Siemens SINUMERIK 840D sl Ctrl-Energy, SINUMERIK 828D Ctrl-Energy System Manual

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SINUMERIK

SINUMERIK 840D sl / 828D Ctrl-Energy

Valid for Control system SINUMERIK 840D sl / 840DE sl / 828D

Software Version CNC Software 4.7 SP1

Preface

Fundamental safety instructions

System Manual

Introduction

Ctrl-E Analysis

Ctrl-E Profiles

Reactive power compensation

Flux reduction

User know-how

Appendix

01/2015

6FC5397-0EP40-5BA2

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Legal information Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG Division Digital Factory Postfach 48 48 90026 NÜRNBERG GERMANY

Order number: 6FC5397-0EP40-5BA2 Ⓟ 07/2015 Subject to change

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Preface

SINUMERIK documentation

The SINUMERIK documentation is organized in the following categories:

● General documentation

● User documentation

● Manufacturer/service documentation

Additional information

You can find information on the following topics at www.siemens.com/motioncontrol/docu:

● Ordering documentation/overview of documentation

● Additional links to download documents

● Using documentation online (find and search in manuals/information)

Please send any questions about the technical documentation (e.g. suggestions for improvement, corrections) to the following address:

[email protected]

My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific machine documentation based on the Siemens content:

www.siemens.com/mdm

Training

For information about the range of training courses, refer under:

● www.siemens.com/sitrain SITRAIN - Siemens training for products, systems and solutions in automation technology

● www.siemens.com/sinutrain SinuTrain - training software for SINUMERIK

FAQs

You can find Frequently Asked Questions in the Service&Support pages under Product Support. http://support.automation.siemens.com

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Preface

SINUMERIK

You can find information on SINUMERIK under the following link:

www.siemens.com/sinumerik

Hotline and Internet address

Technical Support

You will find telephone numbers for other countries for technical support in the Internet under http://www.siemens.com/automation/service&support

EC Declaration of Conformity

The EC Declaration of Conformity for the EMC Directive can be found on the Internet at:

http://support.automation.siemens.com/WW/view/de/10805517/134200

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Preface.........................................................................................................................................................3

1 Fundamental safety instructions...................................................................................................................7

1.1 General safety instructions.......................................................................................................7

1.2 Industrial security.....................................................................................................................7

2 Introduction...................................................................................................................................................9

3 Ctrl-E Analysis............................................................................................................................................11

3.1 SENTRON PAC3200/4200....................................................................................................12

3.1.1 Hardware................................................................................................................................12

3.1.2 Commissioning the Power Monitoring Device........................................................................13

3.1.3 Commissioning the PAC PROFIBUS expansion module (840D sl).......................................14

3.1.4 Commissioning the expansion module PAC PROFINET (828D)...........................................15

3.2 Commissioning the PLC for SENTRON PAC........................................................................15

3.2.1 SINUMERIK 840D sl..............................................................................................................15

3.2.1.1 Commissioning the PLC with PROFIBUS..............................................................................15

3.2.1.2 Commissioning the PLC with PROFINET..............................................................................19

3.2.2 SINUMERIK 828D..................................................................................................................22

3.3 Commissioning the PLC for Ctrl-E Analysis...........................................................................23

3.3.1 Configuring the energy consumption display for SINUMERIK 840D sl..................................23

3.3.1.1 PLC user program for SINUMERIK 840D sl programming....................................................27

3.3.2 Configuring the display of energy consumption for SINUMERIK 828D.................................29

3.3.2.1 Programming the PLC user program for SINUMERIK 828D.................................................33

3.4 Commissioning the HMI for Ctrl-E Analysis...........................................................................37

3.4.1 Changing display texts of the auxiliary systems.....................................................................37

3.5 Long time measurement.......................................................................................................38

3.6 Power display in the status line of the "Machine" operating area..........................................38

4 Ctrl-E Profiles.............................................................................................................................................39

4.1 Commissioning the PLC for Ctrl-E Profiles............................................................................39

4.1.1 Overview................................................................................................................................39

4.1.2 Automatic state machine PLC functions................................................................................40

4.1.3 Checking the energy-saving states........................................................................................42

4.1.4 PLC user program..................................................................................................................43

4.1.5 Interface signals 840D sl........................................................................................................44

4.1.5.1 Signals for controlling energy-saving profiles.........................................................................44

4.1.5.2 Signals for parameterization..................................................................................................45

4.1.6 Interface signals 828D...........................................................................................................46

4.1.6.1 Signals for controlling energy-saving profiles.........................................................................46

4.1.6.2 Signals for parameterization..................................................................................................47

4.2 Creating and editing energy-saving profiles...........................................................................48

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Table of contents

5 Reactive power compensation...................................................................................................................53

6 Flux reduction.............................................................................................................................................55

7 User know-how...........................................................................................................................................57

7.1 Commissioning user screen forms.........................................................................................57

A Appendix.....................................................................................................................................................59

A.1 Overview................................................................................................................................59

Index...........................................................................................................................................................61

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Fundamental safety instructions

1.1 General safety instructions

WARNING

Risk of death if the safety instructions and remaining risks are not carefully observed

If the safety instructions and residual risks are not observed in the associated hardware documentation, accidents involving severe injuries or death can occur.

● Observe the safety instructions given in the hardware documentation.

● Consider the residual risks for the risk evaluation.

WARNING

Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization

As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death.

● Protect the parameterization (parameter assignments) against unauthorized access.

● Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY STOP or EMERGENCY OFF).

1.2 Industrial security

Note Industrial security

Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens’ products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates.

For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered. For more information about industrial security, visit this address (http://

www.siemens.com/industrialsecurity).

To stay informed about product updates as they occur, sign up for a product-specific newsletter. For more information, visit this address (http://support.automation.siemens.com).

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Fundamental safety instructions

1.2 Industrial security

WARNING

Danger as a result of unsafe operating states resulting from software manipulation

Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe operating states to develop in your installation which can result in death, severe injuries and/ or material damage.

● Keep the software up to date. You will find relevant information and newsletters at this address (http://

support.automation.siemens.com).

● Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the installation or machine. You will find further information at this address (http://www.siemens.com/

industrialsecurity).

● Make sure that you include all installed products into the holistic industrial security concept.

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Introduction

The topics of energy efficiency and energy saving are also playing an increasingly important role in the machine tool environment.

With SINUMERIK Ctrl-Energy, Siemens is offering an extensive range of components, functions, software tools and services to increase the efficiency of machine tools.

Ctrl-Energy

You will find an overview of the complete range of functions under the following link:

www.siemens.com/sinumerik/ctrl-energy

Acquisition, evaluation, and control of energy consumption

The functions Ctrl-E Analysis to acquire and evaluate the energy consumption of the machine and Ctrl-E Profiles, to control energy-saving states of the machine are available in SINUMERIK Operate. Additional energy-saving functions or user know-how on this topic can be added in this area of SINUMERIK Operate.

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Introduction

Ctrl-Energy

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Ctrl-E Analysis

In order to sensitize users to the topic of energy efficiency, the power and energy data of the machine are first acquired.

Acquiring and evaluating energy consumption

A control system with SINUMERIK Operate without a connected measuring instrument determines the power directly from the drives and displays this.

Additional consumption-relevant data can be retrieved and displayed at the control using the additional SENTRON PAC Power Monitoring Device.

Depending on where the SENTRON PAC measuring transducer is installed, you have the possibility of either measuring the power of the whole machine or only a specific load.

With an integrated measuring function, the energy consumption during a measuring period can be acquired for all drives together with an additional measuring location – and the electrical power drawn for a selected load can be recorded with respect to time.

Display of energy consumption

● The user can see a graphic of the current power consumption in the first status line of the "Machine" operating area.

● Additionally, in the Ctrl-Energy initial display the user is shown the consumption in the form of colored bars, which indicate the current power and the results of today's and yesterday's long time measurement.

Maximum measuring time

The maximum measuring time for energy between start and stop as well as for an NC part program is, as a result of the trace recording, 922 seconds (00:15:22).

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Ctrl-E Analysis

3.1 SENTRON PAC3200/4200

3.1.1 Hardware

Hardware components

You require the following hardware in order to be able to use all of the "Ctrl-Energy" functions:

● SENTRON PAC3200 (Firmware ≥ V2.2.0) http://support.automation.siemens.com/WW/view/de/25240652/130000

● SENTRON PAC4200 (Firmware ≥ V1.4.0) http://support.automation.siemens.com/WW/view/de/31675630/130000

● SENTRON PAC - accessories http://www.automation.siemens.com/btlv-static/ Lowvoltage_LV10-1_complete_German_2011.pdf

– Power Monitoring Device (page 11/27 ff)

– Current transformer (Page 11/39)

● The expansion modules must be temporarily removed in order to upgrade the firmware using powerconfig.

● Protection/fusing of the supply and measuring voltages according to Configuration Manual

● Expansion module PAC PROFINET; order number 7KM 9300-0AE01-0AA0

● Expansion module PAC PROFIBUS; order number 7KM 9300-0AB01-0AA0

● PC software powerconfig (≥ V2.2) http://support.automation.siemens.com/WW/view/de/50246395

● Current transformer depending on

– the connection type at the SENTRON PAC

– Accuracy requirements

– Currents

DANGER

Open current transformer circuits result in electric shock and arcing

If not observed, will cause death, serious injury or considerable property damage.

Only measure the current using external current transformers. DO NOT protect the circuits using a fuse. Do not open the secondary circuit of the current transformer under load. Short circuit the secondary current terminals of the current transformer before removing this device. The safety information for the current transformers used must be carefully followed.

Selection example

Catalog, Siemens LV 1/Accessories and spare parts:

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References

Ctrl-E Analysis

3.1 SENTRON PAC3200/4200

For a three-phase measurement according to connection type 3P4W (four conductors, unbalanced load, without voltage transformers, with three current transformers), accuracy class 1, primary rated current 100 A, secondary rated current 1A, three window-type transformers are recommended (4NC5117-0CC20).

Note

When measuring the complete machine, it is recommended that the current is sensed directly after the main switch. For the voltage tap, please observe the usual protection/fusing.

Information on the installation, configuration and operation of the Power Monitoring Device and the expansion module can be found in the following references:

● SENTRON PAC3200 Power Monitoring Device Manual

(Document order number A5E01168664A-05)

● SENTRON PAC4200 Power Monitoring Device System Manual

(Document order number A5E02316180A-03)

● PAC PROFIBUS DP, SWITCHED ETHERNET PROFINET Expansion Module Manual

(document order number A5E01168846A-06)

3.1.2 Commissioning the Power Monitoring Device

A detailed description of commissioning of the SENTRON PAC Power Monitoring Device is provided in the corresponding manuals.

Preconditions

● The device has been installed.

● The optional expansion modules have been installed.

● The device has been connected in accordance with the possible connection methods.

● The battery has been inserted into the battery compartment (only for the SENTRON

PAC4200).

General procedure when commissioning the device

● Connected the supply voltage

● Parameterizing SENTRON PAC

● Connect the measuring voltage

● Connect the current to be measured

● Check the displayed measured values

● Check the polarity and phase assignment of the measuring transducer

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Ctrl-E Analysis

3.1 SENTRON PAC3200/4200

Parameterizing SENTRON PAC

You have the option of parameterizing the measuring device in the following ways:

● Using the input keys and display of the SENTRON PAC

● Using a PC connected to the SENTRON PAC, which has the software this has been supplied (powerconfig).

After booting select the language and the measuring device is then ready for operation.

3.1.3 Commissioning the PAC PROFIBUS expansion module (840D sl)

To communicate via Profibus, the SENTRON PROFIBUS module in combination with Sentron PAC3200/4200 must be parameterized differently.

1. Select SENTRON PAC "Settings" > "PROFIBUS modules".

- OR For SENTRON PAC4200, select "Settings" > "Expansion modules" > "MOD1" > "PROFIBUS MODULE".

2. Press "Enter". You obtain the following information in the subsequent window:

– Order number

– Serial number of the SENTRON PROFIBUS module

– Firmware version of the SENTRON PROFIBUS module

– PROFIBUS ADDR.:

The DP address of module is displayed here.

3. Press "Enter". This means that you have the option of entering the same PROFIBUS address as in the automation system.

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3.2 Commissioning the PLC for SENTRON PAC

3.1.4 Commissioning the expansion module PAC PROFINET (828D)

To communicate via PROFINET, the SENTRON SWITCHED ETHERNET PROFINET module in combination with Sentron PAC3200/4200 must be parameterized differently.

1. Select SENTRON PAC "Settings" > "SWITCHED ETHERNET".

- OR Select SENTRON PAC "Settings" > "Expansion modules" > "MOD1" > "SWITCHED ETHERNET".

2. Press "ENTER".

You obtain the following information in the subsequent window:

– Order number

– Serial number of the SENTRON SWITCHED ETHERNET PROFINET module

– Firmware version of the SENTRON SWITCHED ETHERNET PROFINET module

– The first character of the NameOfStation of the SENTRON SWITCHED ETHERNET

PROFINET module that can be a maximum of 26 characters

– IP-ADDR.:

The IP address of the module is displayed here.

Ctrl-E Analysis

3. Using the menu item "- ->", open the next window and obtain among other things the

information about the SUBNET address of the module.

Specifying/changing the device name

The device name can only be entered (it must be specified) using the powerconfig software in the submenu "Expansion slot1".

● Sentron PAC3200: pac3200-pn22

● Sentron PAC4200: pac4200-pn21

The next time that the 828D boots, the 828D IO controller assigns the correct IP address to the expansion module according to the device name:

● pac4200-pn21 --> 192.168.214.21

● pac3200-pn22 --> 192.168.214.22

3.2 Commissioning the PLC for SENTRON PAC

3.2.1 SINUMERIK 840D sl

3.2.1.1 Commissioning the PLC with PROFIBUS

PROFIBUS is commissioned with the PLC Toolbox 4.6 or higher.

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Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

Preconditions

● Configure the hardware, save and compile the project

● Generating the system data for the PLC

● Install the Toolbox software, which also contains the libraries for the PLC basic program of an NCU 7x0.3.

Note

PLC Toolbox 4.6SP1 requires STEP 7 V5.5 SP3 or higher.

Procedure

You are on the main screen of the SIMATIC Manager.

1. Select the "File" > "Open" menu and then click on the "Libraries" tab.

2. Select the library for the PLC basic program "bp7x0_46" and confirm the dialog with "OK".

3. You have inserted the library and selected the PLC program under "PLC-First-Startup 840D sl" > "SINUMERIK" > "PLC317F-3 PN/DP " > "S7 Program".

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3.2 Commissioning the PLC for SENTRON PAC

4. Copy the sources, modules and symbols to the PLC program

Ctrl-E Analysis

Figure 3-1 Hardware catalog after incorporating the GSD file

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Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

5. In HW Config, drag the selected module to the Profibus DP master system.

6. In the hardware catalog, open the required module and assign the subslots as shown in the diagram.

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PROFIBUS interface

PROFIBUS must be configured with a data transfer rate of 12 Mbit/s.

Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

Setting the PROFIBUS address

Set the PROFIBUS address of the expansion module either directly at the SENTRON PAC or enter using the powerconfig software.

References

Additional information about commissioning the PLC can be found in the following references:

CNC Commissioning Manual: NCK, PLC, drive / SINUMERIK 840D sl

3.2.1.2 Commissioning the PLC with PROFINET

PROFINET is commissioned with the PLC Toolbox 4.6 or higher. This requires SIMATIC STEP 7 V5.5SP3 or higher.

Preconditions

● Configure the hardware, save and compile the project

● Generating the system data for the PLC

● Install the Toolbox software, which also contains the libraries for the PLC basic program of

an NCU 7x0.3PN.

● GSDML for PAC PROFINET

http://support.automation.siemens.com/WW/view/de/50186868

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Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

Procedure

You are on the main screen of the SIMATIC Manager.

1. Select the "File" > "Open" menu and then click on the "Libraries" tab.

2. Select the library for the PLC basic program "bp7x0_46" and confirm the dialog with "OK".

3. You have inserted the library and selected the PLC program under "PLC-First-Startup 840D sl" > "SINUMERIK" > "CPU 317F-3 PN/DP" > "S7 Program".

4. Copy the sources, modules and symbols to the PLC program

Figure 3-2 Hardware catalog after linking-in the GSDML file

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3.2 Commissioning the PLC for SENTRON PAC

5. In HW Config, drag the selected module to the Profinet IO system.

Ctrl-E Analysis

6. In the hardware catalog, open the required module and assign the subslots as shown in

the diagram.

Note Port interconnection

To simplify commissioning, in HW Config configure the PAC PROFINET using port interconnection at the PROFINET ports of the NCU. This saves you from having to initialize PAC.

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Ctrl-E Analysis

3.2 Commissioning the PLC for SENTRON PAC

References

Additional information about commissioning the PLC can be found in the following references:

CNC Commissioning Manual: NCK, PLC, drive / SINUMERIK 840D sl

3.2.2 SINUMERIK 828D

The PLC of the 828D has a fixed PLC I/O image.

Using the general machine data MD12986[...], the possible peripheral connections (addresses) are activated or deactivated. When delivered, these addresses are deactivated for the Sentron devices by entering the address.

Activating the peripheral connection

● SENTRON PAC4200

I address

132 ... 135 Total active power

136 ... 139 Active energy, imported, tariff 1 (instantaneous value) 140 ... 143 Active energy, exported, tariff 1 (instantaneous value)

(value saved from SENTRON PAC)

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References

Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

For example, you activate the logical input address 132 by changing the machine data MD[...] with entry 132 to -1.

● SENTRON PAC3200

I address

144 ... 147 Total active power

(value saved from SENTRON PAC) 148 ... 151 Active energy, imported, tariff 1 (instantaneous value) 152 ... 155 Active energy, exported, tariff 1 (instantaneous value)

For example, you activate the logical input address 144 by changing the machine data MD[...] with entry 144 to -1.

The measured values are transferred in the float format.

Additional information about commissioning the PLC can be found in the following references:

SINUMERIK 828D Turning and Milling Commissioning Manual

3.3 Commissioning the PLC for Ctrl-E Analysis

3.3.1 Configuring the energy consumption display for SINUMERIK 840D sl

The energy consumption is displayed in the "SINUMERIK Ctrl-E Analysis" window.

3.3.1.1 PLC user program for SINUMERIK 840D sl programming

Via the expansion modules, SENTRON PAC devices provide the total active power in the unit W and the active energy data in Wh. In HMI the units kW and kWh are used.

PLC basic program

The PLC basic program offers the following functions:

● Provision of the total active power [kW]

● Provision of the values for imported and exported active energy [kWh] for the current day, month and the current year as well as for the previous day, previous month and the previous year. The values of the current time periods are updated in every cycle. If one of the time periods changes (new day, new month or new year) then the "current" variables of the time period that changes is copied into its previous day, previous month or previous year variables and the "current" variables are accumulated again starting from 0.

ActiveEnAuxMeasOFF REAL

ReActiveEnAuxMeasOFF REAL

● Two measuring procedures for imported and exported active energy [kWh]

– Measuring carried out by the basic program

– The user calculates and writes the measured values

This allows user-specific measuring routines to be implemented.

The two values of measured imported energy [kWh] (DBD12) and the measured exported energy [kWh] (DBD16) are made available for the HMI. The source of the values as well as measuring procedure and measuring duration (start, stop) are defined using measurement control bits.

Programming the PLC user program

● You take the total active power from the input address and transfer the value to DB1001.DBD20.

● You take the imported active power from the input address and transfer the value to DB1001.DBD24.

● You take the exported active power from the input address and transfer the value to DB1001.DBD28.

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

● If the control bits DB1001.DBX0.2 and DBX0.3 are equal to 0, then the HMI counts the energy on the basis of the total active power transferred from the SENTRON between the start and stop.

● If the imported and exported energy is to be directly evaluated by SENTRON PAC (DB1001.DBX0.2 and DBX0.3 equal to 1), then program this measurement in the user program as follows:

– SENTRON PAC devices permanently cumulate the "imported active energy (tariff 1)"

or "the exported active energy (tariff 1)" separately when their supply voltages are connected.

– With the positive edge of the signal "Measurement running" (DB1001.DBX2.0) you

buffer these instantaneous values from SENTRON (imported and exported active energy T1)

– Cyclically generate the differences between the energy data now being counted minus

the initial values, divide the differences by 1000.0 and transfer the results to DB1001.DBD12 (for measured imported active energy T1) and DB1001.DBD16 (measured exported active energy T1) up to the STOP signal (falling edge).

– During the measurement, the increasing difference (energy in kWh) is displayed on the

HMI, which can then be read as measured value with Stop measurement.

Measurement control HMI → GP and PLC → GP

● With a 1 signal of the control bit "MeasAuto" (DBX1.0), the user requests that the basic program makes the measurement. If this bit is not set, then the user is responsible for calculating and writing the measured values.

● Using a 1 signal of the control bit "MeasAct" (DBX2.0), via the HMI it is signaled as to when the measurement should be made: 0→1 start measurement, 1→0 stop measurement. The basic program only evaluates this signal if control bit "MeasAuto" (DBX1.0) is set.

Measurement carried out by the basic program: For these measurements, the cyclic increases in the energy values are accumulated in the

measured variables.

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

The behavior for different signal sequences of both measurement control signals are described in the following:

● DBX1.0 is set first

If DBX1.0 ("MeasAuto") is first set, and then remains statically present, every 0-1 edge of DBX2.0 ("MeasAct") deletes the measured value and then starts the measurement. If DBX2.0 is reset, the measurement is canceled and the measured value remains constant. The sequence is repeated at the next 0-1 edge of DBX2.0.

Figure 3-3 Measurement control signal DBX1.0 is set first

● DBX2.0 is set first

If DBX2.0 ("MeasAct") is set first, and then remains statically present, every 0-1 edge of DBX1.0 ("MeasAuto") accumulates the measured value without deleting the previous value. If DBX1.0 is reset, the measurement is only interrupted and the measured value remains constant.

Figure 3-4 Measurement control signal DBX2.0 is set first

3.3.2 Configuring the display of energy consumption for SINUMERIK 828D

The energy consumption is displayed in the "SINUMERIK Ctrl-E Analysis" window.

3.3.2.1 Programming the PLC user program for SINUMERIK 828D

Via the expansion modules, SENTRON PAC devices provide the total active power in the unit W and the active energy data in Wh. In HMI the units kW and kWh are used.

ActiveEnAuxMeasON REAL

ActiveEnAuxMeasOFF REAL

PLC firmware

The PLC firmware offers the following functions:

● Provision of the total active power [kW]

● Provision of the values for imported and exported active energy [kWh]

for the current day, month and the current year as well as for the previous day, previous month and the previous year. The values of the current time periods are updated in every cycle. If one of the time periods changes (new day, new month or new year) then the "current" variables of the time period that changes is copied into its previous day, previous month or previous year variables and the "current" variables are accumulated again starting from 0.

● Two measuring procedures for imported and exported active energy [kWh]

– Measurement carried out by the PLC firmware (see "Measurement control HMI → FW

and PLC → FW")

– The user calculates and writes the measured values

This allows user-specific measuring routines to be implemented.

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

Programming the PLC user program

● You take the total active power from the input address and transfer the value to DB9907.DBD20. This must be realized according to the following point "Adapt byte sequence".

● You take the imported active power from the input address and transfer the value to DB9907.DBD24. This must be realized according to the following point "Adapt byte sequence".

● You take the exported active power from the input address and transfer the value to DB9907.DBD28. This must be realized according to the following point "Adapt byte sequence".

● If the control bits DB9907.DBX0.2 and DBX0.3 are equal to 0, then the HMI counts the energy on the basis of the total active power transferred from the SENTRON between the start and stop.

● If the imported and exported energy is to be directly evaluated by SENTRON PAC (DB9907.DBX0.2 and DBX0.3 equal to 1), then program this measurement in the user program as follows:

– SENTRON PAC devices permanently cumulate the "imported active energy (tariff 1)"

or "the exported active energy (tariff 1)" separately when their supply voltages are connected.

– With the positive edge of the signal "Measurement running" (DB9907.DBX2.0) you

buffer these instantaneous values from SENTRON (imported and exported active energy T1)

– Cyclically generate the differences between the energy data now being counted minus

the initial values, divide the differences by 1000.0 and transfer the results to DB9907.DBD12 (for measured imported active energy T1) and DB9907.DBD16 (measured exported active energy T1) up to the STOP signal (falling edge).

– During the measurement, the increasing difference (energy in kWh) is displayed on the

HMI, which can then be read as measured value with Stop measurement.

Adapting the byte sequence

Save the values of the SENTRON PAC so that the byte sequence of the double words is swapped over (Endian conversion).

The CTRL_E and SENTRON blocks are located in the following directory:

Ctrl-Energy

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

Example for SINUMERIK 828D with SENTRON PAC3200 Swap over the byte sequence of the total active power in ID144:

For the total active power, the numerical value of 18.4 is supplied from SENTRON. This corresponds to a hexadecimal value of 0x41933334, which is located just like this in the double word ID144. To be further processed by the PLC, the sequence of these four bytes must be swapped over: 0x34339341.

Also the values for the active energy import tariff 1 and active energy export tariff 1 must be handled in this way.

Figure 3-5 SWAP_DW subroutine

Figure 3-6 Byte sequence

You can find the SWAP_DW subroutine on the Toolbox-CD under Examples\PLC

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 35

Page 36

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Ctrl-E Analysis

3.3 Commissioning the PLC for Ctrl-E Analysis

Measurement control HMI → FW and PLC → FW

● With a 1 signal of the control bit "MeasAuto" (DBX1.0), the user requests that the firmware makes the measurement. If this bit is not set, then the user is responsible for calculating and writing the measured values.

● Using a 1 signal of the control bit "MeasAct" (DBX2.0), via the HMI it is signaled as to when the measurement should be made: 0→1 start measurement, 1→0 stop measurement. The firmware only evaluates this signal if control bit "MeasAuto" (DBX1.0) is set.

Measurement carried out by the firmware For these measurements, the cyclic increases in the energy values are accumulated in the

measured variables.

The behavior for different signal sequences of both measurement control signals are described in the following:

● DBX1.0 is set first If DBX1.0 ("MeasAuto") is first set, and then remains statically present, every 0-1 edge of DBX2.0 ("MeasAct") deletes the measured value and then starts the measurement. If DBX2.0 is reset, the measurement is canceled and the measured value remains constant. The sequence is repeated at the next 0-1 edge of DBX2.0.

Figure 3-7 Measurement control signal DBX1.0 is set first

● DBX2.0 is set first If DBX2.0 ("MeasAct") is set first, and then remains statically present, every 0-1 edge of DBX1.0 ("MeasAuto") accumulates the measured value without deleting the previous value. If DBX1.0 is reset, the measurement is only interrupted and the measured value remains constant.

Figure 3-8 Measurement control signal DBX2.0 is set first

Ctrl-Energy

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3.4 Commissioning the HMI for Ctrl-E Analysis

No additional adaptation is required.

As soon as the DB1001 (840D sl) or the DB9907 (828D) is available and actively assigned with data words, then the HMI automatically accepts this data.

If you have configured auxiliary systems, these devices are displayed as "AUX1" to "AUX10" in the Ctrl-E analysis. You can assign these devices language-dependent display texts.

3.4.1 Changing display texts of the auxiliary systems

The display texts for the auxiliary systems are stored in the "slnrgauxunits_xxx.ts" file. A dedicated file must be created for each supported language. The file names differ by the language code. Set the appropriate language code for "xxx" (e.g. "slnrgauxunits_eng.ts" for English).

Structure of the "slnrgauxunits_xxx.ts" file

Ctrl-E Analysis

Procedure

In the "slnrgauxunits_xxx.ts" file, the text identifiers from the software are assigned languagedependent texts.

Tag Meaning source Text identifier

The auxiliary systems are identified with "AUX_UNIT_1" to "AUX_UNIT_10".

translation Text which is displayed on the user interface.

You can enter single and multi-line texts. "%n" is used to generate a line

break. chars Text length (number of characters) lines Number of lines

1. Copy the "slnrgauxunits_deu.ts" template file from the directory: siemens/sinumerik/

hmi/template/lng.

2. Save the file to the /oem/sinumerik/hmi/lng or /user/sinumerik/hmi/lng directory.

3. If required, change the file name. If you wish to create texts for additional languages, then a separate file must be created for each language. Save the file with the appropriate language code in the file name.

4. Open the file and enter the text to be displayed between the <translation> and </translation> tags.

5. Restart SINUMERIK Operate. The file must still be converted into a binary format so that the texts can be displayed during the program runtime. This conversion is only executed when the HMI powers up.

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Ctrl-E Analysis

3.6 Power display in the status line of the "Machine" operating area

3.5 Long time measurement

In order that you can read the usage values in the Ctrl-Energy initial window and in the "Long time measurement" window, program the PLC user program as specified in Chapter 2.3.1.1 (840D sl) or 2.3.2.1 (828D).

3.6 Power display in the status line of the "Machine" operating area

The current energy consumption is displayed in the first line of the status display in the "Machine" operating area in the form of colored bars.

To show the power display set DB1001.DBX3.0 = 1 in the STEP 7 program of the PLC.

The following machine statuses are displayed:

Displaying the machine status DB1001.DBB96 = 0 Red bar upwards – the machine is unproductive

DB1001.DBB96 = 1 Dark green bar upwards – the machine is productive and consumes

energy

DB1001.DBB96 = 2 Light green bar downwards – the machine feeds energy back into

the line supply (generator operation)

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Ctrl-E Profiles

To optimize the energy consumption, you have the option of defining energy saving profiles and saving them.

Controlling the energy-saving states of the machine

The following pre-defined energy-saving profiles are available when the system is delivered:

● Simple energy-saving mode (machine standby) A specific interface signal is initiated if the control has not exited the reset state after a defined time. Using this signal, with the PLC a pre-defined energy state is established, where, for example it is still possible to operate the machine for setting-up purposes.

● Full energy-saving mode (NC standby) A specific interface signal is initiated if none of the keys on the machine control panel at the control has been pressed for a specific time. A pre-defined energy state can be established with the PLC using this signal, where it is still possible, for example, to transfer programs to the control or edit them.

● Maximum energy-saving mode (auto shut-off) An additional interface signal is initiated if, at the control, no key on the operator panel and machine control panel has been pressed for a defined time and there is no active communication with the external device. Via the PLC, the main switch is automatically opened, e.g. using the undervoltage release function.

These predefined energy-saving profiles only become effective if the control system is in the reset state. They can be blocked using a PLC user signal. The energy-saving profiles can be changed at any time and supplemented to include up to a total of 8 profiles.

For instance, you have the option of assigning a customer key to an energy-saving profile, with which the control can be immediately shut down.

4.1 Commissioning the PLC for Ctrl-E Profiles

4.1.1 Overview

In every machine tool, the PLC is the central part of the control for the peripherals and mounted equipment/devices. Each machine can have several operating stations.

The energy-saving profiles are managed and stored in the PLC. The signals to monitor energy within the machine are available in the PLC; these signals can then be appropriately logically combined in the PLC user program.

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Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

SINUMERIK 840D sl

In SINUMERIK 840D sl, "Ctrl+Energy" is integrated in the basic program (FB15). Data for each energy-saving profile is saved in DB1000, which is supplied with the Toolbox.

SINUMERIK 828D

In SINUMERIK 828D, "Ctrl+Energy" is integrated in the PLC firmware. The data for each energy-saving profile is saved in the DB9906, which is included in the Programming Tool 828D. In the other versions, for the "basic program (FB15)" for 828D, "PLC firmware" applies.

Energy-saving profiles

The PLC supports 8 energy-saving profiles. After the relevant configured delay times have expired, the energy-saving profiles are individually active. The total time up until the energysaving profile is activated is obtained from its activation time plus the prewarning time. During the two time intervals, the selected signals, enabled using masking, are monitored for any activity and the profile only becomes finally active when the signals are completely inactive. Of course, when required OEMs can configure either one or both times with zero.

The energy-saving profile in the PLC is characterized by the following data:

● the maximum time for T1 – the activation time

● the maximum time for T2 – the prewarning limit time of the user

● the actual value for T1

● the actual value for T2

● masking of the signals to assume/exit the energy-saving state

The times have the units of seconds, are 16 bits wide and unsigned. A maximum time is therefore approximately 18 hours.

Note

The time until the energy-saving profile has been finally activated is obtained by adding the actual values of T1 and T2

The data for each energy-saving profile is saved in DB1000 for the 840Dsl and in DM9906 for the 828D.

4.1.2 Automatic state machine PLC functions

The automatic state machine shows the functionality in the PLC.

The state transition "OFF" results in a change into the "Energy-saving state inactive" from every other state. This corresponds to "waking up" the machine.

After the NCU powered up, every energy-saving profile in the state "Energy-saving state inactive" and the actual values of the times T1 and T2 are set to the maximum values.

Ctrl-Energy

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Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

An energy-saving profile runs through the displayed automatic state machine if the associated "energy-saving profile initialized" bit is set. The HMI resets this bit before changing the times or the signal mask, and sets it after the values have been consistently written into the PLC.

When the "Energy-saving profile active" bit is set, then an energy-saving profile is considered to have been assigned.

Figure 4-1 State monitoring

Transition to "RUN" All of the signals that have been enabled for evaluation using the following masking bits, are

inactive (also see Chapter 3.1.5.2.):

DBX 11.0, DBX 11.1, DBX 11.2 HMI activities DBX 12.0 MCP activities

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 41

DBX 13.0 – DBX 13.7 NCK channel activities DBX 14.0, DBX 14.1 NCK channel activities DBX 15.0, DBX 15.1 Master computer and PLC prohibit signals The specified signals refer to energy-saving profile 1.

Page 42

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Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Transition to "OFF" DBX 10.1 == 1 ("deactivate profile") or delete the profile: highest priority and independent

of the profile initialization

- OR - 0-1 edge at the DBX 10.0 ("profile is initialized")

- OR - At least one of the signals that have been enabled for evaluation using the following masking

bits, is inactive (also see Chapter 3.1.5.2.): DBX 11.0, DBX 11.1, DBX 11.2 HMI activities DBX 12.0 MCP activities DBX 13.0 – DBX 13.7 NCK channel activities DBX 14.0, DBX 14.1 NCK channel activities DBX 15.0, DBX 15.1 Master computer and PLC prohibit signals The specified signals refer to energy-saving profile 1.

4.1.3 Checking the energy-saving states

The following signals are checked when entering or retaining the energy-saving profile. The signals can be masked for each energy-saving profile.

Signal Function Generated by the HMI

Keyboard has been used (state condition "No key press‐

ed on the operator panel")

42 System Manual, 01/2015, 6FC5397-0EP40-5BA2

This signal is set if in the last second the keyboard of the SINUMERIK control was used. This signal is only available once for each control system and is automatically linked through the masking. In the case of several operator panels, the group signal of all keyboards is used. For a keystroke, the HMI sets this bit and the PLC handles the reset process.

Ctrl-Energy

Page 43

Signal Function Data transfer active

(state condition "No communi‐ cation with an external device active (USB, Ethernet, V24)")

Screen change active (state condition "No screen

change realized") Generated by the PLC basic program (828D: PLC firmware) Machine control panel used (state condition "No key press‐

ed on the machine control pan‐ el")

NCK activity (state condition "NC channel/

channels in reset") From the PLC user program interface Master computer prohibits (state condition "master com‐

puter signal prohibits") PLC user program signal (state condition "PLC user sig‐

nal prohibits")

This signal is set if data is being transferred. After completion of the data transfer, the HMI resets this bit. This includes the use of a USB memory medium, a V24 connection or a network drive.

This signal is also set when generating or importing a commissioning archive. This signal is only available once for each control system and is automatically linked through the mask‐ ing. In the case of several operating stations, the group signal is formed. Acyclic S7 com‐ munication in the sense of a connected engineering system or an external HMI does not apply as data transfer in the sense of this signal.

This signal is set if a screen is being changed. After processing, the PLC resets the bit. This signal is only available once for each control system and is automatically linked through the masking. For several operator stations, the group signal is formed here.

This signal is set if the machine control panel in the PLC is used. To do this, a specified address range of the inputs is monitored in the PLC.

● For 840D sl, the ranges addressed via parameters DB7 MCP1In and MCP2IN

● For 828D, the input range of the PN-MCP This signal is only available once for each control system and is automatically linked through

the masking. The group signal is formed when several machine control panels are being used.

This signal is set if the NCK channel is not in the Reset channel state. Note: Static synchronized actions, which are also active in the Reset channel state = TRUE,

are not detected and must be taken into account by the user.

Using this signal, an external master computer or a coupled control system can prevent that the energy-saving profile is activated. This signal is available in the user interface for each energy-saving profile.

Using this signal, from the user program in the PLC, an energy-saving profile can be pre‐ vented from being activated. This signal is available in the user interface for each energysaving profile.

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

4.1.4 PLC user program

The following signals are available in the user program for controlling the energy-saving profiles. These signals are not masked within the energy profile, and are available for each profile.

Signal Function Control signal to "directly acti‐

vate the energy-saving profile"

Set time to prewarning limit When setting this signal, the timer for the prewarning limit T2 is set to its setpoint and is

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 43

The energy-saving profile is immediately activated when this signal is set. The two timers are set to zero. For the case that the energy profile has already been activated, no change is made.

then restarted. This is also the case, even if the energy-saving profile is already active. The activation is then reset, and after the prewarning time is set again.

Page 44

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Signal Function Feedback signal, "prewarning

time T1 expired" Feedback signal, "prewarning

time T2 expired"

This signal is set by the basic PLC program (FB15) if the timer has expired and the pre‐ warning is output on the HMI.

This signal is set by the basic PLC program (FB15) if, after the prewarning limit has been reached, also the prewarning time of the corresponding energy profile has expired. This means that this signal is equivalent to the information "Energy-saving state active".

Note Shutdown auxiliary equipment

If auxiliary equipment is also to be shut down using the "Prewarning time expired" signal, which acknowledges the shutdown process, then using a normal PLC timer and the signal "PLC user program signal", a monitoring function can be installed in the basic PLC program. If the auxiliary equipment has still not been run down after the PLC timer has expired, then the energy-saving state can be exited again using the "PLC user program signal".

4.1.5 Interface signals 840D sl

4.1.5.1 Signals for controlling energy-saving profiles

Dynamic data are cleared when the control powers up.

The signals described in the following section refer to energy-saving profile 1.

Control signals (user program)

DB1000 DBX0.0 Directly activate energy-saving profile

DBX0.1 Set time to prewarning limit

Control signals (HMI)

DB1000 DBX1.0 Directly activate energy-saving profile

Signals to check the energy-saving state (user program)

DB1000 DBX2.0 Master computer prohibits energy-saving state

DBX2.1 PLC user program signal prohibits energy-saving state

Ctrl-Energy

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Status signals

DB1000 DBX4.0 Energy-saving profile is active

DBX4.1 Prewarning limit T1 reached

Actual values

DB1000 DBW6 Actual value T

DBW8 Actual value T

4.1.5.2 Signals for parameterization

Retentive parameterization data.

Effectiveness (HMI → PLC)

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

DB1000 DBX 10.0 Energy-saving profile configured

DBX 10.1 Disable energy-saving profile

Masking (HMI → PLC)

DB1000 DBX 11.0 Keyboard has been used

DBX 11.1 Data transfer active DBX 11.2 Screen change active DBX 12.0 Machine control panel used DBX 13.0 NCK channel 1 DBX 13.1 NCK channel 2 DBX 13.2 NCK channel 3 DBX 13.3 NCK channel 4 DBX 13.4 NCK channel 5 DBX 13.5 NCK channel 6 DBX 13.6 NCK channel 7 DBX 13.7 NCK channel 8 DBX 14.0 NCK channel 9 DBX 14.1 NCK channel 10 DBX 15.0 Master computer prohibits* DBX 15.1 PLC user program signal prohibits*

*prohibits changing into the energy-saving mode

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Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

Maximum times (HMI → PLC)

DB1000 DBW 16 Activation time T

DBW 18 Time for the prewarning limit T

Additional profile instances

DB1000 DBW 20 Energy-saving profile 2

DBW 40 Energy-saving profile 3 DBW 60 Energy-saving profile 4 DBW 80 Energy-saving profile 5 DBW 100 Energy-saving profile 6 DBW 120 Energy-saving profile 7 DBW 140 Energy-saving profile 8

4.1.6 Interface signals 828D

4.1.6.1 Signals for controlling energy-saving profiles

Dynamic data are cleared when the control powers up.

Control signals (user program)

DB9906 DBX0.0 Directly activate energy-saving profile

DBX0.1 Set time to prewarning limit

Control signals (HMI)

DB9906 DBX1.0 Directly activate energy-saving profile

Signals to check the energy-saving profile (user program)

DB9906 DBX2.0 Master computer prohibits energy-saving state

DBX2.1 PLC user program signal prohibits energy-saving state

Ctrl-Energy

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Page 47

Status signals

DB9906 DBX4.0 Energy-saving profile is active

DBX4.1 Prewarning limit T1 reached

Actual values

DB9906 DBW6 Actual value T

DBW8 Actual value T

4.1.6.2 Signals for parameterization

Retentive parameterization data.

Effectiveness (HMI → PLC)

Ctrl-E Profiles

4.1 Commissioning the PLC for Ctrl-E Profiles

DB9906 DBX10.0 Energy-saving profile configured

DBX 10.1 Disable energy-saving profile

Masking (HMI → PLC)

DB9906 DBX11.0 Keyboard has been used

DBX11.1 Data transfer active DBX11.2 Screen change active DBX12.0 Machine control panel used DBX13.0 NCK channel 1 DBX13.1 NCK channel 2 DBX15.0 Master computer prohibits* DBX15.1 PLC user program signal prohibits*

*prohibits changing into the energy-saving mode.

Maximum times (HMI → PLC)

DB9906 DBW16 Activation time T

DBW18 Time for the prewarning limit T

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Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

Additional instances

DB9906 DBW20 Energy profile 2

DBW40 Energy profile 3 DBW60 Energy profile 4 DBW80 Energy profile 5 DBW100 Energy profile 6 DBW120 Energy profile 7 DBW140 Energy profile 8

4.2 Creating and editing energy-saving profiles

You can make the following changes in the list of energy-saving profiles in the commissioning mode:

● Creating new energy-saving profiles with prewarning time and activation time period.

● Changing state conditions, prewarning time and activation time period

● Deleting energy-saving profiles

● Importing externally generated energy-saving profiles into the system

● Backing up energy-saving profiles on an external medium

Note Maximum number of energy-saving profiles

A maximum of 8 energy-saving profiles can be created.

If the maximum number of profiles already exists, then the "New" softkey is no longer available. To create a new energy-saving profile, remove a profile using the "Delete" softkey or change an existing profile using the "Change" softkey.

Note Access level of the energy-saving profiles for users

You specify the access level for the "Energy-saving profiles" softkey in the "Parameter" operating area using the machine data 51071 $MNS_ ACTIVATE_CTRL_E (protection level 1 as standard; this must be explicitly enabled by the manufacturer).

Note Designations of energy-saving profiles that have been created

The names of the new energy-saving profiles that have been created are only visible at the control where you generated them.

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Page 49

Energy conditions

Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

The following criteria are available for configuring an energy-saving profile:

State conditions Meaning No key on the operator panel pressed To activate the energy-saving profile, it is not permis‐

sible that an operator panel key is pressed.

No key on the machine control panel pressed To activate the energy-saving profile, it is not permis‐

sible that a machine control panel key is pressed.

No screen change realized To activate the energy-saving profile it is not permis‐

sible that a screen is being changed.

No communication with an external device ac‐ tive (USB, Ethernet, V24)

NC channel/channels in Reset To activate the energy-saving profile, NC channel/

Master computer signal prohibits To activate the energy-saving profile, it is not permis‐

PLC user signal prohibits To activate the energy-saving profile, it is not permis‐

Activation of the energy-saving profile after Here, you enter the time period after which the ener‐

Prewarning after Here, you enter when the system starts to display the

To activate the energy-saving profile, it is not permis‐ sible that data is being exchanged with an external device, for example.

channels must be in the Reset state.

sible that a signal is received from the master com‐ puter.

sible that a signal is received from the PLC user pro‐ gram.

The OEM can logically combine other state condi‐ tions with this signal and influence the profiles.

gy-saving profile is activated.

prewarning. Note: If you enter the same value into the "Activation of the

energy-saving profile after" and "Prewarning after" fields, then no message is displayed specifying the remaining time up until the energy-saving profile is activated.

Note Protection levels for editing energy-saving profiles

You define the protection level that is required in order to create or edit an energy-saving profile in machine data 51072 $MNS_ACCESS_EDIT CTRL_E (default, protection level 2 (service)).

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Page 50

Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

Procedure

1. Select the "Startup" operating area.

2. Press the "HMI" and "Ctrl-Energy" softkeys. The window "SINUMERIK Ctrl-Energy: Definition of the energy-saving

profile" is opened.

Newly creating/changing energy profiles

3. Position the cursor on the line where you wish to create a new energysaving profile and press the "New" softkey.

The window "SINUMERIK Ctrl-Energy: Definition of the energy-saving profile" is opened.

In the "Designation" field, enter the desired name for the new energysaving profile. Activate the required state conditions. Specify the times to display the prewarning limit and to activate the energy-saving profile.

- OR Position the cursor on the energy-saving profile that you want to edit and

press the "Change" softkey. The window "SINUMERIK Ctrl-Energy: Definition of the energy-saving

profile" is opened. In the "Designation" entry field, enter the modified name of the energy-

saving profile. Select or deselect the state conditions that should be ef‐ fective for the modified energy-saving profile - and when required, change the time data.

4. Press the "OK" softkey.

The new or modified energy-saving profiles are activated. The modified texts (def_conditions<long>.ts) are saved in the \oem\sinu‐

merik\hmi\lng directory.

Importing energy-saving profiles

5. Press the "Import profile" softkey.

The "Import energy-saving profiles" window is displayed. Select the required XML file and press the "OK" softkey. After a prompt,

the energy-saving profiles are downloaded into the PLC. The associated text files (def_conditions<long>.ts) are saved in the \oem

\sinumerik\hmi\lng directory. Note: After importing the energy-saving profiles, a restart is required in order

to make the profiles effective.

Exporting energy-saving profiles

6. Press the "Export profiles" softkey.

The window "Export energy-saving profiles: Select storage location" opens.

Ctrl-Energy

50 System Manual, 01/2015, 6FC5397-0EP40-5BA2

Page 51

7. Select the required storage location and press the "OK" softkey. The language-neutral state data are stored in the XML format, the asso‐

ciated texts in a .ts file. You have the option of selecting a name for the XML file (default: def_conditions.xml).

The text files are saved under a fixed name. All of the defined energysaving profiles are always exported.

Note: Please note that the energy-saving profiles supplied from Siemens are

also deleted. It is recommended that the energy-saving profiles are al‐ ways exported and backed up.

Deleting energy-saving profiles

8. Select the energy-saving profile that you want to delete from the list and press the "Delete" softkey.

9. Confirm the prompt with "OK" to remove the profile.

Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 51

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Ctrl-E Profiles

4.2 Creating and editing energy-saving profiles

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52 System Manual, 01/2015, 6FC5397-0EP40-5BA2

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Reactive power compensation

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In addition, within a sensible scope, this feature can be used to compensate other (generally inductive) loads connected to machine.

As a result of the properties of the SINAMICS S120 Active Line Module as actuator on one hand, the properties of SENTRON PAC4200 as measuring element as well as additional PLC blocks (also as controller), this function can be implemented with the SINUMERIK 840D sl also independent of NC software releases.

Further information

Please contact your local sales organization if you require additional information regarding reactive power compensation.

Function schematic

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 53

Figure 5-1 Principle of operation of reactive power compensation

Page 54

Reactive power compensation

Ctrl-Energy

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Page 55

Flux reduction

In the drive parameters (p1581 [0..n]), the rated magnetization for induction motors – which is normally 100% – can be permanently reduced. This includes the switching times for reducing and building up the flux (r1578, r1579[0…n]).

In this case, not only can the magnetizing losses in the motors be reduced at standstill, but also during operations that only require a lower power.

Optimization criterion

Under no-load conditions, the percentage value of the rated magnetization is reduced in steps of between 5-10% to just above a value where the no-load behavior starts to become uneven.

From this limit value onwards, rough operating behavior can be heard as a result of the significantly fluctuating active current.

It makes sense to monitor the current characteristic and this transition point using a trace function.

Options for use

You have various options to specifically use this.

● Permanently set the actual parameter set p1581 [0] to the determined value <100%. Taking into consideration the time constants, the flux is automatically reduced if the instantaneous active power permits this. If more active power is demanded, then the flex automatically increases back up to 100% with the corresponding time constant. This does not have a negative impact on the process.

● Preselecting various parameter sets If load changes are to be expected in a time shorter than the time constant (e.g. for an interrupted roughing cut with facing head milling tools), it may be more favorable for the process if the flux is permanently controlled by pre-selecting various parameter sets by knowing the machining to be expected or the tool involved. Example ((see the interface signals at the spindle DB31-61.DBB21)) Bit0: = 0: p1581 [0] = 100%; p1578 [0] and p1579 [0] = factory setting, e.g. for an interrupted cut Bit0: = 1: p1581 [1] < 100%; p1578 [1], p1579 [1], adapted for partial load or no load

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 55

Page 56

Flux reduction

Ctrl-Energy

56 System Manual, 01/2015, 6FC5397-0EP40-5BA2

Page 57

User know-how

Machine manufacturers are being increasingly confronted with special demands from users regarding proving energy consumption data or displaying limit values, for example.

Using SINUMERIK Integrate Run MyScreens (Easy Screen), it is possible to visualize the functions obtained from these requirements, and also position them in the context of CtrlEnergy.

Displaying additional measuring data

The SENTRON PAC 3200/4200 Power Monitoring Devices provide, in different expansion stages, a wealth of electrical measured data.

In addition to the active power/active energy displayed today in SINUMERIK Operate, using Easy Screen, you have the option of displaying, for example, the reactive power/reactive energy and the apparent power/apparent energy of the measuring location in customized screen forms.

References

More information on the various measuring options is available in the following references:

● SENTRON PAC3200 Power Monitoring Device Manual

● SENTRON PAC4200 Power Monitoring Device System Manual

7.1 Commissioning user screen forms

General procedure

● You create your own screen forms in SINUMERIK Integrate Run MyScreens (Easy Screen), for example in a xxx.com file.

● You insert the new "xxx.com" project file name in "easyscreen.ini" in the "Parameter" area.

● Save the modified "easyscreen.ini" in the following directory: oem\sinumerik\hmi\cfg\.

● If the released horizontal softkey 7 in the extended softkey bar of the "Parameter" operating area is already used with a "yyy.com", then you have the option of programming the vertical softkey 4 behind the "Ctrl-Energy" softkey for an additional "xxx.com". An additional neutral "aufruf.com" file is created with the following start softkeys:

//S(START)

VS4=("Start XXX")

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 57

Page 58

User know-how

7.1 Commissioning user screen forms

PRESS(VS4)

LM("maske_xxx","xxx.com")

END_PRESS

HS7=("Start YYY")

PRESS(HS7)

LM("maske_yyy","yyy.com")

END_PRESS

//END

These start calls directly access the specified screen forms of the relevant *.com files. A start softkey in these particular *.com files can be omitted.

● Save the project files "xxx.com", "yyy.com" and "aufruf.com" in the following directory: oem \sinumerik\hmi\proj\.

References

Additional information on the design and configuration of user interfaces is provided in the following references on SINUMERIK Integrate Run MyScreens (Easy Screen):

Programming Manual Easy Screen (BE2); SINUMERIK 840D sl

Ctrl-Energy

58 System Manual, 01/2015, 6FC5397-0EP40-5BA2

Page 59

Appendix

A.1 Overview

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 59

Page 60

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Appendix A.1 Overview

60 System Manual, 01/2015, 6FC5397-0EP40-5BA2

Ctrl-Energy

Page 61

Index

Commissioning HMI, 39 Configuring

Energy-saving profiles, 48

Ctrl Energy

Functions, 9

Energy consumption

display in status line, 38

Energy-saving profiles, 39

Edit, 48

Hardware, 12

PLC functions, 40 PLC user program, 43 Power Monitoring Device

Commissioning, 13

PROFIBUS

Commissioning the PLC (840D sl), 15

SENTRON PAC3200/4200

Commissioning the PLC (840D sl), 15, 19 Parameterizing, 14 Profibus (840D sl), 15

Status bar

Displaying energy consumption, 38

Ctrl-Energy System Manual, 01/2015, 6FC5397-0EP40-5BA2 61

Page 62

Index

Ctrl-Energy

62 System Manual, 01/2015, 6FC5397-0EP40-5BA2