600
Frequency converter SINAMICS G110
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SIMATIC S7-1200 CPU
Component list
Products
Table 1-1
Component
No.
MLFB / Order number
S7-1200 CPU1214C
6ES7 214-1AE30-0XB0
RS485 communication
module CM1241
6ES7 241-1CH30-0XB0
DC24V power supply unit

PM 1207
6EP1 332-1SH71
SINAMICS G110 120W

without filter; USS version,
FS A,
6SL3211-0AB11-2UB1
BOP
min. 1
6SL3255-0AA00-4BA1
Asynchronous motors 4pole, aluminum frame,

120W
1LA7060-4AB10
Simulator module for 14

inputs
6ES7 274-1XH30-0XA0
Basic KTP600 panel

(color, PN)
6AV6 647-0AD11-3AX0
V1.0, ID number: 37604154
Note
DC/DC/DC
Optional
1 Automation Task
Accessory
Table 1-2

Component
No.
Note
PROFIBUS cable:
Length [m]
PB FC Standard
Bus line 2-wire
Shielded
Lot size: Max. 1,000m

Minimum quantity:
20m (sold by the
meter)
6XV1830-0EH10
Profibus connector with

PG port
6ES7972-0BB12-0XA0
Adapter for attachment of

the SINAMICS frequency
converter FS A to the top
hat rail
6SL3261-1BA00-0AA0
Optional
Filter for low leakage

currents
6SE6400-2FL01-0AB0
Optional
Commutation inductor
6SE6400-3CC00-4AB3
Optional
Ethernet connection cables 2

between KTP600, S7-1200
CPU and PC
Note
MLFB / Order number
6XV1870-3QH20
The configuration, as it is, is intended for industrial application. For energy

supply, industrial networks are usually implemented. It is therefore not necessary
to use special filters/inductors with low leakage currents.
If the configuration is used in sensible electricity networks (e.g. PCs on the same
network), filters or inductors should be used.
Programming package
Table 1-3
Component
STEP 7 Basic V10.5
No.
1
MLFB / Order number
Note
6ES7 822-0AA0-0YA0
V1.0, ID number: 37604154
2 Automation Solution
Automation Solution
2.1
Connection diagram
Figure 2-1 Wiring

Contactor/
switch
Switch
Fuse
230VAC Fuse

KTP600
Inductor
(optional)
Inductor
(optional)
Inductor
(optional)
Inductor
(optional)
Filter
(optional)
Filter
(optional)
Filter
(optional)
Filter
(optional)
PSU 1200 CM1241 +

S7-1200 CPU1214C
Drive 1
Note
Drive 2
Drive 3
Drive 4
The 4-pole asynchronous motors with 400V/230V star/delta winding have

to be connected to the frequency converter in a delta connection
( 230V).
Figure 2-2 Wiring detail for bus connection

RS485 - CM1241
Terminal strip
PROFIBUS
cable
V1.0, ID number: 37604154
Attention
What should be done to prevent electromagnetic interference:

Make sure a good conductive connection between the frequency converter

and the (grounded) metal mounting plate is provided.
Ensure all devices in the cabinet are earthed using short earthing lines with a
large diameter and are connected to a common earthing point or earthing
bar.
Ensure that the S7-1200 CM connected to the frequency converter is
connected to the same earthing or earthing point as the frequency converter
using a short line with a large diameter.
Please use shielded control lines, e.g. a SIEMENS Profibus cable for setting
up the RS485 bus. Ground the shield on the converter side with shield
connections.
Control lines must be installed separately from power cables in separate
installation channels, if possible. Crossings between power and control lines
should be at 90 angle.
Connect the protective conductor of the motor to the earth connection (PE)
of the respective frequency converter.
The line ends should be properly terminated and unshielded lines kept as
short as possible.
Use shielded lines for motor connections, earth the shielding both on the
converter and the motor side using cable clamps.
2.2
Addressing of bus stations and terminating a RS485 bus with

USS protocol
An RS485 bus transmitting data using the USS protocol via a 2-wire
connection between a master (e.g. CPU 1214C) and up to 31 slaves
(e.g. SINAMICS G110). It is necessary here to identify each slave via a
unique address between 1 and 31.
The USS protocol allows only one master which does not require an
assigned address.
In order to avoid reflections at the bus start or end, which may cause a
falsified data signal, the bus must be closed off with terminating resistors as
illustrated in Figure 2-4.
As illustrated in Figure 2-5, in this example it is done on the control side via
the PROFIBUS connector and at SINAMICS G110 of pump 4 by switching
on both assigned DIP switches below the BOP.
V1.0, ID number: 37604154
Figure 2-3
B
A
B
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1
Pump 1
Pump 2
Pump 3
Pump 4
Address: 1
Address: 2
Address: 3
Address: 4

Figure 2-4
Switch to ON
2.3
Controlling bus stations via RS 485 bus
USS protocol
The USS protocol was developed in order to exchange process data

between a central controller and bus stations on a RS485 bus. Each bus
station is identified here via a unique bus address.
Even if PROFIBUS uses the same physical RS485 technology, PROFIBUS
and USS protocol differ considerably.
Communication of the S7-1200 controller is performed via the
communication module with the bus station by integrating the STEP7 Basic
library included in delivery.
V1.0, ID number: 37604154
Communication with bus stations
For a command to be sent from control to the bus station, a function is

necessary that controls communication between CPU and the bus stations.
This is achieved using the "USS_PORT" block.
During each call of the block, the communication with a bus station is
processed. Communication with the bus stations is asynchronous. This
means that the S7-1200 controller runs several cycles before the data
exchange with a bus station is completed. This is why the block is usually
called from a delay alarm OB in a defined interval. However, it can also be
called up cyclically, which does not increase the number of transactions.
The "port" block parameter specifies the communication module via which
the bus is connected. The "USS_DB" parameter defines the
"USS_DRV_DB" instance data block in which the send and receive data is
called up or stored (Figure 2-5). The instance data block is a buffer which
all USS_Operations can access.

Note
An extensive description of the blocks and a calculation of the call

intervals of "USS_PORT", depending on the transmission rate can be
found in the S7-1200 system manual, chapter 6.3.
Transferring and reading data to bus stations
The "USS_DRV" block exchanges data with the bus station by creating
request messages and evaluating answer messages. The instance data
block is used as storage. For each bus station an own "USS_DRV" block
has to be used.
Up to 16 called "USS_DRV" blocks share an instance data block. Up to
16 bus stations can be managed with a "USS_DRV" block.
Using the parameters on the left side of the "USS_DRV" block the switchon signal (RUN), for example, or the desired speed is sent to the assigned
bus station.
The status signals of the bus station are provided by block "USS_DRV" on
the right block side. The current speed of the bus station is indicated by the
parameter "Speed" (Figure 2-5).
10
V1.0, ID number: 37604154
Figure 2-5
USS_DRV_DB
Reserved
1
Data Drive 1
State
2
3
Communication via RS485
4
5
Control
6
7
8
9
s
s
10
11
12
13

14
15
16
2.4
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1
Address 1
Technological Features
As mapped out in Figure 2-6, the control program takes into consideration
that activated and cascaded pumps must have an identical flow rate. This
prevents the throttle check valves from reducing the water flow rate.
Figure 2-6
Throttle check valve
Consumer
Pump 4
Water reservoir
V1.0, ID number: 37604154
11
The delivery head H of each pump depends on the conveying current Q.

Figure 2-7 shows how the delivery head is increased for a quadrupled
conveying current when cascading 4 pumps.
Figure 2-7
Systems duty point
Delivery head H
Characteristic
1 Pump
Characteristic
2 Pumps
Characteristic
3 Pumps
Characteristic
4 Pumps
Btot.
Bthree
Btwo
System characteristic
Bindividual
Qindividual
Q2P parallel
Q3P parallel

Q4P parallel
100%
200%
300%
400%
Conveying current Q
2.5
Controlling the pumped amount

The control algorithm shall be explained using the following graphic.
12
The algorithm controls pump P1 when demand <100%
If the demand increases to >100% and remains below 200%, the load is
distributed between pump P1 and P2. For a load of 200% both pumps
are used at 100% load each.
distributed between pump P1, P2 and P3. For a load of 300% all
3 pumps are used at 100% load each.
distributed between pump P1, P2, P3 and P4. For a load of 400% all
V1.0, ID number: 37604154
Figure 2-8
400%
Setpoint
2/3
1
3/4
P1
1/2
0
2/3
2/3

2.6
15
20
P2
1
3/4
10
15
P3
1/2
10
1
3/4
P4
1/2
Note
10
1/2
0
2/3
1
3/4
The used algorithm assumes that all used pumps have the same
characteristics!
Balancing of operating hours
Recording the pump operating hours
The control program records the operating hours of each pump. As soon as
a pump is running (even if only slowly) it is considered as switched on.
The speed of the pumps does not enter the calculation of the operating
hours. Only the effective runtimes are calculated.
Switch-on priorities of the frequency converters
Each pump is assigned a priority, which controls which pump will be

switched on next when required. The pump with the lowest operating time
receives the highest priority. This means that this pump is the next to be
switched on if required.
The control algorithm shall be explained using the following graphic Figure
2-9.
The algorithm controls pump P4 if the demand is <100%, since with

5 hours it has the lowest amount of operating hours.
distributed between pump P4 and P3. Pump P3 is selected as with
10 hours it has the lowest number of operating hours. For a load of
200% both pumps are used at 100% load each.
V1.0, ID number: 37604154
13
distributed between pump P4, P3 and P2. Pump P2 is selected as with
15 hours it has the lowest number of operating hours. For a load of
300% all 3 pumps are used at 100% load each.
distributed between pump P4, P3, P2 and P1. For a load of 400% all
Figure 2-9
400%
Setpoint
2/3
1
3/4
1/2
20

2/3
25
15
15
20
25
P1
P2
1
3/4
P3
1/2
10
15
20
25
1
3/4
P4
1/2
2.7
20
1/2
10
2/3
20
1
3/4
15
2/3
20
10
15
20
25
Maintenance
The plant also offers the possibility of excluding individual pumps from the
process, e.g. during failure or if a pump needs to be serviced (as shown in
Figure 2-10).
As long as the requested water consumption is lower or equal 300%, and
an active pump is taken out of the group for servicing, its task is taken over
by a pump which is inactive at that time.
The control algorithm shall be explained using the following graphic.
14
The algorithm controls pump P1 when demand <100%
distributed between pump P1 and P2. For a load of 200% both pumps
are used at 100% load each.
distributed between pump P1, P2 and P4. Since pump P3 is not
available due to maintenance works, the task is taken on by pump P4.
For a load of 300% all 3 pumps are used at 100% load each.
V1.0, ID number: 37604154
After terminating the maintenance works and enabling the maintained

pump, it is reintegrated into the process according to the above rules.
Figure 2-10
400%
300%
2/3
Setpoint
1
3/4
1/2
0
2/3

2/3
2/3
10
15
20
P1
1
3/4
1/2
P2
10
3/4
10
15
10
15
P3
1/2
1
3/4
P4
1/2
V1.0, ID number: 37604154
15
3 Configuration
Configuration
3.1.1
Installing and wiring the hardware
Table 3-1

No.
Instruction
Note/picture
1.
Mount
the fuse
the PM 1207 power supply unit
the S7-1200 CPU 1214C
the CM1241
and the frequency converters
on a top hat rail.
2.
Mount the motors onto a suitable fixture.
3.
Connect the controller to the 24 V DC

supply voltage of the PM 1207
See Figure 2-1
4.
Connect the frequency converters with

the motors.
See Figure 2-1
5.
Connect the PROFIBUS cable with the

S7-1200 CM1241 and the frequency
converters
See Figure 2-2
6.
Connect all ground connections to earth.
Note
For simulating the release of all frequency converters (status I0.0 to I0.3
= "1") we recommend using the simulator module (1214C - 14 E/A).
At this point it is assumed that the necessary software has been installed
on your computer and that you are familiar with handling the software.
Furthermore it is assumed, that STEP7 Basic V10.5 has been installed
on the standard Windows PC for operator control.
16
V1.0, ID number: 37604154
3 Configuration
!
WARNING
3.1.2
Please carefully read all safety and warning notices given in the
operating instructions on the frequency converter and all warning
labels attached to the device before doing any installation and
commissioning procedures. Please maintain warning labels in a
legible condition and do not remove them from the device.
Connect S7-1200 with PG/PC
Table 3-2

No.
Function
1.
Connect your development system (PG/PC) to the S71200 CPU, using an Ethernet cable.
2.
Open the network connection in the control panel of the

PG/PC.
3.
Open the properties of the network connection.
4.
Open the Internet Protocol (TCP/IP) Properties
5.
In "General", select "Use the following IP address" and

set the address:
IP address: 192.168.1.10
Subnet: 255.255.255.0
6.
Confirm with OK to close all windows
V1.0, ID number: 37604154
Remarks
17
3 Configuration
3.1.3
Load project in the S7-1200 CPU1214C
Table 3-3
No.
1.
Function

Extract the included project (*.zip) onto your hard disk

drive.
Open the extracted S7-1200 project (*.ap10 file)
using STEP7 Basic V10.5
2.
Change from the portal view to the project view.
3.
Click project navigation on PLC_1 [CPU 124C

DC/DC/DC] with the right mouse button
4.
Select "Dowload to device" "All"
5.
Set the checkmark in the "Instruction" column and click

"Load"
6.
The hardware configuration and the program are loaded

into the CPU.
7.
After loading confirm that the CPU is set to RUN.
18
Remarks
V1.0, ID number: 37604154
3 Configuration
3.1.4
Load project into the SIMATIC Panel KTP600
Table 3-4

No.
Instruction
1.
2.
Select the "Transfer" button after the "bootloader"

sequence.
The panel is now ready for loading the project.
3.
Click HMI_1 [KTP600] with the right mouse in the project

navigation
4.
Select "Download to device" "All"
5.
Set the checkmark in the "Instruction" column and click

"Download"
6.
The HMI project is loaded. The panel starts automatically

after completion.
Remarks
Connect KTP600 with a DC 24V power supply

Connect your development system (PG/PC) with the
KTP600 using an Ethernet cable
V1.0, ID number: 37604154
19
3 Configuration
3.1.5
Connect SIMATIC Panel KTP600 and S7-1200 CPU 1214C
Table 3-5
No.
Function
Remarks
Once the S7-1200 project was successfully loaded,

connect the KTP600 with the S7-1200 CPU1214C, using
an Ethernet cable.
1.
3.1.6
Close off RS 485 bus with terminating resistors
Table 3-6
No.
1.

Function
2.
Remarks
Remove the BOP of the frequency converter (last bus

station) of pump P4
For activating the terminating resistor you change the
DIP switch as follows:
50Hz: 1=OFF, 2=ON, 3=ON
60Hz: 1=ON, 2=ON, 3=ON

Snatch the BOP back to the frequency converter
In order to activate the terminating resistor at the
controller (first bus station) please bring the switch to
position "ON"
3.1.7
Parameterization of frequency converters
Parameterizing the frequency converter of pump P1 (address 1)

Table 3-7
Step
Instruction
Remarks
1.
Set the BOP to the SINAMICS G110 frequency

converter to whom address 1 is to be assigned
2.
In order to change a parameter proceed as follows:
Switch to parameterization mode: P
Select parameter with cursor:
20
V1.0, ID number: 37604154
3 Configuration
Step

3.
Instruction
Select parameter: P
Select value with cursor:
Accept value: P
Remarks
To set the traversing parameter proceed as follows:

Function
Parameters
Value
Resetting the frequency converter to delivery

status
P0010
30
P0970
P0010
Start the quick startup

Check the parameter setting to suit the
DIP switch:
Europe 50Hz, power in kW 1
Rated motor voltage
P0100
P0304
230 V
Rated motor output
P0307
0.12 kW
Rated motor frequency
P0310
50 Hz
Rated motor speed
P0311
1350 r/min
Command source (USS)
P0700
Frequency setpoint
P1000
Minimum motor frequency
P1080
0.0 Hz
Maximum motor frequency
P1082
50.0 Hz
Startup ramp
P1120
10.0 s
Delay ramp
P1121
10.0 s
End of the quick start
P3900
Activate Expert mode
P0003
Reference frequency
P2000
50.0 Hz
Data transmission speed 57,600 b/s
P2010
Address (Slave)
P2011
USS PZD length
P2012
USS PKW length
P2013
Communication monitoring:
Value 0 without monitoring
P2014
Save data in EPROM
P0971
These values are preset depending on the position of the DIP switch at the front of the
SINAMICS G110 (except for parameter value 2). Details on interaction of P0100 and position of
the DIP switch are given in the parameter list of SINAMICS G110. Parameter value and
position of the DIP switch must be related to parameter value 0 and 1!
V1.0, ID number: 37604154
21
3 Configuration
Step
4.
5.
Instruction
Remarks
To secure the parameters in BOP proceed as follows:

Function
Parameters
Value
P0003
Activate Parameterization mode
P0010
30
Transfer parameters from G110 to BOP
P0802
In order to depict the current frequency during

runtime, select the parameter P0000 and press
the P button

Table 3-8

Step
Instruction
Remarks
1.
Unplug the BOP from the frequency converter

of pump P1 and plug it to the second
SINAMICS G110 (for pump 2).
2.
Select parameter: P
Accept value: P
3.
4.
22
To adopt the settings of the second frequency converter and adjust the address
proceed as follows:
Function
Parameters
Value
P0003
P0010
30
Transfer parameters from BOP to G110
P0803
Change the address to 2
P2011
Save data in EPROM
P0971

the P button
V1.0, ID number: 37604154
3 Configuration

Table 3-9

Step
Instruction
Remarks
1.

of pump P2 and plug it to the third SINAMICS
G110 (for pump 3).
2.
Select parameter: P
Accept value: P
3.
4.
To adopt the settings of the third frequency converter and adjust the address
proceed as follows:
Function
Parameters
Value
P0003
P0010
30
P0803
P2011
Save data in EPROM
P0971

the P button
V1.0, ID number: 37604154
23
3 Configuration

Table 3-10

Step
Instruction
Remarks
1.

of pump P3 and plug it to the fourth SINAMICS
G110 (for pump 4).
2.
Select parameter: P
Accept value: P
3.
4.
Note
24
To adopt the settings of the fourth frequency converter and adjust the address
proceed as follows:
Function
Parameters
Value
P0003
P0010
30
P0803
P2011
Save data in EPROM
P0971

the P button
Ensure that a blinking light is visible at the SINAMICS G110. If this is not the
case, it is in operation and a configuration is not possible.
V1.0, ID number: 37604154
3 Configuration
3.2
Enabling the pumps
Table 3-11

Step
Instruction
1.
To enable pumps P1 to P4 you change the

status of the following inputs "1":
I0.6
I0.7
These two inputs switch the OFF2 and OFF3
inputs at the "USS_DRV" block.
They are wire-break safe and have to be set
before the pumps are released
2.
To enable pumps P1 to P4 you change the

status of the following inputs "1":
I0.0
I0.1
I0.2
I0.3
These four inputs enable a pump each. They
enable the RUN input at the "USS_DRV" block.
The block is enabled when the OFF2 and OFF3
inputs are set to "1" first.
V1.0, ID number: 37604154
Figure/short note
25
3 Configuration
3.3
Change language settings
Table 3-12
Step
Instruction
1.
Press the "Sys" button in order to access the

Control Panel.
2.
Press the "German" button in order to be

able to control the plant in German
language.
Press the "English" button in order to be
able to control the plant in English
language.
Alternatively you can swap between the
languages in each operator display via
softkey F1.

3.4
Figure/short note
Moving pump P1 manually

In manual operation the setpoint speed value for each motor is given
individually.
Table 3-13
Step
1.
Instruction
2.
26
Figure/short note
In order to select the manual mode press

the "Manual Mode" button
The label of this button will subsequently
display "Auto Mode"
Change to the operator screen of pump P1,

by pressing the "P1" button.
V1.0, ID number: 37604154
3 Configuration
Step
3.
Instruction

Figure/short note
Press the selected button until the left bar

shows a setpoint speed value of 100%.
Due to the ramp of 10 sec configured in
the frequency converter, the actual speed
value is delayed. This ramp causes a
delayed rise of the actual speed value in
form of the right-hand bar.
4.
Change the rotation direction by pressing

button I0.4
The rotational speed actual value will
drop to standstill
The rotation direction of the motor is
changed
The actual speed value will increase
again to 100%
5.
Turn off pump P1 via switch I0.6 (with break)

or I0.7 (without break) through the hardware.
This function is the same as an emergency
stop.
6.
To enable pump P 1 again, turn switch I0.6 or

I0.7 back on again.
Furthermore turn switch I0.0 off and on again,
so that the edge for the release is performed
again at the "USS_DRV" block.
7.
The pump starts running again.
8.
Switch off pump P1 by pressing the STOP

button.
V1.0, ID number: 37604154
27
3 Configuration
3.5
Move pump P1 to P4 automatically on demand

In automatic operation one setpoint value is assigned for all pumps. The
startup program automatically calculates the setpoint value for the
individual pumps.
Table 3-14
Step
1.
Instruction

2.
3.
4.
28
Figure/short note
In order to select the automatic mode

press the "Auto Mode" button
display "Manual Mode"
Increase the setpoint value to 100%.

The speed of pump P1 increases with a
delay also to 100% of the maximum value
The BOP of the frequency converter of
pump P1 shows 50 Hz

Since pump P1 cannot handle this load
by itself, it is now distributed to pump P1
and P2. Both pumps P1 and P2 are now
respectively operated with a speed of
60% of the maximum value
pump P1 and P2 now shows 30 Hz
The speed of pumps P1 and P2
increases with a delay to 100% of the
maximum value respectively
V1.0, ID number: 37604154
3 Configuration
Step
5.
Instruction
6.

7.
8.
9.
Figure/short note
Increase the setpoint value of the pumps

to 220%.
Since the pumps P1 and P2 cannot
handle this load alone, it is now
distributed between pump P1, P2 and P2.
All three pumps P1, P2 and P3 are now
pump P1, P2 and P3 now shows
36.67 Hz
to 300%.
The speed of pumps P1, P2 and P3
pump P1, P2 and P3 now shows 50 Hz
Now increase the setpoint value of the

pumps to 320%.
Since the pumps P1, P2 and P3 cannot
handle this load alone, it is now
distributed between pump P1, P2, P3 and
P4. The four pumps P1, P2, P3 and P4
are now respectively operated with a
speed of 80% of the maximum value
pump P1, P2, P3 and P4 now shows
40 Hz
to 400%.
The speed of pumps P1, P2, P3 and P4
pump P1, P2, P3 and P4 now shows
50 Hz
Stop the pumps by pressing the STOP button.
V1.0, ID number: 37604154
29
3 Configuration
3.6
Procedure with balancing of operating hours

Operating the plant with balancing of operating hours causes the pump with
the least operating hours being added upon addition of a further pump.
Table 3-15
Step
1.
Instruction

2.
3.
4.
30
Figure/short note
In order to select the automatic mode

press the "Auto Mode" button
display "Manual Mode"
For the current operating hours of pump

P1 to P4 you set the following values:
P1: 20
P2: 15
P3: 10
P4: 05
To do this you select the marked field,
enter the desired value and acknowledge
the input by pressing the Return key
20
15
10
P1
P2
P3
20
15
10
20
15
10
12
P4
Press the selected buttons in order to

recalculate the pump priority and to
activate the counting of operating hours.

The speed of pump P4 increases with a
delay also to 100% of the maximum value
pump P4 shows 50 Hz
V1.0, ID number: 37604154
3 Configuration
Step
5.
Instruction

6.
7.

Since pump P4 cannot handle this load
by itself, it is now distributed to pump P4
and P3. Both pumps P4 and P3 are now
Now press the "Recalc Balance" button.
The pump priorities are then recalculated.
If at this time the operating hours of pump
P3 and P4 are higher than that of pump
P1 and P2, pump P1 and P2 take on the
tasks of pump P3 and P4. Both pumps P3
and P4 are then switched off.
Figure/short note
20
15
21
16
20
15
21
16
20
15
21
16
In order to terminate this scenario you press

the STOP button.
3.7
Procedure for excluding pump P3 due to servicing

In the case of servicing, it shall be possible to directly deactivate a pump for
maintenance works, and its tasks shall be automatically taken on by
another pump
Table 3-16
Step
1.
Instruction
For the current operating hours of pump

P1 to P4 you set the following values:
P1: 0
P2: 0
P3: 0
P4: 0
To do this you select the marked field,
enter the desired value and acknowledge
the input by pressing the Return key
V1.0, ID number: 37604154
Figure/short note
P1
P2
P3
P4
31
3 Configuration
Step
2.
Instruction

Activate the counting of operating hours

by pressing the "Count up seconds"
button
Update the pump priority by pressing the
"Recalc Balance" button.
3.
Change into automatic operation of the plant

by pressing the "Auto Mode" button.
4.
5.
6.
Figure/short note

to 220%.
All three pumps P1, P2 and P3 are now
pump P1, P2 and P3 now shows 36.67
Hz
Withdraw the release for pump P3 by
switching off input I0.2.
The right image shows how the load of
pump P3 was taken over by pump P4.

further to 300%.
300,0
32
V1.0, ID number: 37604154
3 Configuration
Step
7.
Instruction
Increase the setpoint value to over 300%.

A demand of over 300%, however,
cannot be managed, since only 3 pumps
are available. A respective message
informs of this condition.
Acknowledge the message box by
pressing the "!" icon ".
Close the dialog box by pressing "x"

Figure/short note
V1.0, ID number: 37604154
33
4 Code Elements
Code Elements
4.1
Preliminary remarks
We offer you software examples with test code and test parameters as a
download. These software examples support you in the first steps and tests
with the configuration examples.
The software examples are always assigned to the components used in the
Configuration Example and show their basic interaction. However, they are
not real applications in the sense of technological problem solving with
definable properties.
4.2
Download
The software examples are available on the HTML page from which you
downloaded this document.
Table 4-1

File name
2009.06.05_CE_x8_V1d0.zip
34
Contents
STEP 7 Basic project for S7-1200
CPU1214C and KTP600
V1.0, ID number: 37604154
5 History
History
Table 5-1
Version
20.05.2009
Modifications
First version

V1.0
Date
V1.0, ID number: 37604154
35

ConfigurationExample x8 S7 1200 USS v1d0 en 1

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Cover sheet

Simple networking and cascading of drives

Applications & Tools

Warranty, liability and support

The application examples are not binding and do not claim to be

Warranty, liability and support

Copyright Siemens AG 2009 All rights reserved

Automation Solution ...................................................................................... 7

Application automation task

Copyright Siemens AG 2009 All rights reserved

USS Protokoll via RS485

Copyright Siemens AG 2009 All rights reserved

Power module PM1207

Communication module CM 1241

Basic Panel KTP600

Frequency converter SINAMICS G110

SIMATIC S7-1200 CPU

MLFB / Order number

DC24V power supply unit

SINAMICS G110 120W

Asynchronous motors 4pole, aluminum frame,

Simulator module for 14

Basic KTP600 panel

Copyright Siemens AG 2009 All rights reserved

Lot size: Max. 1,000m

Profibus connector with

Adapter for attachment of

Filter for low leakage

Ethernet connection cables 2

MLFB / Order number

The configuration, as it is, is intended for industrial application. For energy

MLFB / Order number

Figure 2-1 Wiring

Copyright Siemens AG 2009 All rights reserved

PSU 1200 CM1241 +

The 4-pole asynchronous motors with 400V/230V star/delta winding have

Figure 2-2 Wiring detail for bus connection

What should be done to prevent electromagnetic interference:

Copyright Siemens AG 2009 All rights reserved

Make sure a good conductive connection between the frequency converter

Addressing of bus stations and terminating a RS485 bus with

Copyright Siemens AG 2009 All rights reserved

Controlling bus stations via RS 485 bus

The USS protocol was developed in order to exchange process data

Communication with bus stations

For a command to be sent from control to the bus station, a function is

Copyright Siemens AG 2009 All rights reserved

An extensive description of the blocks and a calculation of the call

Transferring and reading data to bus stations

Communication via RS485

Copyright Siemens AG 2009 All rights reserved

The delivery head H of each pump depends on the conveying current Q.

Systems duty point

Copyright Siemens AG 2009 All rights reserved

Controlling the pumped amount

The algorithm controls pump P1 when demand <100%

Copyright Siemens AG 2009 All rights reserved

Balancing of operating hours

Recording the pump operating hours

Each pump is assigned a priority, which controls which pump will be

The algorithm controls pump P4 if the demand is <100%, since with

Copyright Siemens AG 2009 All rights reserved

The algorithm controls pump P1 when demand <100%