Datasync Doku v31 en

Communication:
Performant Data Synchronization

Between Several Field and One Head
PLC
S7-1200 Set 17
Application Example
March 2016
Siemens Industry Online Support

Answers for industry.
Warranty and liability
Warranty and liability

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Datasync
Entry-ID: 39040038,
V3.1,
21.03.2016
Table of contents
Datasync 39040038
Table of contents
Warranty and liability ................................................................................................... 2
1
Task ..................................................................................................................... 4
Solution overview .............................................................................................. 5

2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.2
The blocks of the data synchronization ........................................................ 14

39040038_DATASYNC_DOKU_V31_en.docx
3.1
3.1.1
3.1.2
3.2
3.2.1
3.2.2
3.3
4
Hardware installation .......................................................................... 32

Software installation ........................................................................... 33
Starting up the Application ............................................................................. 34

7.1
7.2
Assigning the IP addresses ................................................................ 34

Download the PLCs and the panels ................................................... 37
Operating the Application ............................................................................... 40
Related literature ............................................................................................. 42
10
History............................................................................................................... 42
11
Appendix A: Measured Data ........................................................................... 43

11.1
11.2
11.3
11.4
V3.1
Conception of the measurement ........................................................ 28

Values of the performance measurement .......................................... 30
Result ................................................................................................. 31
Installation ........................................................................................................ 32
6.1
6.2
Control process in the overview ......................................................... 25

Functioning of the function block DATASYNC_X .............................. 26
Behavior in the event of a power failure ............................................. 27
Performance Measurement ............................................................................ 28

5.1
5.2
5.3
Complete overview of the program blocks ......................................... 14

Program overview of the head PLC ................................................... 14
Program sequence in the field PLC ................................................... 15
Data blocks ......................................................................................... 16
The data block of the head PLC ......................................................... 16
The data block of the field PLC .......................................................... 20
The data block DATASYNC_X ........................................................ 22
Mechanisms of data synchronization ............................................................ 25

4.1
4.2
4.3
Description of the core functionality ..................................................... 7

Overview and description of the user interface .................................... 7
Synchronization of the data .................................................................. 9
Simulation of the data in the field PLCs ............................................. 11
Time synchronization ......................................................................... 12
Hardware and software components used......................................... 12
Head: S7-1200; 6 ms program load ................................................... 43

Head: S7-1200; 50 ms program load ................................................. 43
Head: WinAC; 6 ms program load ..................................................... 44
Head: WinAC; 50 ms program load ................................................... 44
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1 Task
Task
Introduction
For synchronization tasks and for the exchange of control and status information
among a head PLC and field PLCs, e.g. for solar trackers in solar parks, a
performant cyclic communication system is needed.
For reducing the data transfer, e.g. to an HMI or when a remote supervision is
used, the data are to be exchanged in bundles by means of a data concentrator
(here: head PLC).
The figure below provides an overview of the automation task.
Copyright Siemens AG 2016 All rights reserved
Figure 1-1
Field PLC 1
Head PLC
HMI
Field PLC 2
Field PLC n
Description of the automation problem

A module for the data synchronization and the exchange of control and status
information among the head PLC and several field PLCs is to be developed. It is to
assume the following task independently:
Supply of all the field PLCs with the same or different sets of data from the
head PLC (down sync).
Updating the sets of data from all the field PLCs in the head PLC (up sync).
Requirements of the automation task

The following requirements are posed to the block:
V3.1
Optimal and performant utilization of the available connection resources of the

head and field PLC.
Simple adaptation to variable quantities (data volume sent and received).
To be used with S7-1200 and S7-300/400/IPC with Win AC.
The programming is to be done mainly with SCL.
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2 Solution overview
Solution overview
Display
The following figure gives a schematic overview of the most important components
of the solution:
Figure 2-1
Possible Head PLCs with function block

DATASYNC_HEAD
HMI Panel
IPC + WinAC
S7-1200
DATASYNC_
HEAD
DATASYNC_
HEAD
DATASYNC_
SUB
DATASYNC_
SUB
DATASYNC_
SUB
DATASYNC_
SUB
Field PLCs S7-1200 (e.g. in solar trackers) with

function block DATASYNC_SUB
Setup
The application example is demonstrated in a concrete example - controlling solar
trackers.
The expression solar tracker means solar energy systems which can be tracked
according to the position of the sun to ensure the best possible energy yields.
For the field PLC, a CPU S7-1200 is used in this example. For the sake of a better
clarity, the number has been reduced to four.
For the head PLC, this solution uses two types of devices:
V3.1
An S7-1200 controller
An S7-300/400 / IPC with WinAC
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2 Solution overview
Description
With the function block DATASYNC_X (X:= HEAD or SUB), a block has been
developed that assumes the control of the data synchronization automatically.
The head PLC sequentially establishes an ISO-on-TCP communication connection
with each field PLC and terminates it again. Data is sent to the field PLCs and data
is received from them. After all field PLCs have been operated, the process is
repeated.
The following figure summarizes the data exchanged between head PLC and field
PLCs.
Figure 2-2
Data structure of the Head-PLC:

Geographic position (longitude / latitude)
Requirement time synchronization
Current time
Field PLC
1..4
Head PLC
Data structure of the Field PLCs:
Zenith / azimuth angle
Current weather data (temperature / wind)
Production data
It is always the head PLC which takes the initiative.

Since the field PLCs are only passive and wait for the request from the head PLC,
there is a separate DATASYNC_SUB block for the field PLC. Its task is the
supply and disposal of the send and receive data.
The data communication among the PLCs is displayed in images by the HMI panel.
For displaying and updating the images, the panel uses the send and receive data
of the head PLC.
Delimitation
This application does not include any
information concerning the programming language SCL.
basic information on industrial Ethernet.
information on astronomic algorithm or solar tracking.
Basic knowledge of these topics is assumed.
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2 Solution overview
2.1
Description of the core functionality
2.1.1
Overview and description of the user interface

For commissioning, operation and monitoring there is
an overview for operating and configuring the solar trackers.
an information surface for every field PLC.
The user interface has been realized in a comfort panel TP700.

For updating the images with the current data, an HMI connection between the
panel and the head PLC has been configured.
Overview head PLC
In this overview screen, all the field PLCs can be configured when their geographic
position is entered and the time synchronization can be triggered.
The longitude and the latitude are to be entered in decimal degrees.
Figure 2-3
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2 Solution overview
Information screen
There is a separate information screen for every field PLC. The calculated zenith
and azimuth angles and simulated weather information and production data are
displayed here.
Figure 2-4
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2 Solution overview
2.1.2
Synchronization of the data
Schematic layout
The data synchronization between the head PLC and the field PLCs is done
comfortably with the function block DATASYNC_X.
This block implements the cyclic and performant data exchange between the head
PLC and the field PLCs.
The defined data structure is sent from the head PLC to the field PLC when the
connection has been built up on both sides. The field PLC waits for reception and
then sends its own data structure to the head PLC
(see Figure 2-2).
As soon as the head PLC has received the data sent from the field PLC, the data
exchange is completed. The connection is disconnected.
The exchanged data structures and the IP addresses of the field PLCs are stored
in different global data blocks.
Increasing the performance by parallel connections

There is the possibility of operating several field PLCs in parallel (multiplexing). The
function block DATASYNC_HEAD can be called with a different instance data
block in the OB1 of the head PLC for every available connection. The maximum
number of calls is limited by the available connection resources of the head PLC.
In the present Application Example, these parallel connections are being used.
Note
V3.1
The maximum admissible number of parallel connections varies depending in the

head PLC.
S7-1200 supports no more than eight connections.
S7-300/400 / IPC with WinAC supports up to 32 connections.
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2 Solution overview
The following graphic shows the possibility of increasing the performance by

multiplexing.
Figure 2-5
3
2
Multiplex z field PLCs

via several channels
DATASYNC_
HEAD
HEAD PLC
DATASYNC_
HEAD
DATASYNC_
HEAD
DATASYNC_
HEAD
n available
connection
resources
FIELD PLCs
DATASYNC_
FIELD
DATASYNC_
FIELD
DATASYNC_
FIELD
DATASYNC_
FIELD
Example:
An S7-1200 CPU is used as the head PLC, and there are 12 field PLCs. This
makes possible the following combinations:
Number of available connection resources: n = 8
Number of field PLCs: z = 12
Therefore, the DATASYNC_HEAD block can be called in eight instances. There

are eight communication channels for the 12 field PLCs.
In the dynamic multiplex mode, the 12 field PLCs are synchronized through the
eight channels.
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2 Solution overview
Communication blocks
The communication between the head PLC and the field PLCs is done by an ISOon-TOP connection.
The connecting and disconnecting process and the sending and receiving of the
data is internally carried out in the DATASYNC_X block by means of the following
standard communication blocks:
Table 2-1
Block
2.1.3
Description
TCON
The TCON command establishes the communication

connection.
TDISCON
TDISCON establishes the connection to the partner station.
TSEND
TSEND sends data through an existing communication

connection.
TRCV
The counterpart to TSEND is TRCV. With this command, data

can be received through an existing communication
connection.
Simulation of the data in the field PLCs
Determining the position of the sun, using an astronomical algorithm

Depending on the position of the earth, the position of the sun can be calculated
with the aid of an astronomical algorithm, using details on longitude and latitude.
This position of the sun is described with the azimuth angle for the horizontal
alignment and zenith for the vertical alignment. To calculate the position of the sun,
the algorithm needs the Universal Time Coordinated (UTC) to take the earths
changing orbital period around its own axis into account.
Table 2-2
Parameters
Unit
Description
Longitude
[]
Longitude from 0 (North) to 360
Latitude
[]
Latitude from -90 (South pole) to +90 on the North

pole
In this Application Example, the astronomic algorithm is calculated with the function
block SimpleAstroAlgorithm in the cyclic program of the field PLCs.
Simulation of the weather and production data in the field PLCs
The simulation of data that are sent from the field PLCs to the head PLC is done by
time-controlled OBs and a mathematical calculation.
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2 Solution overview
2.1.4
Time synchronization
For the visualization screen the time synchronization of all the CPUs can be
synchronized with the current UTC time in the head PLC. The synchronization
takes place in two steps:
1. With a trigger command, the head PLC reads out the current time and date
head PLC with the button Activate Timesync by means of the function block
RD_SYS_T. This information is stored in the sending reports of the field PLCs
and the time synchronization bit there is set.
2. The field PLCs receive the information with the next data synchronization and
recognize the requirement to carry out a time synchronization. Then they adapt
their real time clocks to the times they received.
2.2
Hardware and software components used

The application was set up with the following components:
Hardware components
Table 2-3
Component
No.
Order number
Note
CPU 1215C AC/DC/Rly
6ES7 215-1BG31-0XB0
Head PLC
IPC 277D PN/IE

Bundle with WinAC RTX (F)
6ES7 647-8A
Head PLC
CPU 1214C DC/DC/DC
6ES7 214-1AE30-0XB0
Field PLC
Field PLC1
CPU 1212C DC/DC/DC
6ES7 212-1AE31-0XB0
Field PLCs
Field PLC2 - 4
HMI panel TP700 Comfort
6AV2124-0GC01-0AX0
SCALANCE X208
6GK5208-0BA10-2AA3
PG / PC
For loading the head

and field PLCs
Standard software components

Table 2-4
Component
V3.1
No.
Order number
Note
STEP 7 Professional V13
6ES7822-0A
Service Pack 1
WinCC Professional V13
6AV210
Service Pack 1
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2 Solution overview
Example files and projects

The following list includes all files and projects used in this example.
Table 2-5
Component
Note
This zip file contains two STEP 7 V13
projects.
DATASYNC_1200 for the S7-1200

CPU as the head PLC.
DATASYNC_IPC for the IPC with

WinAC as the head PLC
39040038_DATASYNC_DOKU_v31_d.pdf
This document.
39040038_DATASYNC_CODE_v22.zip
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3 The blocks of the data synchronization
The blocks of the data synchronization
3.1
Complete overview of the program blocks
3.1.1
Program overview of the head PLC
Program structure
The following graphic shows the complete user program of the head PLC.
Figure 3-1
DATASYNC_HE iDB
iDB
DATASYNC_HE
AD
iDB
iDB
AD
DATASYNC_HE
AD
DATASYNC_
HEAD
DB_IPADDRESS
TCON
TRCV
TSEND
TDISCON
DB_MANAGE
DB_STATE
OB 1
DB_RCV_
DATA
DB_SND_
DATA
RD_SYS_T
Description
Table 3-1
Block
V3.1
Note
DATASYNC_HEAD
Function block for data synchronization; to enable a parallel

data synchronization with all the other field PLCs (solar tracker),
the block is called several times - each time with a different
instance data block - cyclically in the application program.
Per field PLC, there is one call of the FB in the OB1 in this
Application Example (4 field PLCs 4 calls).
TCON, TRCV, TSEND

and TDISCON
Function blocks for the communication (see also chapter 2.1.2);

the enable the data communication.
DB_IPADDRESS
Data block; contains the IP addresses of all the field PLCs.
DB_STATE
Data block; contains status information of every field PLC.
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Block
3.1.2
Note
DB_MANAGE
Data block; contains information setting up the communication

channels.
DB_RCV_DATA
Data block; contains the receive data of the field PLC in

separate structures.
DB_SND_DATA
Data block; contains the receive data of the field PLC in

separate structures.
RD_SYS_T
Function block; responsible for reading out the current and local
time for the time synchronization.
Program sequence in the field PLC
Program structure
The following graphic shows the complete user program of the field PLCs.
Figure 3-2
iDB
DATASYNC_
SUB
TCON
TRCV
TSEND
DB_SND_RCV
_DATA
OB 1
SimpleAstro
Algorithm
WR_SYS_T
OB 30
OB 31
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Description
Table 3-2
Block
Note
DATASYNC_SUB
Function block for data synchronization
TCON, TRCV, TSEND
Function blocks for the communication (see also chapter 2.1.2);

the enable the data communication.
DB_SND_RCV_DATA
Data block; contains sending data for and receiving data from
the head PLC.
SimpleAstroAlgorithm
Function block; calculates the position of the sun on the basis of

the position data (longitude and latitude) sent.
WR_SYS_T
Function block; responsible for reading out the current and local
time for the time synchronization.
OB 30, OB 31
Time-controlled organization block for the simulation of the

weather and production data
3.2
Data blocks
3.2.1
The data block of the head PLC
Overview
For establishing a communication connection, the data block DATASYNC_HEAD
needs more information
about the field PLC
IP addresses
number of project engineers
feedback concerning the status of the connection
the maximum number of possible parallel connections
with an S7-1200 as head PLC: eight connections
with an S7-300/400 / WinAC as head PLC: 32 connections
about the sending and receive structure
size of each structure
storage location
All these pieces of information are stored in different global data blocks:
Table 3-3
Data block
Responsible for...
DB_IPADDRESS
IP addresses of the field PLCs used
DB_MANAGE
Number of field PLCs, length of the structures, global trigger for

starting the data synchronization
DB_RCV_DATA
Storage location for the received data of every field PLCs
DB_SND_DATA
Storage for the data to be sent
DB_STATE
Communication status of every field PLC
These data blocks are described in the following:
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DB_IPADDRESS
In the global data block DB_IPADDRESS, the IP addresses for every field PLC
are stored. Every IP address is defined as the data type Struct, and divided into
the segments REM_1, REM_2, REM_3 and REM_4 with the data type
USInt (S7-1200) or byte (WinAC).
Figure 3-3
DB_MANAGE
The global data block DB_MANAGE serves for the communication of the
connections.
Figure 3-4
In the parameter Act_SubStation, the DATASYNC_HEAD blocks store the

number of the last field PLC they called, or read the number of the next free field
PLC.
The parameter Nr_of_Substations contains the number of field PLCs.
REQ_x are Bool variables for using (REY_x True) or the release (REQ_x
False) of a DATASYNC_HEAD block and therefore with a connection resource.
For every DATASYNC_HEAD one bit is provided.
The parameters LEN_SNDData and LEN_RCVData each contain the length of
the send and receive structure in number of bytes.
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DB_STATE
In this data block, the communication status of each field PLC is listed and updated
and observed while DATASYNC_HEAD is running. For every station, one byte is
provided.
Figure 3-5
The value of the status byte is to be interpreted as follows:

Table 3-4
Value
Meaning
A connection between the head and the field PLCs is being established.
The connection between the head and the field PLC was successfully
established.
The data exchange between the head and the field PLC is completed and the
communication connection is disconnected.
The first attempt to establish a connection between the head and the field PLC
failed.
From the second attempt onwards (the status was 4 before), the system tries to
establish a connection for a certain period of time.
Field PLC available for access.
DB_SND_DATA and DB_RCV_DATA

The two data blocks contain the data to be synchronized.
The following rule is applied:
The structure of the send data of the head PLC must be identical with the
receive structure of the field PLC.
The structure of the receive data of the head PLC must be identical with the
send structure of the field PLC.
The send and receive structure is the same for every field PLC.
For every field PLC one structure is stored in the data block.
Since the send and receive structure must be identical for all field PLCs, we
recommend the use of templates (PLC data types).
PLC data types are defined data structures which can be opened several times in
the program. The structure of a PLC data type is composed of several components
which can have different data types. There are the following possibilities of using
PLC data types:
V3.1
PLC data types can be used as data types for variables in a variable
declaration of code blocks or in data blocks
PLC data types can be used as templates for creating global data blocks with
the same data structure.
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UDT_HEAD_RCV_STRUCT
As the data type of the receive data, the template UDT_HEAD_RCV_-STRUCT is
used:
Figure 3-6
With this template, one sector is defined for every field PLC in the receive data
block DB_RCV_DATA of the head PLC.
Figure 3-7
UDT_HEAD_SND_STRUCT
used:
Figure 3-8
With this template, one sector is defined for every field PLC in the send data block
DB_SND_DATA of the head PLC.
Figure 3-9
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3.2.2
The data block of the field PLC
DB_SND_RCV_DATA
Since this communication connection is always initiated by the head PLC, it is
sufficient to integrate only one data block into the user program of the field PLC.
The global data block DB_SND_RCV_DATA contains the send and receive
structure for the data exchange.
The rules for the send and receive structure are also applied here:
The structure of the send data of the field PLC must be identical with the
receive structure of the head PLC.
The structure of the receive data of the field PLC must be identical with the
send structure of the head PLC.
Here, the data block template is also created by a template.

UDT_SUB_SND_STRUCT
As the data type of the receive data, the template UDT_SUB_SND_-STRUCT is
used:
Figure 3-10
UDT_SUB_RCV_STRUCT
used:
Figure 3-11
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With these templates, the data block of the field PLC is defined.
Figure 3-12
Since the send and receive structures must be identical for all field PLCs, these
templates can be reused for the other field PLCs.
Note
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3.3
The data block DATASYNC_X
Description
The function block DATASYNC_X controls the data synchronization between the
head and the field PLC.
For the head and the field PLC, there are different DATASYNC_X blocks which
differ as far as their functionalities scope and therefore their interface configuration
are concerned.
Interfaces for the head PLC
Calling the block has been described as follows:
Figure 3-13
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Parameters
The parameters have the following meaning:
Table 3-5
Parameters
Type
Data
type
ID
WORD
A unique number for the communication connection. If

the DATASYNC_HEAD is called several times, a
different number must be selected.
REQ
BOOL
With True the data synchronization is triggered and a

supply resource is assigned.
With False" the synchronization process is stopped and
the approval of the communication is initiated
NR_SUBSTATIONS
INT
Number of project field PLCs
DB_NR_IPADDRESS
DB_NR_STATE
Meaning
Number of the data block

DB_IPADDRESS.
INPUT

DB_STATE.
DB_NR_SND_DATA

DB_SND_DATA.
LEN_SND_DATA
Length of the send structure
DB_NR_RCV_DATA

DB_RCV_DATA.
LEN_RCV_DATA
Length of the receive structure
IDB_NR_LOC
Number of the instance block of this

DATASYNC_HEAD block
ACT_SUBNET_NUM
BER
IN/
OUT
INT
Variable for interim storage of the field PLC used last.
RSC_FREE
OUT
BOOL
With True, the connection resource is released, as soon

as REQ has been set to False.
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Interfaces for the field PLC

Calling the block has been described as follows:
Figure 3-14
Parameters
The parameters have the following meaning:
Table 3-6
Parameters
Type
ID
Data type
WORD
REM_IP1
REM_IP2
USINT
REM_IP4
RCV_DATA
V3.1
A unique number for the communication connection.

First part of the IP address of the head PLC
INPUT
REM_IP3
SND_DATA
Meaning
Second part of the IP address of the head PLC

Third part of the IP address of the head PLC
Fourth part of the IP address of the head PLC
IN/ OUT
VARIANT
Pointer to the send section

Pointer to the receive section
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4 Mechanisms of data synchronization
Mechanisms of data synchronization
4.1
Control process in the overview

With the block DTASYNC_X a possibility of replacing control and status
information between the head PLC and the field PLCs (solar trackers in solar
parks) automatically and effectively and of synchronizing the time has been
realized.
The following diagram shows the process in the head and in a field PLCs:
Figure 4-1
Head PLC with

DATASYNC_HEAD
Initiation of the data

synchronization
Find next free field PLC
Copy IP address of the field

PLC from the global DB into
the instance DB
Field PLC z with

DATASYNC_SUB
Establish connection
Establish connection
Copy send structure from the

global DB to the instance DB
Receive data from the

head PLC
Send data to the free field PLC
Copy receive structure from

the instance DB
into the global DB
Receive data from the field PLC
Copy send structures from the

global DB to the instance DB
Copy receive structure from

the instance DB
to the global DB
Send data to the central PLC
Disconnect the connection
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4.2
Functioning of the function block DATASYNC_X

In this chapter, the functioning of the DATASYNC_X block is briefly explained.
For more details, please refer to the program code which has good comments.
Establish communication connection

The command TCON establishes and builds up the communication connection.
As soon as the connection is working, it is automatically maintained and monitored
by the CPU. TCON is carried out in several cycles.
The block receives the required information such as
the IP address of the connection partner
the number of the connection
through the input parameters in the DATASYNC_X block.

Send data
The command TSEND sends data through an existing communication

connection. TSEND is carried out in several cycles.
The block receives the required information through the input parameters in the
DATASYNC_X block.
Receive data
The command TRCV sends data through an existing communication connection.
TRCV is carried out in several cycles.
The received data are buffered in a receive area, and then they are transmitted to
the receive area.
The receive area is defined by the following two dimensions:
pointer at the beginning of the area
length of the area in number of bytes.
This information is transmitted by the parameters at the DATASYNC_X block.

Establish a communication connection (head PLCs only)
The instruction TDISCON disconnects the communication connection of the CPU
to the communication partner. TDISCON is a command working over several
cycles.
When the connection has been disconnected successfully, the ID entered in the FB
TCON is no longer valid and can therefore be neither used for sending nor for
receiving.
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Copy data
The transmission of the data (IP address, send and receive structure) between a
global data block and an instance data block is done by MOVE commands.
The storage address where the information of the current field PLC is located, is
determined by an Offset calculation.
The following graphic shows the principle with the example of an IP address.
The global data block DB_IPADDRESS contains the IP address for all the field
PLCs. The block DATASYNC-HEAD calculates the Offset for the storage area of
the IP address of the field PLC to be edited on the basis of the IN/OUT variables
ACT_SUBNET_Number.
Figure 4-2
Global DB
DB_IPADDRESS
IP address
Field PLC 1
IP addresse
Field PLC 2
Instance DB
DATASYNC-HEAD
ACT_SUBNET_NUMBER:=3
4- Bytes
Offset: 2 * 4-Bytes
IP address
Field PLC 3
IP address
Field PLC 3
IP address
Field PLC z
4.3
Behavior in the event of a power failure

If more than one field PLCs are involved in the data synchronization, it must be
made sure that the synchronization mechanism to the intact field PLCs is not
blocked in the event if one or more field PLCs break down (e.g. because the
connection cable is pulled out).
To solve this problem, the status of the communication connection of each field
PLCs is documented in the data block DB_STATE (see chapter 3.2.1). These
status values are compiled by means of the status parameters TCON_Busy or
TRCV_Error of the communication blocks (TCON, TSEND, TRCV, TDISCON).
If an interruption of the communication to a field PLC is detected (status value: 4),
the block DATASYNC_HEAD tries to reestablish the connection for a defined
period of time (status value: 5). If it does not succeed, this will be acknowledged
with an error message.
As soon as a connection has been reestablished, the error message is deleted.
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5 Performance Measurement
Performance Measurement
Objective
In order to be able to describe the performance of the program, a performance
measurement is carried out.
The following chapter describes:
5.1
the concept of the performance measurement.
the measurement results.
an analysis of the values.
Conception of the measurement
Structure
The following hardware constellation was used for the measurement:
Constellation 1:
Head PLC S7-1200-CPU
Field PLCs: up to 32 S7-1200-CPUs
Constellation 2:
Head PLC IPC
Field PLCs: up to 32 S7-1200-CPUs
These components were interconnected in accordance with the instructions in

chapter 6.
Figure 5-1
Head PLCs with up to eight function blocks
DATASYNC_HEAD
IPC + WinAC
S7-1200
DATASYNC_
DATASYNC_
HEAD
DATASYNC_
HEAD
DATASYNC_
HEAD
HEAD
DATASYNC_
SUB
DATASYNC_
DATASYNC_
HEAD
DATASYNC_
HEAD
DATASYNC_
HEAD
HEAD
DATASYNC_
SUB
DATASYNC_
SUB
...
1, 4, 8, 16, 32 Field-PLCs S7-1200 with function
block DATASYNC_SUB
In the user program of the head PLC, up to eight function blocks

DATASYNCH_HEAD are called in the OB1 (see also chapter 2.1.2).
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Measuring scenarios
For the performance measurement, several variants were measured that differ in
the following aspects:
type of head PLC
number of substations
data load
program load.
The following table shows the values:

Table 5-1
Parameters
Settings
Type of head PLC
S7-1200 (CPU 1215), WinAC (IPC 227D)
Number of substations
1, 4, 8, 16, 32
Size of the area to be synchronized (in

bytes)
10, 100, 200, 1000
Program load (in ms)
6, 50
Measure cycle
The measuring clock is started before the connection to the first substation is built
up. The end of a measure cycle is the point in time when all the substations have
been synchronized once.
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5.2
Values of the performance measurement
Data conditioning
To avoid systematic errors, the measuring parameters are determined by repeated
measurement.
100 subsequent measurements are determined and processed as representative
measuring data. All the values and the maximum and the minimum synchronization
time of a measure of a series of measurements are listed in the Annex (see
chapter 11).
Diagrams
The following diagrams show the time for a synchronization cycle the S7-1200
(gray line) needs as compared to the WinAC (blue line) for two measuring
scenarios.
Figure 5-2
Time in ms
Zeit in ms
4000
200 byte,
program
load
200
Byte,6 ms
6 ms
Programmlast
3000
2000
S7-1200
1000
WinAC
0
1
16
32
Anzahl
NumberSubstationen
of substations
Figure 5-3
10000
1000 Byte,
byte, 5050
msms
program
load
1000
Programmlast
Time in ms
in ms
Zeit
8000
6000
S7-1200
4000
WinAC
2000
0
1
16
32
Anzahl
Substationen
Number
of substations
Detailed values
The detailed values of the performance measurement are listed in chapter 11
Appendix A: Measured Data.
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5.3
Result
Overview
These are the results of the individual measurements:
The WinAC always synchronizes the data fields quicker than the S7-1200.
The higher the number of substations, the higher is the time difference
between the synchronization for the S7-1200 and the Win AC.
The synchronization time increases clearly when more than 8 substations are
being used.
The synchronization time increases with the number of substations and the
volume of the data to be synchronized.
Analysis
The measured values allow the following conclusions:
The first two observations can be attributed to the increased performance of

the current Intel atomic chip of the IPC as compared to the processor of the
S7-1200 CPU.
Up to a number of 8 substations there is a call of the FB DATASYNC_HEAD

per substation in the OB1. Accordingly, the computing time increases, but the
synchronization time does not increase proportionally to the number of
substations, since the connection resources can be used in parallel.
From a number of 8 substations or more, the maximum number of connection
resources of the two head PLC is used up, so that the parallel processing is
completed by a serial processing. For more details about the behavior of the
program, please refer to Figure 2-5.
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6 Installation
Installation
6.1
Hardware installation
The figure below shows the hardware setup of the application.
Figure 6-1
Possible Head PLCs

TP700
IPC 277D
CPU 1215C
PG
192.168.0.50
24V
192.168.0.45
192.168.0.55
24V
24V
X208
24V
CPU 1214C
192.168.0.1
24V
CPU 1212C
192.168.0.2
24V
CPU 1212C
192.168.0.3
24V
CPU 1212C
192.168.0.4
24V
Connect one head PLC (a CPU 1215C or an IPC277D), the field PLCs, the
SCALANCE X208 and the panel to one 24V power supply each. Connect all the
devices with a SCALANCE X208 by means of a standard Ethernet cable.
Note
V3.1
The installation guidelines for these components must always be observed.
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6 Installation
6.2
Software installation
Development software
Install the TIA V13 SP1 on your configuration computer.
Follow the instructions of the installation program.
Application software
For each head PLC, a sample program is available.
Unpack the zipped code folder 39040038_DATASYNC_CODE_v22.zip from the
download area into a folder you chose.
In this folder, there are the STEP 7 V13 project folders:
DATASYNC_1200 for the S7-1200 CPU as the head PLC.
DATASYNC_IPC for the IPC with WinAC as the head PLC
Navigate to the project folder you need and open the TIA project Datasync.ap13
with a double click.
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7 Starting up the Application
Starting up the Application
7.1
Assigning the IP addresses

The following IP addresses are used in this application:
Table 7-1
IP address
Component
192.168.0.45
Head PLC S7-1200
192.168.0.55
Head PLC IPC
192.168.0.50
HMI panel
192.168.0.100
PG / PC
192.168.0.1
Field PLC 1
192.168.0.2
Field PLC 2
192.168.0.3
Field PLC 3
192.168.0.4
Field PLC 4
The subnet mask is 255.255.255.0.

PG / PC
Change the IP addresses of the PG / PC as follows:
Table 7-2
No.
1.
Action
Note
For changing the network

address, open the Internet log
(TCP/IP) settings with Start >
Control Panel > Network and
Internet > Network Connections
Enter the IP address according
to the figure.
Then close all dialogs with OK.
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SIMATIC components
The SIMATIC components are addressed in the TIA portal by means of the online
function Assign IP address.
Table 7-3
No.
Action
1.
Open the portal view of the TIA

portal project.
2.
First open the tree for the HEAD

PLC and then double-click on
the function Online &
diagnostic.
Note:
If you use the IPC as the head
PLC, you use the function
Online & diagnostic in the
section of the WinAC.
3.
In Functions, select Assign IP

address.
Click on the button Accessible
devices.
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No.
Action
4.
If necessary, select the PG / PC

interface. The search for
accessible devices is carried out
automatically.
The result is shown in a list.
Identify the PLC you use as
HEAD via the MAC address and
click on Apply.
5.
Assign the IP address stored in

the project with the command
Assign IP address.
The HEAD PLC now owns the IP
address stored in the project.
6.
Change the IP addresses of the

field PLCs and of the panel in
the same way.
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7.2
Download the PLCs and the panels

In the following, the SIMATIC components with the hardware configuration and the
user program are downloaded.
Note
Please find a detailed instruction in the FAQ How is a project downloaded in the
CPU in STEP 7 (TIA portal) V11? in the Entry ID: 59728694.
Table 7-4
No.
1.
Action
Note
At first, select the first field PLC.
Then download the device

configuration and the program to
the field PLC with the respective
symbol in Online > Download to
Device.
2.
V3.1
The project is compiled.

Click the Load button.
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No.
Action
Activate Start all to start the
block.
Exit the download with Finish.
4.
Proceed in the same way for the

3 other remaining field PLCs.
Select the stations PLC_2 to
PLC_4 and download the
respective field PLC.
5.
Select the head PLC.

Note:
When you use the IPC as the
head PLC, select the WinAC.
3.
Note
Then download the device

configuration and the program to
the head PLC with the respective
symbol in Online > Download to
Device.
The next download procedure is
carried out according to steps 2
and 3.
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No.
Note
For transferring the HMI project,

select the HMI station in the TIA
project and download it to the
panel with the respective symbol
or Online > Download to Device.
The next download procedure is
carried out according to step 2.
Note:
Any warning messages
concerning the name of the
objects in the visualization
images can be ignored.
6.
Action
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8 Operating the Application
Operating the Application
To describe the principle of data synchronization clearly, several visualization

images were created for the panel.
Note
HEAD PLC: This overview serves for entering the positions of the field PLCs
and for activating the time synchronization.
Field PLC 14: These images display the information transmitted by the field
PLCs:
weather data
production data
calculated position of the sun
The data synchronization is started automatically.
Table 8-1
No.
Action
In the HMI screen HEAD PLC,
enter the coordinates of every
field PLC. With these data, the
field PLCs calculate the current
position of the sun.
2.
With the button Activate

TimeSync, you initiate the time
synchronization with all the field
PLCs.
1.
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8 Operating the Application
No.
Action
Change to the visualization of
the field PLCs with the
navigation.
Here, the information is
displayed which the field PLCs
transmit to the head PLC.
4.
With the HOME button you

change back to the HEAD PLC
overview screen at any time.
5.
With the switch-off symbol, you

exit the runtime.
3.
Note
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Related literature
Datasync 39040038
Related literature
This list is not complete and only represents a selection of relevant literature.
Bibliography
Table 9-1
Subject
Title
/1/
STEP7
SIMATIC S7-300/400
Automating with STEP7 in STL and SCL

Author: Hans Berger
Publicis MCD Verlag
ISBN: 978-3-89578-397-5
/2/
STEP7
SIMATIC S7-1200
Automating with SIMATIC S7-1200

Author: Hans Berger
Publicis MCD Verlag
ISBN: 978-3-89578-355-5

Internet link specifications

This list is not complete and only represents a selection of relevant information
Table 9-2
Subject
Title
/1/
Reference to the
document
http://support.automation.siemens.com/WW/view/en/39040038
/2/
Siemens Industry
Online Support
http://support.automation.siemens.com
/3/
10
History
Table 10-1
Version
V3.1
Date
Modifications
V1.0
10/2009
First version
V2.0
05/2013
Complete review of code and document.
V3.1
03/2016
New warranty, Change V12 to V13 SP1
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Appendix A: Measured Data
Datasync 39040038
11
11.1
Head: S7-1200; 6 ms program load

Number of
substations
Number of bytes
10
1
in ms
4
in ms
8
in ms
16
in ms
32
in ms
min
234 min
443 min
500 min
987 min
1912
max
323 max
3522max
3539max
3009 max
5155
average
280 average
741 average
1752average
2047 average
2334
min
357 min
376 min
507 min
1111 min
1923
max
459 max
2673max
3570max
4002 max
4413
average
399 average
725 average
982 average
2100 average
2417
min
342 min
411 min
449 min
956 min
2134
max
430 max
3467max
3446max
4052 max
6077
average
392 average
823 average
939 average
1356 average
3526
min
300 min
387 min
470 min
1116 min
2860
max
393 max
3484max
3066max
4004 max
7819
average
351 average
772 average
924 average
2115 average
3395
100
200

1000
11.2
Head: S7-1200; 50 ms program load

Number of
substations
Number of bytes
10
100
200
1000
V3.1
1
in ms
4
in ms
8
in ms
16
in ms
32
in ms
min
1637 min
1486min
1739min
3313 min
6944
max
1834 max
4710max
6899max
8053 max
12347
average
1740 average
2781average
3775average
5131 average
8490
min
1867 min
1740min
1724min
3494 min
7202
max
2009 max
4793max
6601max
6799 max
12598
average
1975 average
2805average
3230average
4977 average
8854
min
1657 min
1611min
1661min
3417 min
7157
max
1857 max
4757max
5743max
7205 max
12065
average
1721 average
2777average
3158average
4726 average
9226
min
1672 min
1484min
1558min
3468 min
7000
max
1952 max
4645max
5010max
8668 max
12709
average
1853 average
2698average
3149average
5168 average
8830
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Datasync 39040038
11.3
Head: WinAC; 6 ms program load

Number of
substations
1
min
max
average
min
max
average
min
max
average
min
max
average
Number of bytes
10
100
200

1000
11.4
in ms
198
219
209
203
221
215
204
222
213
202
221
211
4
min
max
average
min
max
average
min
max
average
min
max
average
in ms
187
362
257
187
590
277
186
792
287
193
795
444
8
min
max
average
min
max
average
min
max
average
min
max
average
in ms
16
192 min
536 max
304 average
192 min
402 max
280 average
200 min
2188 max
463 average
202 min
1833 max
475 average
in ms
32
385 min
643 max
479 average
457 min
576 max
523 average
378 min
1144 max
667 average
178 min
987 max
785 average
in ms
3108
803
1187
785
2617
1189
4441
789
1850
799
3062
1834
Head: WinAC; 50 ms program load

Number of
substations
Number of bytes
10
100
200
1000
V3.1
1
in ms
4
in ms
8
in ms
16
in ms
32
in ms
min
1694min
1550min
1538min
3124min
6223
max
1750max
3260max
2982max
4377max
10534
average
1704average
1812average
1972average
3353average
7537
min
1681min
1543min
1749min
3130min
6154
max
1741max
2344max
2649max
4321max
10668
average
1704average
2070average
2286average
3355average
7416
min
1681min
1532min
1538min
3128min
6256
max
1740max
3077max
3082max
7341max
11114
average
1703average
2178average
2428average
4182average
7502
min
1678min
1533min
1541min
3134min
6010
max
1790max
3659max
4126max
6807max
10124
average
1707average
2172average
2566average
4065average
7700
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Communication:

Performant Data Synchronization

Siemens Industry Online Support

Warranty and liability

Warranty and liability

Siemens AG 2016 All rights reserved

Solution overview .............................................................................................. 5

The blocks of the data synchronization ........................................................ 14

Siemens AG 2016 All rights reserved

Hardware installation .......................................................................... 32

Starting up the Application ............................................................................. 34

Assigning the IP addresses ................................................................ 34

Operating the Application ............................................................................... 40

Related literature ............................................................................................. 42

Appendix A: Measured Data ........................................................................... 43

Conception of the measurement ........................................................ 28

Control process in the overview ......................................................... 25

Performance Measurement ............................................................................ 28

Complete overview of the program blocks ......................................... 14

Mechanisms of data synchronization ............................................................ 25

Description of the core functionality ..................................................... 7

Head: S7-1200; 6 ms program load ................................................... 43

Copyright Siemens AG 2016 All rights reserved

Description of the automation problem

Requirements of the automation task

Optimal and performant utilization of the available connection resources of the

Simple adaptation to variable quantities (data volume sent and received).

To be used with S7-1200 and S7-300/400/IPC with Win AC.

The programming is to be done mainly with SCL.

Possible Head PLCs with function block

Copyright Siemens AG 2016 All rights reserved

Field PLCs S7-1200 (e.g. in solar trackers) with

An S7-300/400 / IPC with WinAC

Data structure of the Head-PLC:

Requirement time synchronization

Copyright Siemens AG 2016 All rights reserved

Zenith / azimuth angle

Current weather data (temperature / wind)

It is always the head PLC which takes the initiative.

information concerning the programming language SCL.

basic information on industrial Ethernet.

information on astronomic algorithm or solar tracking.

Basic knowledge of these topics is assumed.

Description of the core functionality

Overview and description of the user interface

an overview for operating and configuring the solar trackers.

an information surface for every field PLC.

The user interface has been realized in a comfort panel TP700.

Copyright Siemens AG 2016 All rights reserved

Copyright Siemens AG 2016 All rights reserved

Synchronization of the data

Copyright Siemens AG 2016 All rights reserved

Increasing the performance by parallel connections

The maximum admissible number of parallel connections varies depending in the

S7-1200 supports no more than eight connections.

S7-300/400 / IPC with WinAC supports up to 32 connections.

The following graphic shows the possibility of increasing the performance by

Multiplex z field PLCs

Copyright Siemens AG 2016 All rights reserved

Number of available connection resources: n = 8

Number of field PLCs: z = 12

Therefore, the DATASYNC_HEAD block can be called in eight instances. There

Copyright Siemens AG 2016 All rights reserved