Siemens SITOP PSU8200 User manual

https://support.industry.siemens.com/cs/ww/en/view/109481908
Application example 04/2016
Integration of a
SITOP 24 V Power Supply in
SIMATIC PCS 7
SITOP PSU8200, PSE202U, PSE200U, UPS1600, PSU8600

Warranty and Liability
Integration of a SITOP 24 V Power Supply in PCS 7
Entry ID: 109481908, V1.0, 04/2016
2
Siemens AG 2016 All rights reserved
Warranty and Liability
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Table of contents
Integration of a SITOP 24 V Power Supply in PCS 7
Entry ID: 109481908, V1.0, 04/2016
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Table of contents
Warranty and Liability..............................................................................................2
1Task.................................................................................................................5
2The solution....................................................................................................6
2.1 Overview...........................................................................................6
2.2 Hardware and software components..................................................8
3Basics .............................................................................................................9
3.1 SITOP PSU8200 ...............................................................................9
3.2 SITOP PSE202U.............................................................................10
3.3 SITOP UPS1600 with UPS1100 ......................................................11
3.4 SITOP PSE200U.............................................................................12
3.5 Power supply system SITOP PSU8600............................................13
4Redundant 24 V DC power supply...............................................................14
4.1 Configuring the hardware configuration............................................15
4.2 Copying process tag types...............................................................16
4.3 Creating an AS program..................................................................17
4.4 Parameterizing messages ...............................................................19
4.5 Creating a process picture...............................................................20
4.6 Runtime...........................................................................................21
5Uninterruptible 24 V power supply..............................................................22
5.1 UPS1600 on the PROFINET IO fieldbus..........................................22
5.1.1 Configuring the hardware configuration............................................23
5.1.2 Copying process tag types...............................................................28
5.1.3 Creating an AS program ..................................................................29
5.1.4 Messages........................................................................................30
5.2 UPS1600 with monitoring of the signal contacts...............................31
5.2.1 Configuring the hardware configuration............................................32
5.2.2 Copying process tag types...............................................................32
5.2.3 Creating an AS program ..................................................................33
5.2.4 Parameterizing messages ...............................................................36
5.3 Creating a process picture...............................................................37
5.4 Runtime...........................................................................................38
6Selective monitoring of 24V feeders............................................................39
6.1 Configuring the hardware configuration............................................40
6.2 Copying process tag types...............................................................41
6.3 Creating an AS program..................................................................42
6.4 Parameterizing a message ..............................................................44
6.5 Creating a process picture...............................................................45
6.6 Runtime...........................................................................................46
7Power supply system SITOP PSU8600........................................................47
7.1 Hardware configuration....................................................................48
7.2 Copying process tag types...............................................................53
7.3 Creating an AS program..................................................................54
7.4 Messages........................................................................................55
7.5 Creating a process picture...............................................................56
7.6 Runtime...........................................................................................57
8Commissioning the demo project ...............................................................58
8.1 Installation.......................................................................................58
8.2 Operating SITOP modular ...............................................................60

Table of contents
Integration of a SITOP 24 V Power Supply in PCS 7
Entry ID: 109481908, V1.0, 04/2016
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8.2.1 Overview of the power supply..........................................................60
8.2.2 Monitoring of redundancy ................................................................61
8.2.3 Monitoring of the DC UPS................................................................62
8.2.4 Monitoring the selectivity module.....................................................66
8.3 Operating the PSU8600 power supply system .................................67
9References....................................................................................................70
10 History ..........................................................................................................70

1 Task
Integration of a SITOP 24 V Power Supply in PCS 7
Entry ID: 109481908, V1.0, 04/2016
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1 Task
Introduction
The reliable 24V power supply is an important factor in high plant availability during
the operation of SIMATIC PCS 7. SITOP makes available 1- or 3-phase basic
power supply units with different output power ratings of up to 1000 W. These units
have comprehensive certifications like ATEX or IECex as well as MTBF values of
up to 1 million hours in 24-hour uninterrupted duty.
Depending on the requirements and plant configuration, they can be extended on a
scalable basis. In the present application example, we will go into the details of the
following configurations:
Redundant 24 V DC power supply
Buffered 24 V power supply with battery storage
Selective monitoring of individual 24 V feeders
Power supply system SITOP PSU8600
Other 24 V supply concepts are described in Chapter 18 of the manual entitled
SIMATIC PCS 7 Standard Architectures.
Description of the automation task
It is intended to implement a 24V power supply from the SITOP range in a PCS 7
system for the automation technology and the external peripherals. If possible, the
power supply must be designed on a failsafe basis. The system operating
personnel must be able to monitor the status of the 24V power supply on the PCS
7-Operator Station.
Fig. 1-1
SITOP UPS1100
SITOP UPS1600
SITOP PSE202U
SITOP PSU8200
SITOP PSU8200
SIMATIC PCS 7
SITOP modular
Redundancy Buffering Selectivity
SITOP PSU8600 Power Supply System
SITOP PSU8600

2 The solution
Integration of a SITOP 24 V Power Supply in PCS 7
Entry ID: 109481908, V1.0, 04/2016
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2 The solution
2.1 Overview
The 24 V power supply of the PCS 7 automation technology is implemented using
SITOP modular power supply units and the associated expansion modules or using
the SITOP PSU8600 power supply system.
The application example shows how to configure the hardware in the SIMATIC
Manager and to easily integrate it into the PCS 7 control system. Default blocks
from the PCS 7 Advanced Process Library and product-specific blocks are used for
the AS program.
You can download the library containing the pre-configured process tag types and
the product-specific blocks for SITOP UPS1600 and SITOP PSU8600 in the item
entitled SITOP Library for SIMATIC PCS 7.
The enclosed demo project gives you a comprehensive overview of configuration
and the way of functioning.
SITOP modular
This variant uses SITOP PSU8200 power supply units, the SITOP PSE202U
redundancy module, the SITOP UPS1600/UPS1100 uninterruptible power supply
with battery module, and the SITOP PSE200U selectivity module.
Fig. 2-1
OS Server
OS Client Industrial Ethernet /
PROFINET IO
120/230V AC
DC +24V
DC 24V GND
UPS1100UPS1600
2x PSU8200
PSE202U
Switch
AS
ET 200
SCALANCE
PSE200U
ET 200

2 The solution
Integration of a SITOP 24 V Power Supply in PCS 7
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Power supply system SITOP PSU8600
Another variant uses the SITOP PSU8600 power supply system. The basic unit
with four outputs that are selectively monitored is expanded by four more outputs
(CNX8600) that are selectively monitored. Using the (BUF8600) buffer module, it is
possible to bypass brownouts.
Fig. 2-2
OS Server
OS Client
Industrial Ethernet /
PROFINET IO
DC +24V
DC 24V GND
Switch
400V AC
120/230V AC
4x DC +24V Selective
4x DC +24V Selective
ET 200
ET 200
AS
SCALANCE
PSU8600 / CNX8600 / BUF8600

2 The solution
Integration of a SITOP 24 V Power Supply in PCS 7
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2.2 Hardware and software components
The application has been created with the following components:
Hardware components
Table 2-1
Component
Qty.
Article number
Note
AS 410-5H
1
6ES7 410-5HX08 0AB0
Automation system
ET 200SPHF
1
6ES7 155-GAU00-0CN0
External peripherals
PSU8200
2
6EP3 334-8SB00-0AY0
DC 24 V/10 A power supply
PSE202U
1
6EP1 961-3BA21
Redundancy module
UPS1600
1
6EP4 134-3AB00-2AY0
DC 24 V/10 A DC UPS
UPS1100
1
6EP4131-0GB00-0AY0
Battery module, 1.2 Ah
PSE200U
1
6EP1 961-2BA11
Selectivity module, 4x 3 A
PSU8600
1
6EP3437-8MB00-2CY0
Power supply system
DC 24 V/4x 10 A
CNX8600
1
6EP4437-8XB00-0CY0
Expansion module, 4x 10 A
BUF8600
1
6EP4297-8HB10-0XY0
Buffer module, 300 ms/40 A
Software components
Table 2-2
Component
Qty.
Article number
Note
SIMATIC PCS 7 V8.1
1
6ES7651-5AA18-0YA0
Standard engineering
software
SITOP Library
1
Module library for SITOP
Download
UPS1600 GSD
1
Download
PSU8600 GSD
1
Download
Example files and projects
Table 2-3
Component
Note
109481908_PCS7_SITOP24V_Demo_V10.zip
This archive contains the PCS 7
demo project
109481908_PCS7_SITOP24V_Docu_V10_en.pdf
This document

3 Basics
Integration of a SITOP 24 V Power Supply in PCS 7
Entry ID: 109481908, V1.0, 04/2016
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3 Basics
3.1 SITOP PSU8200
One- and three-phase SITOP PSU8200 devices are the technology power supplies
for demanding solutions. The wide-range input makes it possible to connect to
almost any electrical power system worldwide and ensures a high degree of safety
even when large voltage fluctuations occur. They offer outstanding overload
characteristics: Power boost delivers up to three-times the rated current for short
periods of time, and with extra power of 150%, loads with high power consumption
can be connected without any problems. The very high degree of effectivity keeps
energy consumption and heat dissipation in the control cabinet very low and the
compact metal housing also saves space.
You can find detailed information here: SITOP modular
Fig. 3-1
PSU8200
120/230V AC
DC 24V
Signal „24V OK“

3 Basics
Integration of a SITOP 24 V Power Supply in PCS 7
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3.2 SITOP PSE202U
SITOP redundancy modules provide additional protection from failure of the 24 V
supply. The redundancy module continuously monitors two identical power supply
units. If one unit fails, the other one automatically supplies the power. Additionally,
a signal is sent via a signal contact that can be evaluated by a controller, PC, or
control system.
You can find detailed information here: SITOP redundancy modules
Fig. 3-2
120/230V AC
DC 24V (Redundant)
PSU8200 / PSE202U
Signal PSU8200(2) „24V OK“
Signal PSU8200(1) „24V OK“
Signal PSE202U „24V OK“

3 Basics
Integration of a SITOP 24 V Power Supply in PCS 7
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3.3 SITOP UPS1600 with UPS1100
In the case of a power failure, the SITOP UPS1600 uninterruptible power supply can
supply the automation system with 24V for up to several hours. Depending on the
version of the DC UPS, it is integrated into the control system by means of digital
I/Os or via PROFINET (Figure 3-3). The intelligent battery management of the
UPS1600 ensures optimum charging and continuous monitoring of the UPS1100
battery modules. The buffer time of the DC UPS depends on the load current and
capacity and the number of battery modules. When choosing the correct DC UPS
configuration, the SITOP Selection Tool helps you in an optimum way.
You can find detailed information here: SITOP DC UPS with battery modules
Fig. 3-3
DC 24V (Buffered)
UPS1600 UPS1100
DC 24V
PROFINET IO
You can find more information about using PROFINET here:
SIMATIC PCS 7 with PROFINET

3 Basics
Integration of a SITOP 24 V Power Supply in PCS 7
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3.4 SITOP PSE200U
The selectivity and diagnostics modules are the optimum enhancement for all 24V
power supplies to distribute the load current to several feeders and to monitor it.
The module detects an overload or short-circuit in one or more feeders and shuts
them down as needed. This is ensured even on high-resistance lines and in the
case of "creeping" short-circuits. The intact feeders continue to supply the SITOP
selectivity modules with 24 V on an absolutely interruption- and reaction-free
basis. Their signal contact can be looped across several selectivity modules and
can be evaluated as a common alarm in SIMATIC PCS 7.
You can find detailed information here: SITOP selectivity modules
Fig. 3-4
DC 24V (Load Feeder 1)
DC 24V (Load Feeder 2)
DC 24V (Load Feeder 3)
DC 24V (Load Feeder 4)
SITOP
PSE200U
DC 24V
Summary Signal „24V OK“

3 Basics
Integration of a SITOP 24 V Power Supply in PCS 7
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3.5 Power supply system SITOP PSU8600
The SITOP PSU8600 power supply system consists of a PSU8600 basic unit, up to
three CNX8600 expansion modules, and a maximum of two BUF8600 buffer modules.
The three-phase basic unit provides either one selectively monitored output or four
selectively monitored outputs (Figure 3-5). Using the power boost of 150 %, loads
with high power consumption can be connected without any problems. The modular
system with the innovative System Clip Link connection system allows for an
individual combination of the power supply system without needing additional wiring.
The order of the expansion modules and buffer modules is irrelevant in this case.
The power supply is monitored by means of the integrated Ethernet/PROFINET
interface or, as an alternative, using the digital signal contacts.
You can find detailed information here: Power supply system SITOP PSU8600
Fig. 3-5
4x DC 24V Selective
PROFINET IO
4x DC 24V Selective
3-ph AC
PSU8600 CNX8600 BUF8600
You can find more information about using PROFINET here:
SIMATIC PCS 7 with PROFINET

4 Redundant 24 V DC power supply
Integration of a SITOP 24 V Power Supply in PCS 7
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4 Redundant 24 V DC power supply
For redundant power supply, you need two identical (PSU8200) power supply units
and one (PSE202U) redundancy module. Ideally, you should connect both power
supply units to separate 120/230V electric circuits. To monitor redundancy, the
signal contact of the redundancy module is connected to one of the digital inputs of
the external peripherals. The signal contact is executed as a changeover switch,
which means that it can signal the “good” and “bad” states. Apart from this, it is
possible to connect the power supply units to the external peripherals. The signal
contact of the power supply units is executed as a normally open contact and it
signals the “good” state.
Fig. 4-1
OS Server
OS Client Industrial Ethernet /
PROFINET IO
120/230V AC
AS
PSU8200/
PSE202U
ET 200
SCALANCE
DC +24V
DC 24V GND
Switch
Signal „24V OK“

4 Redundant 24 V DC power supply
Integration of a SITOP 24 V Power Supply in PCS 7
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4.1 Configuring the hardware configuration
You do not configure the hardware of the power supply and the of the redundancy
module in the SIMATIC Manager. You configure the AS and the external
peripherals according to the PCS 7 standard. To monitor the power supply units
and the redundancy module, the signal contacts are each connected to one of the
digital inputs of the external peripherals and symbolized appropriately in the
hardware configuration.
The procedure is as follows:
1. In SIMATIC Manager, open the hardware configuration of the automation system.
2. Highlight the digital input assembly of the external peripherals (1) and choose
menu command “Edit > Symbols…”.
3. Enter an appropriate symbolic name (2) for the inputs that are connected to the
power supply units and the redundancy module.
4. Click on "OK" to confirm your changes.
5. Compile and load the changed hardware configuration.
Fig. 4-2
1
2

4 Redundant 24 V DC power supply
Integration of a SITOP 24 V Power Supply in PCS 7
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4.2 Copying process tag types
Before starting to create the AS program, it is advisable to copy the necessary plan
templates to the master data library of the PCS 7 project. Process tag type
“PSU2ModulesRed” is available for the redundant power supply. This process tag
type contains the three “Pcs7DiIn” driver blocks and three “MonDiL” monitoring
blocks that have already been interconnected correctly.
The procedure is as follows:
1. Open the SITOP library.
2. Copy process tag type “PSU2ModulesRed” (1) to the “Process tag types”
folder in the master data library.
3. Make sure that you copy the APL blocks that are used to the master data
library too. To do this, create a CFC plan (2) by copying blocks “Pcs7DiIn” and
“MonDiL” from the PCS 7 APL.
Fig. 4-3
1
2

4 Redundant 24 V DC power supply
Integration of a SITOP 24 V Power Supply in PCS 7
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4.3 Creating an AS program
The procedure is as follows:
1. Drag and drop process tag type “PSU2ModulesRed” to the desired folder in the
technological hierarchy and rename it (1).
Fig. 4-4
2. Open the plan and adapt each input signal as follows:
–Rename the monitoring blocks to match their uses (2).
–Interconnect inputs “PV_In” with the corresponding symbols of the external
peripherals (3).
–Invert the “In” input signals (4) on the monitoring blocks of the power
supply units, since their signal contact is closed in the “good” state.
–At the “Color” inputs of the monitoring blocks (5), parameterize the value
“16#1”. This is so that the system displays the value in red in the
faceplates in accordance with an alarm.
1

4 Redundant 24 V DC power supply
Integration of a SITOP 24 V Power Supply in PCS 7
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Fig. 4-5
3. Compile the AS program and update the view of the CFC plan.
4. Load the program into the automation system.
3
5
2
4

4 Redundant 24 V DC power supply
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4.4 Parameterizing messages
To allow operators to assign the message if one of the devices fails, they are
adapted on the monitoring blocks.
The procedure is as follows:
1. Open one after the other the properties of the “MonDiL” blocks and click on the
“Messages…” pushbutton.
2. In the message configuration dialog, change the message text (1). However,
leave the “$$BlockComment$$” system instruction in the message text.
3. Click on the “Save” pushbutton (2) to confirm your change.
4. Close the properties of the monitoring block.
Fig. 4-6
Note
If you need message texts in several languages, you use the menu command
Tools > Manage multilingual texts > Change language… in the SIMATIC
Manager to change the language for display texts and adapt the text in the
message configuration for the set language.
2
1

4 Redundant 24 V DC power supply
Integration of a SITOP 24 V Power Supply in PCS 7
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4.5 Creating a process picture
You need a process picture to visualize the status of the redundant power supply.
The procedure is as follows:
1. Create a new process picture or open an existing one (1) in the folder of the
technological hierarchy in which the CFC plan that you edited before is located.
Fig. 4-7
2. Execute the Compile OS function so that the system creates the process
variables and the messages in the OS project as well as the block icons in the
process picture.
3. Open the process picture using the WinCC Graphics Designer.
4. Draw the process picture as you want it to appear and position the block icons
(2) at the intended location in the picture.
5. Save the adapted process picture and close it.
Fig. 4-8
1
2