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Added cabinet temperature and modbus registers

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added cabinet temperature to each module, scs and bms cabinet, added corresponding config, hmi interface, hardware & links. Added corresponding warning bits to modbus registers
This commit is contained in:
Markus Neukirch
2025-08-04 18:10:15 +02:00
parent ee3367eaec
commit e2a44b0d37
21 changed files with 2029 additions and 805 deletions
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2
PLC/DUTs/Modbus/ErrorWarningRegisters/ST_DWORD_UNIT_WARNING_BITMAP.TcDUT
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@@ -1,5 +1,5 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<DUT Name="ST_DWORD_UNIT_WARNING_BITMAP" Id="{fe3a1ecb-072b-4492-b355-17d925e9fa12}">
<Declaration><![CDATA[TYPE ST_DWORD_UNIT_WARNING_BITMAP :
STRUCT

11
PLC/DUTs/Modbus/ErrorWarningRegisters/ST_WORD_BMS_WARNING_BITMAP.TcDUT
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@@ -1,11 +1,20 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<DUT Name="ST_WORD_BMS_WARNING_BITMAP" Id="{6dfd9c4b-4e74-434e-9f65-01d443c224d5}">
<Declaration><![CDATA[TYPE ST_WORD_BMS_WARNING_BITMAP :
STRUCT
bNotAllInAuto : BIT;
bSafetyIntlkString1 : BIT;
bSafetyIntlkString2 : BIT;
bTCabinetBMSHigh : BIT;
bTCabinetSCSString1High : BIT;
bTCabinetSCSString2High : BIT;
bTCabinetString1Module1High : BIT;
bTCabinetString1Module2High : BIT;
bTCabinetString1Module3High : BIT;
bTCabinetString2Module1High : BIT;
bTCabinetString2Module2High : BIT;
bTCabinetString2Module3High : BIT;
END_STRUCT
END_TYPE
]]></Declaration>

3
PLC/DUTs/ST_MODULE_HMI_INTERFACE.TcDUT
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@@ -8,6 +8,9 @@ STRUCT
stHMIInterfaceUnit3 : ST_UNIT_HMI_INTERFACE;
stHMIInterfaceUnit4 : ST_UNIT_HMI_INTERFACE;
// Temperature sensor control cabinet
stTempCabinet : ST_HMI_ANALOG_VALUE;
// Current voltage for HMI
// ==============================
rVoltage : REAL;

5
PLC/DUTs/ST_STRING_HMI_INTERFACE.TcDUT
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@@ -1,5 +1,5 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<DUT Name="ST_STRING_HMI_INTERFACE" Id="{b74e184a-a1d0-4499-8ac0-7e2226af9a4f}">
<Declaration><![CDATA[TYPE ST_STRING_HMI_INTERFACE :
STRUCT
@@ -7,6 +7,9 @@ STRUCT
stHMIInterfaceModule2 : ST_MODULE_HMI_INTERFACE;
stHMIInterfaceModule3 : ST_MODULE_HMI_INTERFACE;
// Temperature sensor SCS control cabinet
stTempCabinetSCS : ST_HMI_ANALOG_VALUE;
// Current voltage for HMI
// ==============================
rVoltage : REAL;

22
PLC/GVLs/GVL_CONFIG.TcGVL
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@@ -1,5 +1,5 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<GVL Name="GVL_CONFIG" Id="{0773bf51-0237-454d-a970-cfd896054edb}">
<Declaration><![CDATA[{attribute 'qualified_only'}
VAR_GLOBAL CONSTANT
@@ -183,6 +183,26 @@ VAR_GLOBAL PERSISTENT
stEWLSCSCurrent : ST_ANALOG_EW_LEVELS;
stEWDSCSCurrent : ST_ANALOG_EW_DELAYS;
// ===========================
// Control cabinet temperature sensor config
// ===========================
// Temperature sensor control cabinets
stConfigCabinetTemp : ST_ANALOG_IO_CONFIG := (iAIMax := 32767, iAIMin := -32768, rPVMax := 3276.7, rPVMin := -3276.8, sUnit := '°C');
stEWLCabinetTemp : ST_ANALOG_EW_LEVELS := (rErrorMin := -20, rWarningMin := -15, rWarningMax := 40, rErrorMax := 80);
stEWDCabinetTemp : ST_ANALOG_EW_DELAYS :=
(
timHardwareSignalLevelOn := T#0S,
timHardwareSignalLevelOff := T#5S,
timErrorLowOn := T#1S,
timErrorLowOff := T#5S,
timWarningLowOn := T#1S,
timWarningLowOff := T#5S,
timWarningHighOn := T#1S,
timWarningHighOff := T#5S,
timErrorHighOn := T#1S,
timErrorHighOff := T#5S
);
// ===========================
// General settings

5
PLC/GVLs/GVL_SCADA.TcGVL
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@@ -1,11 +1,14 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<GVL Name="GVL_SCADA" Id="{8186ff04-764f-4b24-8a6b-d0a44d528e6f}">
<Declaration><![CDATA[{attribute 'qualified_only'}
VAR_GLOBAL
// Array for string HMI
stHMIInterface : ARRAY [0..1] OF ST_STRING_HMI_INTERFACE;
// Temperature sensor BMS control cabinet
stTempCabinetBMS : ST_HMI_ANALOG_VALUE;
// Acknowledge alarm button
stAckAlarmsButton : ST_HMI_CONTROL_BUTTON := (xRelease := TRUE);

501
PLC/PLC.tmc
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File diff suppressed because one or more lines are too long

37
PLC/POUs/FB_Module.TcPOU
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@@ -1,5 +1,5 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<POU Name="FB_Module" Id="{87be924f-018d-4c09-997b-f0c0054414cc}" SpecialFunc="None">
<Declaration><![CDATA[FUNCTION_BLOCK FB_Module
VAR_INPUT
@@ -86,6 +86,9 @@ VAR_OUTPUT
// One unit has a warning
xWarning : BOOL;
// Temperature control cabinet above 40 °C
xTempCabinetWarning : BOOL;
// All modules in automatic mode
xAllUnitsInAutomatic : BOOL;
@@ -104,6 +107,9 @@ VAR
_fbUnit3 : FB_Unit(CONCAT(Name, ' - Unit 3'));
_fbUnit4 : FB_Unit(CONCAT(Name, ' - Unit 4'));
// Temperature sensor cabinet
_fbTempSensorCabinet : FB_AnalogInput(CONCAT(Name, ' - T1_Cabinet'));
// Flag for unit balance checking
_xBalanceOk : BOOL;
@@ -143,6 +149,8 @@ END_VAR
_fbUnit2.Name := CONCAT(Name, ' - Unit 2');
_fbUnit3.Name := CONCAT(Name, ' - Unit 3');
_fbUnit4.Name := CONCAT(Name, ' - Unit 4');
_fbTempSensorCabinet.Name := CONCAT(Name, ' - T1_Cabinet');
END_IF
// Reset error and warning flag
@@ -384,6 +392,33 @@ IF NOT _fbUnit4.xAllComponentsInAuto THEN
END_IF
// ===============================
// Temperature sensor control cabinet
// ===============================
_fbTempSensorCabinet(
stScalingConfig:= GVL_CONFIG.stConfigCabinetTemp,
stEWConfig:= GVL_CONFIG.stEWLCabinetTemp,
stEWDelayConfig:= GVL_CONFIG.stEWDCabinetTemp,
xReleaseErrors:= xReleaseErrors,
xReleaseLimitErrors:= xReleaseLimitErrors,
xReleaseHardwareErrors:= xReleaseErrors,
xConfirmAlarms:= xConfirmAlarms,
stHMIInterface=> refstHMIInterface.stTempCabinet);
// Set warning output for modbus register bits
IF _fbTempSensorCabinet.xWarningHigh THEN
xTempCabinetWarning := TRUE;
END_IF
IF _fbTempSensorCabinet.xError THEN
xError := TRUE;
END_IF
IF _fbTempSensorCabinet.xWarning THEN
xWarning := TRUE;
END_IF
// ===============================
// Units ready check
// ===============================

21
PLC/POUs/FB_String.TcPOU
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@@ -1,5 +1,5 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<POU Name="FB_String" Id="{46501225-f446-4674-bfed-3be64273e576}" SpecialFunc="None">
<Declaration><![CDATA[FUNCTION_BLOCK FB_String
VAR_INPUT
@@ -100,6 +100,15 @@ VAR_OUTPUT
xError : BOOL;
xWarning : BOOL;
// Temperature control cabinet module 1 above 40 °C
xTempCabinetModule1Warning : BOOL;
// Temperature control cabinet module 2 above 40 °C
xTempCabinetModule2Warning : BOOL;
// Temperature control cabinet module 3 above 40 °C
xTempCabinetModule3Warning : BOOL;
eStatus : E_COMPONENT_STATUS;
// Inverter status data
@@ -275,7 +284,8 @@ _fbModule1(
xReleaseManualMode := xReleaseManualMode,
xConfirmAlarms:= xConfirmAlarms,
xAllToManualMode := xAllToManualMode,
rBalancingTargetVoltage := rSmallestSegmentVoltage);
rBalancingTargetVoltage := rSmallestSegmentVoltage,
xTempCabinetWarning => xTempCabinetModule1Warning);
// ===============================
@@ -296,7 +306,8 @@ _fbModule2(
xReleaseManualMode := xReleaseManualMode,
xConfirmAlarms:= xConfirmAlarms,
xAllToManualMode := xAllToManualMode,
rBalancingTargetVoltage := rSmallestSegmentVoltage);
rBalancingTargetVoltage := rSmallestSegmentVoltage,
xTempCabinetWarning => xTempCabinetModule2Warning);
// ===============================
@@ -317,7 +328,8 @@ _fbModule3(
xReleaseManualMode := xReleaseManualMode,
xConfirmAlarms:= xConfirmAlarms,
xAllToManualMode := xAllToManualMode,
rBalancingTargetVoltage := rSmallestSegmentVoltage);
rBalancingTargetVoltage := rSmallestSegmentVoltage,
xTempCabinetWarning => xTempCabinetModule3Warning);
// ===============================
@@ -966,7 +978,6 @@ END_IF
_xIsoError := ((NOT xIsoErrorL1) OR (NOT xIsoErrorL2)) AND (NOT _fbInverter.xActive) AND (xDCCBOpen);
_fbTONIsoError(IN := _xIsoError, PT := GVL_CONFIG.timIsoErrorTimeout);
// _fbInverter
IF _fbTONIsoError.Q AND (NOT _fbIsolationAlarm.bRaised) AND xReleaseErrors THEN
_fbIsolationAlarm.Raise(0);
END_IF

2
PLC/POUs/FB_Unit.TcPOU
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@@ -1,5 +1,5 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<POU Name="FB_Unit" Id="{e9bb815b-eb46-4920-800d-910484e58b22}" SpecialFunc="None">
<Declaration><![CDATA[FUNCTION_BLOCK FB_Unit
VAR_INPUT

76
PLC/POUs/MAIN.TcPOU
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@@ -1,5 +1,5 @@
<?xml version="1.0" encoding="utf-8"?>
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.12">
<TcPlcObject Version="1.1.0.1" ProductVersion="3.1.4026.8">
<POU Name="MAIN" Id="{bbd7302c-91ce-4697-9f4b-743f57ca5819}" SpecialFunc="None">
<Declaration><![CDATA[PROGRAM MAIN
VAR
@@ -149,6 +149,15 @@ VAR
_rDeltaUm : REAL;
_arPowerString : ARRAY[0..(GVL_CONFIG.uiNumberOfStrings-1)] OF REAL;
// Temperature sensor SCS String 1
_fbTempCabinetSCSString1 : FB_AnalogInput('String 1 - SCS - T1_Cabinet');
// Temperature sensor SCS String 1
_fbTempCabinetSCSString2 : FB_AnalogInput('String 2 - SCS - T1_Cabinet');
// Temperature sensor BMS cabinet
_fbTempCabinetBMS : FB_AnalogInput('BMS - T1_Cabinet');
_ui : UINT := 0;
_xStringsReady : BOOL;
_xStringsErrorActive : BOOL;
@@ -328,6 +337,28 @@ END_IF
// Dely release of errors during PLC startup phase
_tonStartupDelay(IN := TRUE);
// ===============================
// Temperature sensor control cabinet BMS
// ===============================
_fbTempCabinetBMS(
stScalingConfig:= GVL_CONFIG.stConfigCabinetTemp,
stEWConfig:= GVL_CONFIG.stEWLCabinetTemp,
stEWDelayConfig:= GVL_CONFIG.stEWDCabinetTemp,
xReleaseErrors:= _xReleaseErrors,
xReleaseLimitErrors:= _xReleaseLimitsErrors,
xReleaseHardwareErrors:= _xReleaseErrors,
xConfirmAlarms:= _xConfirmAlarms,
stHMIInterface=> GVL_SCADA.stTempCabinetBMS);
// Set modbus error register bit
IF _fbTempCabinetBMS.xWarningHigh THEN
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetBMSHigh := TRUE;
END_IF
IF _fbTempCabinetBMS.xError THEN
_xErrorActive := TRUE;
END_IF
// Call string 1
_afbStrings[0](
xEnable := _xEnableString AND GVL_CONFIG.axStringEnabled[0],
@@ -351,11 +382,33 @@ IF _afbStrings[0].xError THEN
_xErrorActive := TRUE;
END_IF
// ===============================
// Temperature sensor control cabinet SCS string 1
// ===============================
_fbTempCabinetSCSString1(
stScalingConfig:= GVL_CONFIG.stConfigCabinetTemp,
stEWConfig:= GVL_CONFIG.stEWLCabinetTemp,
stEWDelayConfig:= GVL_CONFIG.stEWDCabinetTemp,
xReleaseErrors:= _xReleaseErrors,
xReleaseLimitErrors:= _xReleaseLimitsErrors,
xReleaseHardwareErrors:= _xReleaseErrors,
xConfirmAlarms:= _xConfirmAlarms,
stHMIInterface=> GVL_SCADA.stHMIInterface[0].stTempCabinetSCS);
IF _fbTempCabinetSCSString1.xError THEN
_xErrorActive := TRUE;
END_IF
// Handle string 1 modbus error and warning
GVL_MODBUS.stBMSErrorReg.wStringErrorActive.0 := _afbStrings[0].xError;
GVL_MODBUS.stBMSErrorReg.wStringWarningActive.0 := _afbStrings[0].xWarning;
GVL_MODBUS.stBMSErrorReg.wBMSErrorActive.stBitmap.bDCSwitchS1 := (NOT _afbStrings[0].xRepairSwitchOk);
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bSafetyIntlkString1 := (NOT _afbStrings[0].xSafetyIntlksOk);
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetString1Module1High := _afbStrings[0].xTempCabinetModule1Warning;
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetString1Module2High := _afbStrings[0].xTempCabinetModule2Warning;
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetString1Module3High := _afbStrings[0].xTempCabinetModule3Warning;
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetSCSString1High := _fbTempCabinetSCSString1.xWarningHigh;
// Call string 2
@@ -381,11 +434,32 @@ IF _afbStrings[1].xError THEN
_xErrorActive := TRUE;
END_IF
// ===============================
// Temperature sensor control cabinet SCS string 2
// ===============================
_fbTempCabinetSCSString2(
stScalingConfig:= GVL_CONFIG.stConfigCabinetTemp,
stEWConfig:= GVL_CONFIG.stEWLCabinetTemp,
stEWDelayConfig:= GVL_CONFIG.stEWDCabinetTemp,
xReleaseErrors:= _xReleaseErrors,
xReleaseLimitErrors:= _xReleaseLimitsErrors,
xReleaseHardwareErrors:= _xReleaseErrors,
xConfirmAlarms:= _xConfirmAlarms,
stHMIInterface=> GVL_SCADA.stHMIInterface[1].stTempCabinetSCS);
IF _fbTempCabinetSCSString2.xError THEN
_xErrorActive := TRUE;
END_IF
// Handle string 1 modbus error and warning
GVL_MODBUS.stBMSErrorReg.wStringErrorActive.1 := _afbStrings[1].xError;
GVL_MODBUS.stBMSErrorReg.wStringWarningActive.1 := _afbStrings[1].xWarning;
GVL_MODBUS.stBMSErrorReg.wBMSErrorActive.stBitmap.bDCSwitchS2 := (NOT _afbStrings[1].xRepairSwitchOk);
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bSafetyIntlkString2 := (NOT _afbStrings[1].xSafetyIntlksOk);
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetString2Module1High := _afbStrings[1].xTempCabinetModule1Warning;
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetString2Module2High := _afbStrings[1].xTempCabinetModule2Warning;
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetString2Module3High := _afbStrings[1].xTempCabinetModule3Warning;
GVL_MODBUS.stBMSErrorReg.wBMSWarningActive.stBitmap.bTCabinetSCSString2High := _fbTempCabinetSCSString2.xWarningHigh;
// Copy general error to modbus error register
GVL_MODBUS.stBMSErrorReg.wBMSErrorActive.stBitmap.bError := _xErrorActive;