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Micro Application Example

Distance and Level Measurement in Industrial Applications

Micro Automation Set 3

Note

Micro Automation Set 3 21689394

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Note The Micro Automation Sets are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Micro Automation Sets do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible for ensuring that the described products are correctly used. These Micro Automation Sets do not relieve you of the responsibility of safely and professionally using, installing, operating and servicing equipment. When using these Micro Automation Sets, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Micro Automation Sets at any time without prior notice. If there are any deviations between the recommendations provided in these Micro Automation Sets and other Siemens publications – e.g. Catalogs – the contents of the other documents have priority.

Warranty, Liability and Support We accept no liability for information contained in this document.

Any claims against us – based on whatever legal reason – resulting from the use of the examples, information, programs, engineering and performance data etc., described in this Micro Automation Set shall be excluded. Such an exclusion shall not apply in the case of mandatory liability, e.g. under the German Product Liability Act (“Produkthaftungsgesetz”), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract (“wesentliche Vertragspflichten”). However, claims arising from a breach of a condition which goes to the root of the contract shall be limited to the foreseeable damage which is intrinsic to the contract, unless caused by intent or gross negligence or based on mandatory liability for injury of life, body or health. The above provisions does not imply a change in the burden of proof to your detriment.

Copyright© 2007 Siemens A&D. It is not permissible to transfer or copy these Micro Automation Sets or excerpts of them without first having prior authorization from Siemens A&D in writing.

For questions about this document please use the following e-mail-address:

[email protected]

mailto:[email protected]

Foreword


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Foreword Micro Automation Sets are fully functional and tested automation configurations based on A&D standard products for simple, fast and inexpensive implementation of automation tasks for small-scale automation. Each of the available Micro Automatic Sets covers a frequently occurring subtask of a typical customer problem in the low-end performance level.

The sets help you obtain answers with regard to required products and the question how they function when combined.

However, depending on the system requirements, a variety of other components (e.g. other CPUs, power supplies, etc.) can be used to implement the functionality on which this set is based. Please refer to the respective SIEMENS A&D catalogs for these components. The Micro Automation Sets are also available by clicking the following link:

http://www.siemens.de/microset

http://www.siemens.de/microset

Foreword


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Table of Contents

Table of Contents ......................................................................................................... 4

1 Application Areas and Usage ........................................................................ 5

2 Configuration .................................................................................................. 7

3 Hardware and Software Components........................................................... 8

4 Function Principle .......................................................................................... 9 4.1 Sonar proximity switch...................................................................................... 9 4.2 LOGO! Logic module ...................................................................................... 11

5 Configuring the Startup Software ............................................................... 14 5.1 Preliminary remark.......................................................................................... 14 5.2 Download of the startup code ......................................................................... 14 5.3 Configuring Components ................................................................................ 15 5.3.1 Installing and wiring the hardware .................................................................. 15 5.3.2 LOGO! Logic module / configuring the startup code...................................... 16

6 Live Demo...................................................................................................... 17 6.1 HMI screen ..................................................................................................... 17 6.2 Overview of live demo .................................................................................... 19 6.2.1 Manual on and off switching of the motor (compressor) ................................. 19 6.2.2 Automatic on and off switching of the motor (compressor)............................. 20 6.2.3 Changing the switching thresholds for switching on/off .................................. 22 6.2.4 Diagnosis: wire break ..................................................................................... 24 6.2.5 Diagnosis: contactor contacts sticking together.............................................. 25

7 Technical data............................................................................................... 26

Application Areas and Usage


1 Application Areas and Usage

Application Example Plastic parts are to be produced in a factory. The plastic granulate is transported from a central silo via a line into a tank at the injection molding machine. From there it is fed into the production process via a valve.

A level monitoring for the store tank is to ensure the availability of the plastic granulate for the injection molding machine, and automate the granulate transport from the silo by means of the compressor. Figure 1-1 Sketch of the application principle

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Silo

Motor/Compresor

Sonar Bero

Con

tain

er

Valve

Molding Machine

Conveyor

Monitoring the filling level as well as automatic filling of the tank with plastic granulate is meant to reduce production downtimes.

The motor of the compressor shall only be switched on when the minimal filling height of the tank is fallen short of, and be operated at setpoint speed.

Underrun of the minimum filling level height is to be displayed as a message on a text display.

Application Areas and Usage


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Automation solution – Set 3 A LOGO! is installed in the automation solution. A logic module is used as a controller. An ultrasonic sensor is used for filling level monitoring and it is connected to a frequency input at the LOGO! logic module.

A threshold switch realized in the LOGO! control program evaluates the various signals of the ultrasonic sensor and controls the asynchronous motor connected via a contactor (compressor).

The automation solution fulfills the following operating requirements:

• Simple changing of filling level monitoring thresholds

• Detached operating unit with filling level display

• Manual on and off switching of the compressor motor

• Messages or alarms for shortage of raw materials

Application Areas Tasks

• Filling level or height measurements

• Distance or level measurements

Applications

• Collision monitoring

• Stacking height monitoring

• Bottling plants

Benefit • Cost efficient and simple filling level monitoring with LOGO!

• Operations (e.g. changes for switching point of ultrasonic sensor, switching the motor on and off) can be performed via the integrated operator field of LOGO!

• Switching point changes for the ultrasonic sensor need no changes in the sensor configuration

• Direct display of messages and device states (e.g. operating hours of the motor, filling level of the store tank) via the integrated LOGO! display

• Supplementing further threshold values enables differentiating between warning and alarm

• Further not assigned digital outputs of LOGO! Enable switching signal lamps

Configuration


2 Configuration

Layout Diagram

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Figure 2-1 Layout diagram

1 N

2 N

s

5SY6 016-6KV

3305

MCBB 16~230V

1 N

2 N

s

5SY6 016-6KV

3305

MCBB 16~230V

1 L1 3 L2 5 L3

SIRIUS 3Rs

OFF ON

3RV1011-0KA10G/980604 *E01*

TEST/ >> 15A

CLASS 10

1,25A

1,1 0,9

2 T1 4 T2 6 T3

1 L1 3 L2 5 L3

SIRIUS 3Rs

OFF ON

3RV1011-0KA10G/980604 *E01*

TEST/ >> 15A

CLASS 10

1,25A

1,1 0,9

2 T1 4 T2 6 T3

L1 N + -+ -

22,2…26,4V

24V okLOGO!Power6EP1331-1SH02

s

Input:AC 100-240V

Output: DC 24V/1,3AClass 2

L1 N + -+ -

22,2…26,4V

24V okLOGO!Power6EP1331-1SH02

s

Input:AC 100-240V

Output: DC 24V/1,3AClass 2

s

1 L1 3 L2 5 L3 21NC A1+DC 24V

2 T1 4 T2 6 T3 22NC A2-

s

1 L1 3 L2 5 L3 21NC A1+DC 24V

2 T1 4 T2 6 T3 22NC A2-

s

LOGO! 12/24RC

DC 12/24V INPUT 8xDC

L+ M I1 I2 I3 I4 I6 I7 I8

6ED1 052-1MD00-0BA5

Output 4xRelay/10AX 34 5

21Q1

21Q2 Q3

1 2Q4

1 2

ESC OK

I5

I7=AI1 (0..10V)I8=AI2 (0..10V)

s

LOGO! 12/24RC

DC 12/24V INPUT 8xDC

L+ M I1 I2 I3 I4 I6 I7 I8

6ED1 052-1MD00-0BA5

Output 4xRelay/10AX 34 5

21Q1

21Q2 Q3

1 2Q4

1 2

ESC OK

I5

I7=AI1 (0..10V)I8=AI2 (0..10V)

reservoir

L1L2L3N

MY

+24V

-

The PIN assignment of the sonar proximity switch is listed in chapter 5.3.1.

Note

Hardware and Software Components


3 Hardware and Software Components

Products Table 3-1

Component Qty. MLFB / Order number Note

LOGO! Power 24V 1.3A 1 6EP1331-1SH02 LOGO! 12/24RC 1 6ED1052-1MD00-0BA5

Sonar proximity switch 1 3RG6013-3RS00 200...1300mm 20 ... 130Hz

Contactor (1RT10) 1 3RT1015-1BB42 Circuit breaker for motor protection 1 3RV1011-0KA10 0.9A..1.25A

Motor 1 1LA7060-4AB10

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e.g. for demonstration purposes

!

The drive section in this Micro Application Example was designed for the purpose of live demonstration. Attention If you are using a different motor than the one specified, you must reconfigure your drive section accordingly.

Accessories Table 3-2


Overvoltage limitation for contactor 1 3RT1916-1CB00 RC element

Line protection switch 1 5SY6010-7KV

SONOPROG 1 3RX4000 optional (for reprogramming the Beros)

Connection line for Sonar proximity switch 1 3RX8000-0CB52-1AF0 5 pole, 5m

Configuration software/tools Table 3-3


LOGO! Soft Comfort V5.0 1 6ED1058-0BA01-0YA0 LOGO! PC cable 1 6ED1057-1AA00-0BA0

Function Principle


4 Function Principle

4.1 Sonar proximity switch

Measuring principle The sonar proximity switch sends ultrasonic pulse (t1). These are reflected (t2) by an object (e.g. plastic granulate). The sonar proximity switch receives the echo (t3) and measures the time between sending the ultrasonic pulse and receiving the echo (t3-t1). This interval is proportional to the distance between sound source (i.e. the sonar proximity switch) and the object. Figure 4-1, Sending and receiving ultrasonic sound waves

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Object Object Object

t1 t2 t3

Output signal The distance to the object, which is proportional to the measured time interval, is output by the Sonar proximity switch as a frequency (short distance corresponds to a lower frequency.

Function Principle


Figure 4-2 Travel/frequency interdependence of the sensor

ca. 5°

smin smax

Measuring field of the sonar proximity switch The propagation of the ultrasonic pulses from the source into the measured space is referred to as sound cone. An example of a sound cone is depicted in the figure below. Figure 4-3, Sound cone sonar proximity switch, type M 30, 130 cm, damping 0, optimal

reflection

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Object

Object distance in cm

Sou

nd c

one

wid

th in

cm

Average

Filling level measurement For filling level measurement, the sonar proximity switch is installed at the top of the tank (see Figure 4-4).

The sonar proximity switch sends ultrasonic pulses. These are reflected by the filling material in the tank. The echo is recognized by the sonar proximity switch and output as a frequency proportional to the time interval.

The output frequency is therefore a measure for the filling level of the tank.

Function Principle


Figure 4-4 Evaluation of different filling levels

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Container

Plastic granulate

Container

Plastic granulate

Sonar BeroSonar Berot1 t2

Fequency output: Fequency output :

Using several Sonar proximity switches If several Sonar proximity switches are used in one tank1, they must be synchronized via an additional line. Otherwise there is the danger of the ultra-signals mutually affecting each other.

4.2 LOGO! Logic module

Process inputs Table 4-1

inputs Description

I1, feedback contactor At this input, the feedback of the contactor (NC contact) is evaluated. At this input, the frequency output of the sonar proximity switch is evaluated.

I5, sonar proximity switch fa

1 A maximum number of two sonar proximity switches can be attached at the LOGO!. Please use inputs I5 and I6. They are suitable for frequencies up to 2kHz.

Function Principle


Process outputs Table 4-2

Inputs Description

The motor contactor is controlled via this output.

Q1, contactor control

Frequency measurement A frequency can also be referred to as “number of pulses over a certain time“.

Using the LOGO! function block “Threshold value switch“, LOGO! counts all pulses at an input in a defined time (e.g. 1 second). The number of counted pulses within this time is a measure for the frequency. 40 pulses per second correspond to e.g. 40Hz.

Fill level control

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The LOGO! function block “Threshold switch“, used with a switching on and off limit, controls the motor.

If the distance between the sonar proximity switch and the granulate surface (Smeasure) becomes too large (switching on limit is fallen short of), output ”Q1“ of the function block is set to ON. Exceeding of the switching off limit causes the resetting of output ”Q1“.

Figure 4-5, t1, Filling level drops; t2 filling level below switching on limit – plastic conveyor

starts; t3 filling risen above switching off limit – conveyer stopped

Container

Plastic Granulate

Sonar-Berot1

Frequency output:

Switching offlimit

Switching onlimit

Container

Plastic Granulate

Sonar-Berot2

Frequency output :

Switching offlimit

Switching onlimit

Thresholdswitch: OFF

Thresholdswitch :

Sonar-Berot3

Frequency output :

ON

Container

Plastic Granulate

Switching offlimit

Switching olimit

Thresholdswitch : Off

Sm

easu

re

S mea

sure Sm

easu

re

n

Function Principle


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The hysteresis behavior of the process is due to using two switching limits (separate switching on and off limit). This prevents frequent switching on and off of the compressor motor

Diagnostic functions The LOGO! is informed of the current ACTUAL switching state of the contactor, as the auxiliary contact is evaluated at the contactor. It is compared with the SETPOINT switching state.

If the comparison yields a difference between both, a function error is suspected – a respective diagnostic message is then output via the LOGO! display. Table 4-3 Diagnostics messages

No SETPOINT state ACTUAL state Diagnostic conclusion

1. Contactor ON Contactor OFF Contactor jammed (e.g. contacts fused)

2. Contactor OFF Contactor ON

Contactor does not pick up (e.g. wire break in the contactor control line)

Configuring the Startup Software


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5 Configuring the Startup Software

5.1 Preliminary remark

For the startup, we offer you a software example with the Startup Code as a download. The software example supports you during the first steps and tests with this Micro Automation Set. They enable quick testing of hardware and software interfaces between the products described in the Micro Automation Sets.

The software example is always assigned to the components used in the set and show their principal interaction. However, it is not a real application in the sense of technological problem solving with definable properties.

5.2 Download of the startup code

The software example is available on the HTML page from which you downloaded this document. Table 5-1

No. Object File name Contents

1. LOGO! Configuration

Set3_LOGO_V1d3_en.lsc LOGO! Soft Comfort configuration for the LOGO! 12/24 RC logic module



5.3 Configuring Components

It is assumed that the necessary software LOGO! Soft Comfort V5 SP1 has been installed on your computer and that you are familiar with handling the software.

Note

5.3.1 Installing and wiring the hardware

In the following table it is described how the components from chapter 3 are set up and connected with each other.

Table 5-2

Action Comment No.

Mount all components on a top-hat rail according to Figure 2-1.

1.

2.

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Wire the components according to Figure 2-1.

Connect the sonar proximity switch as follows:

1: L+ 20V ... 30V DC3: M (L- 0V)4: FA (frequency output)



5.3.2 LOGO! Logic module / configuring the startup code

Table 5-3

No. Action Comment

Connect LOGO! 12/24 RC and the serial interface of the PC using the LOGO! PC cable.

1. LOGO!-PC-Kabel

Projektierungs-PC 2. Open the file from Table 5-1 with LOGO!.

Download the project via “Tools\Transfer\PC -> LOGO!“ in the LOGO! logic module.

3.

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Set the LOGO! logic module into “RUN” mode.

4.

Live Demo


6 Live Demo

Overview of features The following features of this Micro Automation Set can be demonstrated:

• Automatic switching on and off of the conveyor with hysteresis

• Simple changing of switching on and off limits during operation

• Diagnostic functions

6.1 HMI screen

Overview of configured operating images Table 6-1

No.

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Figure Description

1. Line 1: • Current filling level Line 2: • Operating mode: MANUAL/

AUTO • Switching state: ON/ OFF

2.

Line 1: • Current filling level Line 2: • Operating mode: MANUAL/

AUTO • Switching state: ON/ OFF

Live Demo


No. Figure Description

3.

Line 1: • Current filling level Line 2: • Operating mode: MANUAL/

AUTO • Switching state: ON/ OFF Line 3: • Switching on limit (conveyor

switches ON)

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Line 4: • Switching off limit (conveyor

switches OFF) 4.

Line 1: • Current filling level Line 2: • Operating mode • Switching state Line 3: • Switching on limit (conveyor

switches ON) Line 4: • Switching off limit (conveyor

switches OFF) 5.

Line 1: • Current filling level Line 2-4: • Error message: Contactor does

not switch ON

6. Line 1: • Current filling level Line 2-4: • Error message: Contactor does

not switch OFF

Live Demo


6.2 Overview of live demo

Scenarios The following scenarios can be displayed in the live demo:

• Manual on and off switching of the motor (compressor)

• Automatic on and off switching of the motor (compressor)

• Changing the switching thresholds for switching on/off

• Diagnosis “Wire break”

• Diagnosis “Contactor contacts sticking together“

6.2.1 Manual on and off switching of the motor (compressor)

Table 6-2

No.

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Description / Activity Figure / Explanation

1. Switch on the configuration. LOGO! displays the following screen.

2. Switch on the motor with the button

combination “ESC + “. The following screen is displayed by LOGO!:

3. Switch off the motor with the button combination “ESC + “.

The following screen is displayed by LOGO!:

Live Demo


No. Description / Activity Figure / Explanation

6.2.2 Automatic on and off switching of the motor (compressor)

Table 6-3


1.

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Switch on the configuration if necessary.

LOGO! displays the following screen.

Live Demo



2. Switch to automatic mode with the button combination “ESC + “.


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or:

3. Change the measuring distance

smeasure between Sonar-Bero and obstacle.

If measuring distance smeasure is larger than the switching on threshold, the motor switches on. If measuring distance smeasure is smaller than the switching off threshold, the motor switches on. See also Figure 4-4.

4. Switch to automatic mode with the button combination “ESC + “.


Live Demo


6.2.3 Changing the switching thresholds for switching on/off

Table 6-4


1. Switch on the configuration if necessary.


2. Switch on the automatic mode with

the button combination “ESC + “. The following screen is displayed by LOGO!:

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or:

Live Demo


Description / Activity Figure / Explanation No.

Press ESC until “_“ is displayed.

3.

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Use the buttons “ “ and “ “ to navigate to the parameters ”ON:“, and “OFF:“.

4.

5. If there is a “_“ before the parameter to be changed, press “OK“ and navigate to the decimal place you wish to change using the ” “ and ” “ buttons.

6. Using the “ “ and “ “ buttons, you can change the number value of the decimal place. Confirm your modification with "OK".

7. Repeat steps 8 and 9 for the next digit or the next parameter. Quit change mode with "ESC".

8. Change the measuring distance smeasure between Sonar-Bero and obstacle. The LOGO! now uses the changed switching limits.

If measuring distance smeasure is larger than the switching on threshold, the motor switches on. If measuring distance smeasure is smaller than the switching off threshold, the motor switches on. See also Figure 4-5.

Live Demo


6.2.4 Diagnosis: wire break

Table 6-5




2. Switch on the motor with the button

combination “ESC + “.

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3. Disconnect the line leading to the contactor at output “Q1“.


Live Demo


6.2.5 Diagnosis: contactor contacts sticking together

Table 6-6



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2. Please ensure, that the contactor is

switched off and also disconnect the diagnostic line at terminal “22 NC“. or


press the red button of the relay

Technical data


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7 Technical data

LOGO!Power 24 V/1.3 A Table 7-1:

Criterion Technical data Additional note

Supply voltage 85 to 264 V AC Output voltage/current DC 24 V / 1.3 A (range 22.2 V to 26.4V) Dimensions (W x H x D) 54 x 90 x 55 in mm

LOGO! 12/24 RC Table 7-2


Supply voltage DC 10.8 V bis 28.8 V

Digital inputs 8

I5, I6: quick counter I7, I8: also to be used as analog input (0-10V) (I7 = AI1, I8 = AI2)

Digital outputs 4 relays No short-circuit protection, external fuse necessary

Clock Existing (date / time) Dimensions (W x H x D) 72 x 90 x 55 in mm

LOGO!Soft Comfort V5.0 Table 7-3


Program representation Functional plan, contact plan Simulation Yes without hardware Online test Yes with hardware Languages 6 languages (G,E,F,S,I,P)

Required operating system WIN98SE/ NT4.0/ME/2000/XP,MAC OS X,LINUX

all Linux distributions, with Java 2 SDK Version 1.3.1

SONAR proximity switch Table 7-4


Supply voltage/current 24 V DC / 300mA Application range 200 ... 1,300 mm Frequency output 20 ... 130 Hz Connection Connector M12

Documents

Micro Application Example - Siemenscmsapps.sea.siemens.com/automation/microplc/docs... · The Micro Automation Sets are not binding and do not claim to be complete ... copy these