Micro Application Example
Distance and Level Measurement in Industrial
Applications
Micro Automation Set 3
Note
Micro Automation Set 3 21689394
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:
[e-mail]
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Foreword
Micro Automation Set 3 21689394
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
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Foreword
Micro Automation Set 3 21689394
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
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Application Areas and Usage
Micro Automation Set 3 21689394
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
Motor/Compresor
Sonar Bero
Valve
Molding Machine
Silo
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.
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Application Areas and Usage
Micro Automation Set 3 21689394
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
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Configuration
Micro Automation Set 3 21689394
2 Configuration
Layout Diagram
Figure 2-1 Layout diagram
L1
L2
L3
N
1 L1 3 L2 5 L3
1 L1 3 L2 5 L3
3305
3305
1 N
1 N
s
s
SIRIUS 3R
SIRIUS 3R
s
s
1,25A
1,25A
5SY6 016-6KV
5SY6 016-6KV
OFF ON
OFF ON
1,1 0,9
1,1 0,9
CLASS 10
CLASS 10
/ >> 15A
/ >> 15A
TEST
TEST
MCB
MCB
B 16
B 16
~230V
~230V
+
G/980604 *E01* 3RV1011-0KA10
G/980604 *E01* 3RV1011-0KA10
24V
-
2 N
2 N
2 T1 4 T2 6 T3
2 T1 4 T2 6 T3
L1 N + + - - L+ M I1 I2 I3 I4 I5 I6 I7 I8
L1 N + + - - L+ M I1 I2 I3 I4 I5 I6 I7 I8
DC 24V
DC 24V
Input: Output: DC 24V/1,3A DC 12/24V INPUT 8xDC I7=AI1 (0..10V)
Input: Output: DC 24V/1,3A DC 12/24V INPUT 8xDC I7=AI1 (0..10V)
1 L1 3 L2 5 L3 21NC A1+
1 L1 3 L2 5 L3 21NC A1+
I8=AI2 (0..10V)
I8=AI2 (0..10V)
AC 100-240V Class 2
AC 100-240V Class 2
s
s
s s
s s
LOGO!Power
LOGO!Power
6EP1331-1SH02
6EP1331-1SH02
24V ok
24V ok
ESC OK
ESC OK
LOGO! 12/24RC 6ED1 052-1MD00-0BA5
LOGO! 12/24RC 6ED1 052-1MD00-0BA5
2 T1 4 T2 6 T3 22NC A2-
2 T1 4 T2 6 T3 22NC A2-
X 3
X 3
Output 4xRelay/10A 4 5
Output 4xRelay/10A 4 5
1 2 1 2 1 2 1 2
1 2 1 2 1 2 1 2
22,2& 26,4V
22,2& 26,4V
Q1 Q2 Q3 Q4
Q1 Q2 Q3 Q4
M
Y
reservoir
Note
The PIN assignment of the sonar proximity switch is listed in chapter
5.3.1.
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Hardware and Software Components
Micro Automation Set 3 21689394
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
3RG6013-3RS00 200...1300mm
Sonar proximity switch 1
20 ... 130Hz
Contactor (1RT10) 1 3RT1015-1BB42
Circuit breaker for motor 3RV1011-0KA10
1 0.9A..1.25A
protection
e.g. for
Motor 1 1LA7060-4AB10 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
Component Qty. MLFB / Order number Note
Overvoltage limitation for
1 3RT1916-1CB00 RC element
contactor
Line protection switch 1 5SY6010-7KV
optional (for
SONOPROG 1 3RX4000 reprogramming the
Beros)
Connection line for Sonar
1 3RX8000-0CB52-1AF0 5 pole, 5m
proximity switch
Configuration software/tools
Table 3-3
Component Qty. MLFB / Order number Note
LOGO! Soft Comfort V5.0 1 6ED1058-0BA01-0YA0
LOGO! PC cable 1 6ED1057-1AA00-0BA0
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Function Principle
Micro Automation Set 3 21689394
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
t1 t2 t3
Object Object Object
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.
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Function Principle
Micro Automation Set 3 21689394
Figure 4-2 Travel/frequency interdependence of the sensor
smin smax
ca. 5°
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
Average
Object
Object distance in cm
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.
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Sound cone width in cm
Function Principle
Micro Automation Set 3 21689394
Figure 4-4 Evaluation of different filling levels
t1 Sonar Bero t2 Sonar Bero
Fequency output: Fequency output :
Container Container
Plastic granulate Plastic granulate
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.
I5, sonar proximity switch fa At this input, the frequency output of
the sonar proximity switch is evaluated.
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.
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Function Principle
Micro Automation Set 3 21689394
Process outputs
Table 4-2
Inputs Description
Q1, contactor control The motor contactor is controlled via
this output.
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
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
t1 t2 t3
Sonar-Bero Sonar-Bero Sonar-Bero
Frequency output: Frequency output : Frequency output :
Threshold Threshold Threshold
switch: OFF switch : ON switch : Off
Container Container Container
Switching off Switching off Switching off
limit limit limit
Switching on
Switching on Switching on
limit
limit limit
Plastic Granulate Plastic Granulate Plastic Granulate
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measure
S
measure
measure
S
S
Function Principle
Micro Automation Set 3 21689394
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
Diagnostic
No SETPOINT state ACTUAL state
conclusion
Contactor jammed (e.g.
1. Contactor ON Contactor OFF
contacts fused)
Contactor does not
pick up (e.g. wire break
2. Contactor OFF Contactor ON
in the contactor control
line)
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Configuring the Startup Software
Micro Automation Set 3 21689394
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! Set3_LOGO_V1d3_en.lsc LOGO! Soft Comfort
Configuration configuration for the LOGO!
12/24 RC logic module
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Configuring the Startup Software
Micro Automation Set 3 21689394
5.3 Configuring Components
Note
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.
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
No. Action Comment
1. Mount all components on a top-hat rail
according to Figure 2-1.
2. Wire the components according to Figure Connect the sonar proximity switch as
2-1. follows:
1: L+ 20V ... 30V DC
3: M (L- 0V)
4: FA (frequency output)
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Configuring the Startup Software
Micro Automation Set 3 21689394
5.3.2 LOGO! Logic module / configuring the startup code
Table 5-3
No. Action Comment
1. Connect LOGO! 12/24 RC and the serial
interface of the PC using the LOGO! PC
LOGO!-PC-Kabel
cable.
Projektierungs-PC
2. Open the file from Table 5-1 with LOGO!.
3. Download the project via
 Tools\Transfer\PC -> LOGO!
in the LOGO! logic module.
4. Set the LOGO! logic module into  RUN
mode.
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Live Demo
Micro Automation Set 3 21689394
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. 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
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Live Demo
Micro Automation Set 3 21689394
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)
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
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Live Demo
Micro Automation Set 3 21689394
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. Description / Activity Figure / Explanation
1. Switch on the configuration. LOGO! displays the following
screen.
2. Switch on the motor with the button The following screen is displayed by
combination  ESC +  . LOGO!:
3. Switch off the motor with the button The following screen is displayed by
combination  ESC +  . LOGO!:
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Live Demo
Micro Automation Set 3 21689394
No. Description / Activity Figure / Explanation
6.2.2 Automatic on and off switching of the motor (compressor)
Table 6-3
No. Description / Activity Figure / Explanation
1. Switch on the configuration if LOGO! displays the following
necessary. screen.
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Live Demo
Micro Automation Set 3 21689394
No. Description / Activity Figure / Explanation
2. Switch to automatic mode with the The following screen is displayed by
button combination  ESC +  . LOGO!:
or:
3. Change the measuring distance If measuring distance smeasure is
smeasure between Sonar-Bero and larger than the switching on
obstacle. 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.
Switch to automatic mode with the
4. The following screen is displayed by
button combination  ESC +  .
LOGO!:
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Live Demo
Micro Automation Set 3 21689394
6.2.3 Changing the switching thresholds for switching on/off
Table 6-4
No. Description / Activity Figure / Explanation
1. Switch on the configuration if LOGO! displays the following
necessary. screen.
2. Switch on the automatic mode with The following screen is displayed by
the button combination  ESC +  . LOGO!:
or:
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Live Demo
Micro Automation Set 3 21689394
No. Description / Activity Figure / Explanation
3. Press ESC until  _ is displayed.
4. Use the buttons   and   to
navigate to the parameters  ON: ,
and  OFF: .
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 If measuring distance smeasure is
smeasure between Sonar-Bero and larger than the switching on
obstacle. threshold, the motor switches on.
The LOGO! now uses the changed If measuring distance smeasure is
switching limits. smaller than the switching off
threshold, the motor switches on.
See also Figure 4-5.
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Live Demo
Micro Automation Set 3 21689394
6.2.4 Diagnosis: wire break
Table 6-5
No. Description / Activity Figure / Explanation
1. Switch on the configuration if LOGO! displays the following
necessary. screen.
2. Switch on the motor with the button The following screen is displayed by
combination  ESC +  . LOGO!:
3. Disconnect the line leading to the The following screen is displayed by
contactor at output  Q1 . LOGO!:
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Live Demo
Micro Automation Set 3 21689394
6.2.5 Diagnosis: contactor contacts sticking together
Table 6-6
No. Description / Activity Figure / Explanation
1. Switch on the configuration if LOGO! displays the following
necessary. screen.
2. Please ensure, that the contactor is The following screen is displayed by
switched off and also disconnect the LOGO!:
diagnostic line at terminal  22 NC .
or
press the red button of the relay
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Technical data
Micro Automation Set 3 21689394
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
Criterion Technical data Additional note
Supply voltage DC 10.8 V bis 28.8 V
I5, I6: quick counter
I7, I8: also to be used as
Digital inputs 8
analog input (0-10V)
(I7 = AI1, I8 = AI2)
No short-circuit protection,
Digital outputs 4 relays
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
Criterion Technical data Additional note
Program representation Functional plan, contact plan
Simulation Yes without hardware
Online test Yes with hardware
Languages 6 languages (G,E,F,S,I,P)
WIN98SE/
all Linux distributions, with
Required operating system NT4.0/ME/2000/XP,MAC OS
Java 2 SDK Version 1.3.1
X,LINUX
SONAR proximity switch
Table 7-4
Criterion Technical data Additional note
Supply voltage/current 24 V DC / 300mA
Application range 200 ... 1,300 mm
Frequency output 20 ... 130 Hz
Connection Connector M12
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