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MICRO-EPSILON combiSENSOR KSB6430-PROFINET Operating Instructions Manual

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Operating Instructions
combiSENSOR
KSB6430-PROFINET

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Summary of Contents for MICRO-EPSILON combiSENSOR KSB6430-PROFINET

  • Page 1 Operating Instructions combiSENSOR KSB6430-PROFINET...
  • Page 2 MICRO-EPSILON MESSTECHNIK GmbH & Co. KG Koenigbacher Straße 15 94496 Ortenburg / Germany Tel. +49 (0) 8542 / 168-0 Fax +49 (0) 8542 / 168-90 info@micro-epsilon.com www.micro-epsilon.com...

  • Page 3: Table Of Contents

    Inhalt Safety ................................ 5 Symbols Used ..................................5 Warnings ....................................5 Notes on Product Marking ..............................6 1.3.1 CE Marking ................................. 6 1.3.2 UKCA Marking ..............................6 Intended Use ..................................7 Proper Environment................................7 Functional Principle, Options, Technical Data ......................8 Measuring Principle ................................
  • Page 4 Operation ..............................22 Initial Operation ................................... 22 Controller LEDs ................................... 22 Triggering ..................................... 23 Measurement Averaging ..............................25 5.4.1 Preliminary Remarks ............................25 5.4.2 Moving Mean ..............................25 5.4.3 Arithmetic Average ............................26 5.4.4 Median ................................26 5.4.5 Dynamic Noise Suppression ........................... 26 Initial Operation ................................

  • Page 5: Safety

    Safety Safety System operation assumes knowledge of the operating instructions. Symbols Used The following symbols are used in these operating instructions: Indicates a hazardous situation which, if not avoided, may result in minor or moderate injury. Indicates a situation that may result in property damage if not avoided. Indicates a user action.

  • Page 6: Notes On Product Marking

    Safety Notes on Product Marking 1.3.1 CE Marking The following apply to the product: - Directive 2014/30/EU ("EMC") - Directive 2011/65/EU ("RoHS") Products which carry the CE marking satisfy the requirements of the EU Directives cited and the relevant applicable harmonized Euro- pean standards (EN).

  • Page 7: Intended Use

    Safety Intended Use - The combiSENSOR 6430 measuring system is designed for use in industrial and laboratory applications. It is used for ƒ Film thickness measurement of plastics ƒ Thickness measurement of insulators ƒ Thickness measurement of conductive battery film - The system must only be operated within the limits specified in the technical data, see 2.3.

  • Page 8: Functional Principle, Options, Technical Data

    Functional Principle, Options, Technical Data Functional Principle, Options, Technical Data Measuring Principle The measurement coil and measurement electrodes have a concentric design. Thus, both measure against the same target surface. The signal of the capacitive displacement sensor is a function of the working distance, the thickness of the insulator and ( r). At the same time the eddy current displacement sensor measures the distance to the ground electrode (e.g.

  • Page 9: Eddy Current Measuring Technique

    Functional Principle, Options, Technical Data 2.1.2 Eddy Current Measuring Technique The eddy current measurement method is used for measurements on objects made of electrically conductive materials, which may have ferromagnetic and non-ferromagnetic properties. A high frequency alternating current is passed through a coil potted in a sensor housing. The electromagnetic field of the coil induces eddy currents in the conducting measuring object, whereby the resulting impedance of the coil changes.
  • Page 10 Functional Principle, Options, Technical Data Sensor T<A Insulator ( Target Ground electrode Fig. 2 Measurement arrangement for thickness measurement The thickness of the insulator is calculated from the factors: Max. working distance, capacitive displacement measuring signal A and the dielectric constant of the insulator: Thickness measuring object [µm] Signal eddy current sensor [%] ...

  • Page 11: Structure

    Functional Principle, Options, Technical Data A constant dielectric constant of the medium to be measured is required for correct thickness measurement. The thickness value is calculated in the controller. With measuring objects presenting a structured surface, a target thickness up to a maximum of 50 % of the working distance is recommended.

  • Page 12: Sensor Cable

    Functional Principle, Options, Technical Data 2.2.2 Sensor Cable Sensor and controller are connected via a special, double-shielded 1m-long KC1 sensor cable. Do not shorten or lengthen this special sensor cable. Do not kink the sensor cable. Do not change the sensor cable. This leads to a loss of functionality or the specified technical data.

  • Page 13: Technical Data

    Functional Principle, Options, Technical Data Technical Data Controller KSB6430 Sensor KSH5(03) Target thickness insulator 5 µm ... 3 mm Working distance 2.5 ... 4 mm (2 ... 5 mm with reduced accuracy) static 100 Hz 0.0004 % Resolution dynamic 3.9 kSa/s 0.0015 % Frequency response 1 kHz (-3 dB)

  • Page 14: Delivery

    Delivery Delivery Unpacking, Included in Delivery - 1 Controller KSB6430 - 1 Sensor KSH5(03) - 1 Sensor cable KC1 or KC1,5 - 1 Supply cable PC6200-3/4 - 1 Operating instructions Carefully remove the components of the measuring system from the packaging and ensure that the goods are forwarded in such a way that no damage can occur.

  • Page 15: Installation And Assembly

    Installation and Assembly Installation and Assembly Precautions No sharp or heavy objects should be allowed to affect the cable sheath. In areas with increased pressure, the cable must always be protected from pressure loads. The minimum bending radius is 20 mm. Kinks must be avoided at all costs. The plug connections must be checked for firm seating.

  • Page 16: Sensor Cable

    Installation and Assembly Circumferential Clamping This type of sensor installation ensures the highest level of reliability because the sensor’s cylindrical cover is clamped over a relatively large area. It is imperative in complex installation environments, such as machines, production plants, etc. Tension on the cable is not permitted.

  • Page 17: Controller

    Installation and Assembly Controller 75 (2.95) 125 (4.92) Range SENSOR POWER/TRIG. SIGNAL OUT MICRO-EPSILON KSB6430 DL6435 34 (1.34) 25 (0.98) 8 (0.31) Fig. 9 Dimensional drawing of controller with base unit, demodulator and housing cover, dimensions in mm (inches, rounded off)

  • Page 18: Ground Connection, Grounding

    Installation and Assembly Mounting hole M4 for wall fastening respectively mounting on DIN-rail 8 (.31) 90 (3.54) (.20) (.31) Fig. 10 Dimensional drawing of housing cover, dimensions in mm (inches, rounded off) Ground Connection, Grounding Ensure sufficient grounding of the target, for example by connecting it to the sensor or the power supply ground. If necessary, use the grounding connection on the housing cover.

  • Page 19: Electrical Connections

    Installation and Assembly Electrical Connections 4.6.1 Connection Possibilities The power supply and the signal output are located at the front side of the controller. Controller LAN cable E th RJ-45-connectors CCxxx PS 2020 Ammeter/ Sensor Voltmeter Fig. 11 Measuring system structure combiSENSOR KSB6430 PROFINET Page 19...

  • Page 20: Pin Assignment Supply, Trigger

    Installation and Assembly 4.6.2 Pin Assignment Supply, Trigger Wire color Signal Description PC6200-3/4 brown +24VIN +24 VDC supply white Zero VIN GND supply yellow TRI_IN+ Trigger IN+, TTL level POWER/TRIG. green TRI_IN- Trigger IN- KSB6430 Shield PC6200-3/4 is an assembled supply and View: solder side, Supply input on controller, trigger cable that is 3 m long.

  • Page 21: Fieldbus Cabling

    Installation and Assembly Fieldbus Cabling During cabling, channel 0 of the IO controller is connected to a port on the first IO device (slave device). The second port of the first slave device is connected to the input port of the next slave device, etc. One port of the last slave device and channel 1 of the master device remain unused.

  • Page 22: Operation

    Operation Operation Initial Operation Connect the display/output devices via the signal output socket, see 4.6 before connecting the device to the supply voltage and switching it on. Let the measuring system warm up for about 15 minutes after applying the supply voltage. Controller LEDs Color Function...

  • Page 23: Triggering

    Operation Triggering The measured value output of the combiSENSOR KSB6430 can be started via an external trigger signal or a software command. Only the digital output is affected. Triggering takes place via: Controller I = 5 ... 45 mA Trigger in - Trigger input (pin 3 and pin 4 on 4-pole power supply connector or 100 Ohm , HIGH...
  • Page 24 Operation Rising edge (gate). Starts measured value output with set data rate as soon as the rising edge is present at the trigger input. Another rising edge stops the output of measured values or switches it on again. Fig. 16 Rising edge trigger (U ), relevant digital signal (D There is no factory-set triggering, the controller starts transmitting data as soon as it is switched on.

  • Page 25: Measurement Averaging

    Operation Measurement Averaging 5.4.1 Preliminary Remarks The measured values are averages before they are output via the PROFINET interface. The averaged measurements improve the resolution, enable to mask individual interfering points or "smooth" the measurement result. The linearity behavior is not affected by averaging. Averaging has no effect on the data rate. The controller is shipped from the factory without averaging.

  • Page 26: Arithmetic Average

    Operation 5.4.3 Arithmetic Average The arithmetic average M is formed and output via the selectable number N of successive measured values. Method Measured values are collected based on which the mean value is calculated. This method leads to a reduced amount of data because an average value is only output after every Nth measured values.

  • Page 27: Initial Operation

    Initial Operation General This section describes how to use a SIMATIC S7 controller with Micro-Epsilon sensors (controller). Basic Settings Module After setting up the KSB6430 in the TIA Portal, see Chap. A 2, the Input_1 module is an easy way to make the necessary settings...

  • Page 28: Data Format

    Initial Operation Data Format All configuration parameters and data are transmitted in Little Endian format. Fig. 18 Data format and conversion of a DWORD to REAL The IO-Area contains the data as shown, see Fig. Timestamp Milliseconds passed since device power up Error Code Status code of the communication module Sensor Counter...

  • Page 29: Object Directory

    Initial Operation Object Directory 6.4.1 Error Protocol Index Subindex Data type Name Description 0x2010 0 Uint32[64] R device error log Reads out the last 32 error codes with time stamp 6.4.2 Device Reset Index Subindex Data type Name Description 0x2026 0 Uint8 reset device One byte performs reset/restart...

  • Page 30: Filter Settings

    Initial Operation 6.4.4 Filter Settings Index Subindex Data type Name Description 0x2032 1 8 bytes RW Filter Settings 0: No filter 1: Moving average Uint16 Filter type 2: Arithmetic average 4: Median Uint16 Reserved Uint32 Filter value Filter length: 2 / 3 / 4 / 5 / 6 / 7 / 8 6.4.5 Sample Time Index...

  • Page 31: Thickness Measurements

    Initial Operation 6.4.6 Thickness Measurements Index Subindex Data type Name Description 0x2037 Thickness measurement 16 bytes function 0: Not active Uint8 RW Activate 1: Active Uint8 RW Reserved Value 0 Uint8 RW Reserved Value 0 Uint8 RW Reserved Value 0 RW e Float32 Dielectric constant (float >...

  • Page 32: Sequence When Writing And Reading Acyclical Data

    Initial Operation Sequence when Writing and Reading Acyclical Data Determine the hardware identification (ID) of the module. To do this, switch to the General > PROFINET interface > Ad- vanced options tab. In the example to the right, you get the value 273. On the SPS, WRREC_DB with input parameters (:=) is called.

  • Page 33: Sequence When Writing Structured Data

    Initial Operation Sequence when Writing Structured Data WRREC_DB REQ := Enable-Flag ID := HW-ID INDEX := 0x2038 Objekt Index LEN := Write-Header (8 Byte) 8Byte + Data Length RECORD := 0 0 0x01 0 0x01 0 0 0 0x01 DONE => BUSY =>...

  • Page 34: Operation And Maintenance

    > Static discharge > Risk of injury If the controller, sensor or sensor cable is defective: MICRO-EPSILON MESSTECHNIK - If possible, save the current settings in a param- GmbH & Co. KG eter set to reload them into the controller after the Koenigbacher Straße 15...

  • Page 35: Disclaimer

    MICRO-EPSILON or to your distributor / retailer. MICRO-EPSILON undertakes no liability whatsoever for damage, loss or costs caused by or related in any way to the product, in par- ticular consequential damage, e.g., due to...

  • Page 36: Decommissioning, Disposal

    Here you can inform yourself about the respective national collection and return points. - Old devices can also be returned for disposal to MICRO-EPSILON at the address given in the imprint at https://www.micro-epsilon.com/legal-details - We would like to point out that you are responsible for deleting the measurement-specific and personal data on the old devices to be disposed of.

  • Page 37: Appendix A 1 Accessories

    Anhang| Accessories Appendix Accessories SCACx/5 Signal output cable analog, length 3 m and 6 m PS2020 Power supply for top-hat rail installation Input 230 VAC (115 VAC) Output 24 VDC/2.5 A; L/W/H 120 x 120 x 40 mm combiSENSOR KSB6430 PROFINET Page 37...

  • Page 38: A 2 Integration Into Tia Portal

    Anhang| Integration into TIA Portal Integration into TIA Portal A 2.1 Importing KSB6430 into the Software This section describes how to connect KSB6430 to SIMATIC S7 controllers. Start the TIA (Totally Integrated Automation) Portal. Therefore, either double-click the TIA Portal icon on your desktop or call up the framework via the start menu.
  • Page 39 Anhang| Integration into TIA Portal Click Add new device. Select the S7 CPU series you are using in the device list and click the Add button. Make sure that the checkbox Open device view on the bottom left of the window is activated. Identify your CPU module based on the order number on the S7 device, its packaging, or the delivery note.
  • Page 40 The GSDML file contains information about a PROFINET device. This file is needed for the PROFINET controller and must be integrat- ed into the corresponding configuration software. You get the GSDML file from Micro-Epsilon. Import the GSDML file. To do so, in the Extras > Manage device description files (DDF) menu, select the path for the file <GSD- ML-V2.43-MICRO-EPSILON-KSB6430PNET-20231201.xml>.
  • Page 41 Anhang| Integration into TIA Portal Click the Install button. Fig. 20 Importing the device description file After installation, switch to the project view. Click on Devices & networks in the Proj- ect navigation. combiSENSOR KSB6430 PROFINET Page 41...
  • Page 42 Add KSB6430 to the project. Make sure that KSB6430 has been integrated correctly. Wechseln Sie in den Reiter Hardware Catalog. In the menu, select Other field devices > PROFINET IO > I/O > MICRO-EPSILON MESSTECHNIK GmbH > PNS > KSB6430-PROFINET.

  • Page 43: A 2.2 Unique Integration Of Ksb6430 Into The Profinet Network

    Anhang| Integration into TIA Portal A 2.2 Unique Integration of KSB6430 into the PROFINET Network Switch to the Network view of the Working window and add KSB6430-PROFINET from the hardware catalog by drag and drop. Connect the Port 0 LAN socket of KSB6430 with the one of the PLC by clicking one of the green boxes with the left mouse but- ton.
  • Page 44 Anhang| Integration into TIA Portal Enter the device name for identification in the PN network. Switch to the Device view, double-click your KSB6430-PROFINET and set its device name in the Inspection window (Properties > General tab). This is one of several possibilities to change the device name. Fig.
  • Page 45 Anhang| Integration into TIA Portal The change of name must be communicated to the PN network. Right-click on KSB6430-PROFINET. You now reach the context menu shown. Select the Assign device name entry. In the open dialog window, click the Update list button. Potential devices on the PN network are displayed.
  • Page 46 Anhang| Integration into TIA Portal If you activate the Flash LED checkbox in the orange highlighted area you can verify which device you are currently address- ing. This is especially helpful in larger networks. combiSENSOR KSB6430 PROFINET Page 46...

  • Page 47: A 2.3 Loading The Configuration Into The Plc

    Anhang| Integration into TIA Portal A 2.3 Loading the Configuration into the PLC Click on the Download to device button in the Toolbar. Alternatively, you can also right-click on the image of your S7 in the Network view and select the function in the Context menu. In the Dialog window that opens, select the option PN/IE_1 (the previously created PROFINET subsystem) under Connec- tion to interface/subnet.
  • Page 48 Anhang| Integration into TIA Portal Select the Stop all option under Stop modules. The device configuration can only be loaded when the CPU is in the operating state STOP . Depending on whether you created a new project or opened an existing one, it might be necessary to overwrite the so-called additional information.

  • Page 49: A 2.4 Accessing Input And Output Data

    Anhang| Integration into TIA Portal A 2.4 Accessing Input and Output Data Switch to the Device view and take a look at the Device overview of KSB6430. Memorize the start address of the input module as an example. Depending on the module, the address space (memory address bytes) is visible in the I address or the Q address columns.
  • Page 50 Anhang| Integration into TIA Portal Proceed as follows to read out the content of the input module at its start address: Assign a (tag) Name and select the Data type DWord. Open the extended view of the Address definition. This facilitates the correct specification of operand and memory space. Enter the start address from Point 1 and confirm the entry by clicking the symbol button with the green check mark.
  • Page 51 Anhang| Integration into TIA Portal You can monitor the values of the PLC tags in online mode directly via the Default tag table. Click either the Moni- tor all symbol button (monitor all symbols) in the Toolbar or select this function by right-clicking within the tag table. This leads to the online mode and the column Monitor value is displayed in the table.
  • Page 52 MICRO-EPSILON MESSTECHNIK GmbH & Co. KG Koenigbacher Str. 15 · 94496 Ortenburg / Germany Tel. +49 (0) 8542 / 168-0 · Fax +49 (0) 8542 / 168-90 X9751485-A012094TSw info@micro-epsilon.com · www.micro-epsilon.com Your local contact: www.micro-epsilon.com/contact/worldwide/ MICRO-EPSILON MESSTECHNIK...