Festo

FMS50 Conveyor MPS 2000 Trainee Edition

© Festo Didactic GmbH & Co. • MPS

1

Order no.: Description:

Mechatronics Teachware FMS50 Conveyor MPS 2000

Designation:

Trainee Edition

Status:

03/2004

Author:

Wolfgang Eckart, Intercon-Asia

Graphicss:

Wolfgang Eckart, Festo Didactic GmbH & Co

Layout:

Festo Didactic GmbH & Co

© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2004 Internet: www.festo.com/didactic e-mail: [email protected] All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without the prior written permission of Festo Didactic.

Table of Contents

Table of Contents _______________________________________________________ 1 Introduction____________________________________________________________ 4 What is Mechatronics _________________________________________________ 4 Project overview _____________________________________________________ 7 Theory of Actuator Sensor Interface – AS-I ________________________________ 9 General informations on Fieldbus-systems ______________________________ 10 Hierarchy levels of communication systems _____________________________ 11 Short description of important Fieldbus-systems _________________________ 13 Actuator Sensor Interface – AS-I _______________________________________14 Actuator Sensor Interface – AS-I _______________________________________ 15 AS-I –basic components ______________________________________________ 16 AS-I – additional energy ______________________________________________ 16 AS-I – run of communication __________________________________________ 17 AS-I – data transfer and transmission security____________________________ 18 AS-I – economical installation _________________________________________ 20 AS-I – connection example with slaves 4 bit, 8 bit_________________________ 21 AS-I – input/output connection to the slave M12 (4 bit) and clamp (8 bit) _____ 22 AS-I – input/output connection to the pneumatic valve interface ____________24 AS-I – slave addressing with programming and service device ______________ 26 AS-I – slave addressing with addressing device __________________________ 27 AS-I – absolute hardwareaddresses within the S7 PLC program _____________ 29 AS-I – peripheral addresses regarding the slave address ___________________ 31

© Festo Didactic GmbH & Co. • MPS

1

Table of Contents

Frequency converter – general informations _____________________________ 33 Commissioning ________________________________________________________44 1.1

Analysis – Components identification__________________________44

1.2

Analysis – Emergency Stop system ____________________________46

1.3

Analysis – Input and Output adresses __________________________49

1.4

Analysis – Input and Output adresses expanded _________________ 55

1.5

Commissioning – Adjustment of the Station _____________________ 61

1.6

Commissioning – Adjustment of the Station expanded ____________ 63

1.7

Commissioning – Download Project and Test ___________________ 71

1.7.1

Commissioning – Driver Control ______________________________ 76

1.7.2

Commissioning – Online check of the Driver Control______________84

Programming__________________________________________________________ 88

2

2.1

Programming – Hardware-configuration ________________________ 88

2.1.1

Programming – Transfer of the peripheral AS-I-adresses within OB1102

2.2

Programming – Basics in Digital Technology – AND ______________107

2.3

Programming – Basics in Digital Technology – OR _______________123

2.4

Programming – Basics in Digital Technology – RS-Flip-Flop _______127

2.5

Programming – Basics in Digital Technology – AND NOT__________131

2.6

Programming – Basics in Digital Technology – IDENTITY __________134

2.7

Programming – Condition Call of a Program ____________________137

2.8

Programming – Condition Call of a Program expanded ___________140

2.9

Programming – On-Delay-Timer function ______________________142

© Festo Didactic GmbH & Co. • MPS

2.10

Programming – Off-Delay-Timer function ______________________146

2.11

Programming – Counter Down function________________________148

2.12

Programming – Programming of a Flashlight ___________________150

2.13

Programming –Programming of a Auto/Manu sequence__________152

2.14

Programming – Conveyor movement__________________________154

2.15

Programming – Conveyor movement expanded _________________156

2.16

Project – Basics of I/O– communication _______________________159

2.17

Project – Test the I/O– communication ________________________163

2.18

Project – Communication via Profibus-DP _____________________166

Trouble Shooting _____________________________________________________200

© Festo Didactic GmbH & Co. • MPS

3.1

Program – Trouble Shooting_________________________________200

3.2

Process – Trouble Shooting _________________________________229

3

Introduction

What is Mechatronics

Mechatronics is a comprehensive combination of Technologies and is mostly mentioned as a new way of thinking and learning and not as a “stand-alone” technology. The technological part of Mechatronics could be called Automation Technology.

Structure of Mechatronics The structure of Mechatronical training is devided into three levels:

© Festo Didactic GmbH & Co. • MPS

4

Introduction

The Basic Training in the single technologies is another part of training. In the following you will see some examples of the different levels:

Totally Integrated System

Partly Integrated Systems

Basic Technologies

© Festo Didactic GmbH & Co. • MPS

5

Introduction

Basically in Automation and Mechatronics training, the contents should cover the following learning steps, or functions within a company: Commissioning:

Analyse a system, Installation&Commissioning

Programming:

Programming single Station, Communication with other Stations

Trouble Shooting: Programming Errors, Trouble Shooting in the Process

which are covered within the following projects. Furtheron this Teachware is based on the idea of a Flexible Manufacturing System – FMS, this means, this conveyor is connected to other stations, called Connection Stations within this Teachware.

6

© Festo Didactic GmbH & Co. • MPS

Introduction

Project overview

The following table give you an overview about all projects within this documentation in the structure of: Commissioning:

Analysis (Analyse a system) and Commissioning (Installation&Commissioning)

Programming:

Programming (Programming single Station and Project (Communication with other Stations)

Trouble Shooting: Program (Programming Errors) and Process (Trouble Shooting in the Process)

© Festo Didactic GmbH & Co. • MPS

7

Introduction

Project overview Commissioning and Programming Learning Step

Designation

Project Description

Commissioning

Analysis

Commissioning

Analysis

Commissioning

Analysis

Commissioning

Analysis

Commissioning

Commissioning

Commissioning

Commissioning

Commissioning

Commissioning

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Programming

Project

Programming

Project

Programming

Project

Components identification: description of the function of some components used within the stations Emergency Stop system: define and identificate the Emergency Stop system In-and Output adresses of the PLC: find out the hardwareadresses of in- and outputs in the technical docum. In-and Output adresses of the PLC expanded: find out the hardwareadresses of in- and outputs in the technical docum. Adjustment of the Station: check the adjustment all sensors and mechanical components Adjustment of the Station expanded: check the adjustment all sensors and mechanical components Download Project and Test: download all project-programs and test the function of the FMS-system Hardwareconfiguration of the PLC: define the existing Siemens S7-300 PLC-hardware with the software STEP 7 Basics in digital technology–AND: programming of the basic function AND Basics in digital technology–OR: programming of the basic function OR Basics in digital technology–RS-Flip-Flop: programming of the basic function RS-Flip-Flop Basics in digital technology–AND NOT: programming of the basic function AND NOT Basics in digital technology–IDENTITY: programming of the basic function IDENTITY Condition Call of a Program: activate a program in OB1 by a condition of the Control Panel Condition Call of a Program expanded: activate a program in OB1 by a condition of the Control Panel ON-Delay-Timer: programming of a ON-delay timer function using the Control Panel OFF-Delay-Timer: programming of a OFF-delay timer function using the Control Panel Counter down: programming of a Counter down function using the Control Panel Programming of one flashlight: programming a flashlight with 500 ms on/off as long as a button is pressed Programming of a Auto/Manu-sequence: program starts with Start-button/continues by Start or Auto/Manu-switch Conveyor movement: edit a program to move the conveyor to station 6 Conveyor movement expanded: expanded program to move the conveyor to station 6 Theory Basics of I/O-communication: example of different in-/output communications using different controllers Test the I/O-communication: edit a program to test the I/O-communication at the stations Communication via Profibus-DP: 1-bit bidirectional communication between conveyor and one MPS-station

Proj..

Page

1.1

42

1.2

42

1.3

47

1.4

53

1.5

59

1.6

61

1.7

69

2.1

86

2.2

105

2.3

121

2.4

125

2.5

129

2.6

132

2.7

135

2.8

138

2.9

140

2.10

144

2.11

146

2.12

148

2.13

150

2.14

152

2.15

154

2.16

157

2.17

161

2.18

164

Trouble Shooting

Program

Error in Project 2.2 – 2.13 Æ time for each approx.

3.1

198

Trouble Shooting

Process

Maintenance Trouble ShootingÆ14 Process-ErrorsÆtime for each approx.

3.2

227

8

© Festo Didactic GmbH & Co. • MPS

Introduction

Theory of Actuator Sensor Interface – AS-I

To offer the opportunity to get the know-how of all levels of industrial networking, the conveyor systems inputs and outputs are wired via the Fieldbus-system AS-I (Actuator Sensor Interface) which represents the basic level of networking – the sensor/actuator or field level.

In the following, please find some helpful informations about AS-I to be able to understand the basics of this fieldbus system

© Festo Didactic GmbH & Co. • MPS

9

Introduction

General informations on Fieldbus-systems

Nowadays, in complex systems with big amounts of input/output signals, it is no more practicable to realize automation tasks by only one central controller.Industrial practice shows, that it is senseful to distribute the tasks on several small automation devices. These are co-ordinated by faster controllers or Master PCs and integrated into the entire process by a bus system. Also inputs and outputs are not longer connected directly to central signal modules of the PLC. They are connected de-centralized to I/O-terminals within the process, which are part of a fieldbus network with different controllers. The summaries of a network are: • • • • • •

Information (data) are transferred in a row over a two-wire cable (bus) Information interchange of all participants are enabled by logical connections Connection of all sensors and actuators to a master controller Interconnection of equivalent controllers Connection of all process-oriented devices to a master controller Continuous evaluation of functionality of network participants

Network advantages: • Flexible system construction, a plant may be easily expanded by connecting new participants • Less commissioning than with conventional wiring • Centralized data processing and process data acquisition, new data may be slipped into the process immediately • Higher dataset available • Less sources of error because of less wiring expediture • Centralized error control, therefore less downtime/higher operational reliability • Less service costs

10

© Festo Didactic GmbH & Co. • MPS

Introduction

Hierarchy levels of communication systems

In order to handle the complex flow of information within big companies, there are to be formed several hierarchy levels within the automated areas.The flow of information is spread within as well as between the different levels, which means, in vertical and in horizontal direction. Each hierarchy level has an additional level, which is setting the requirements for communication. Because the various communication tasks cannot be executed by one network, there have been developed different communication systems. In the higher levels, there are complex computer systems. In domination are big data sets with uncritical times of response, big amounts of participants and a wide extension of networks. Communication of the lower levels is performing less data sets and a high data processing as well as less amount of participants. Here the tasks are requirements of real time, the extension of network is mostly small.

© Festo Didactic GmbH & Co. • MPS

11

Introduction

The following hierarchy levels are to distinguish: • The evaluation of information from the manufacturing process, order planning and maintaining of guidelines and strategies for the production, is done in the planning level. Here, big data sets are being transferred over big distances within longer periods of time. • The coordination of different production areas is done in the process level. Here, the cell level is provided by order- and program data, and it is decided, how to execute production. This is the level of the process control computers as well as the computers for projecting, diagnosis operation and protocolling. • The cell level is connecting the several manufacturing cells, which are controlled by cell computers or PLCs. Their task is purposeful communication between intelligent systems. • In the field level, there are programable devices for controlling, adjusting and supervising like PLCs or industrial computers, which are evaluating data of the actuator/sensor level. For a connection to the higher systems, transfer of bigger data sets with critical times of response are necessary. • The actuator/sensor level is part of the field level and is connecting the technical process with the controller. This is done by simple field devices like sensors and actuators. Here, a quick and cyclic updating of input and output data is in the centre of interest, whereas short messages are being transferred. The time for updating of input- and output data has to be marginally shorter than the cycle time of the controller.

12

© Festo Didactic GmbH & Co. • MPS

Introduction

Interbus-S – one of the first Short description of important Fieldbus-systems Already in 1985 the Interbus-S was developped by Phoenix Contact, in order to integrate extensive parallel wiring into PLC periphery. In the beginning it was not the task of Interbus-S to perform a universal communication medium, it was only connecting programmable logic controllers, CNC controllers or process automation systems to their peripheral devices. Today INTERBUS-S offers a wide range of different communication levels with one protocoll. The benefits of Interbus-S are its high transmitting efficiency at very few data of each participant. Therefore, the Interbus-S is only suitable for the lowest hierarchy level. It is combining sensors and actuators with controllers, it is not providing a networking of controllers among eachother. Profibus – the allrounder The Profibus (Process Field Bus) is suitable as multi-master protocol for networking of devices, which are providing more complexity. The Profibus is EN standardized.Its area of use is broad and applies from field level up to master level. The Profibus in its principles is providing operation also down to the sensor-/actuator level. However, for an economical connection of a higher number of sensors and actuators, it is more profitable to apply a faster bus on a lower level (for ex. AS-I). AS-I – fast and small This bus system is specialized on demands of the lowest level (Actuator-SensorInterface). AS-I is combining binary and analog actuators and sensors with the first control level and is substituting cable harness, control cabinets and terminal strips. Meanwhile, many producers are offering intelligent sensors and actuators connectable to AS-I, in order to transmit more information than 1 and 0. AS-I is providing easy handling - by cut-and-clamp technique, field devices are simply clamped on to the unprotected 2-wire flat cable. Thus, installation may be done even by persons without specific know-how. CAN – fieldbus on wheels The CAN-Bus System (Controller Area Network) had been originally concepted by Bosch in co-operation with Intel in order to reduce cable harness inside the automobile. If the demands on automotive bus systems and industrial fieldbus systems are to compare, one would find amazing similarities: less costs, functionality under difficult environmental conditions, high real-time ability and ease of handling. The bus system is suitable to networking of intelligent sensors and actuators within a machine.

© Festo Didactic GmbH & Co. • MPS

13

Introduction

Actuator Sensor Interface – AS-I

The term "AS-I" derives from actuator-sensor-interface. One could translate: interface between actuators, sensors and the PLC. This bus system is a networking system for the lowest field level of the automation area - the process level. On the process level, data throughput is very less, because interchange of signals of the connected devices (switches, buttons, BERO, contactor relays, solenoid valves etc.) is only binary. However, demands on the rate of data transfer are very high. Mechanical as well as electrical specifications for the ASI-bus have been prepared by 11 competent companies working in the field of actorics, sensorics and construction of controllers. In this case, a manufacturer-independent standard of sensors and actuators could be developped. Besides this, an AS-I association was founded to evaluate all AS-I components for their compatibility to the standard and then awards the AS-I-logo.

The ”Verein zur Förderung busfähiger Interfaces für binäre Aktuatoren und Sensoren e. V.“ (association for the development of bus compatible interfaces for binary actuators and sensors) made it their business to support use and spreading of the AS-I system and to proceed specification, standardization, certification and general information of the users. The development of a small IC made it possible to integrate the AS-I bus also directly into small devices. Caused by this, innovative new generations of actuators and sensors could come up. Further new benefits were arising, as there are: • • • • • •

14

Elimination of cable harness between sensors, actuators and PLC Quick and simple assembly Automatic bonding by cut-and-clamp technique High protection against interferences High protection IP67, therefore possibility of local operation Self-healing bus cable

© Festo Didactic GmbH & Co. • MPS

Introduction

Actuator Sensor Interface – AS-I

The technical data and transmission protocol of the AS-Interface are fixed in the standard EN 50 295. Concerning the AS-Interface, the following data of performance are given: • • • • • •

• •

• • •

max. 31 AS-i-participants with 4 bit I/O effective data max. 124 I/O sensors and actuators access procedure by cyclic polling at master-slave-procedure cycle time max. 5ms error security, identification and repetition of interferred telegrams the medium of transmission is a simple two-core wire (2 x 1,5 mm²) for data and 2 A auxiliary energy maximum for each AS-I string. Supply voltage is 30 V DC. The signal of the data transfer is modulated. Additional supply of auxiliary energy 24 V DC is possible connection and mounting of AS-I components in throughput technology AS-i-slave-module with an integrated circuit (AS-i-chip), which are not in need of a processor and as well of no software. Therefor results nearly non-delayed telegram processing and a small volume of the slaves. special AS-I sensors and –actuators with directly integrated AS-i-chips as well. flexible construction opportunities like electric installation techniques length of wiring max. 100m or 300m (with repeater)

The AS-Interface is a single-master system. Therefore, in a system, there is always existing one master and up to 31 slaves. If there are further slaves necessary, another AS-Interface system with another master has to be installed.

© Festo Didactic GmbH & Co. • MPS

15

Introduction

AS-I –basic components

Creation of the AS-Interface is modular by using the following components: • power supply 30 V DC directly connected to the data cable • AS-I data cable is an unprotected yellow two-core wire. Connection of the AS-I components is done in throughput technique, whereas the AS-I wire is providing a profile in order to avoid wiring errors by installation. • AS-i master as coupling unit for control of the user or of an higher ranking bus system with the resp. master chips. The AS-I master is providing access for the user to the I/O data of the AS-I slaves. On the S7-300 this is done in the user program of the CPU. • AS-i slaves with slave ASIC: There is existing a big collection of slaves of different manufacturers for the ASInterface. By commissioning, every slave has to be allocated a definite AS-I address, which is then stored in it. Addressing is done either by a projecting device or by the master, whereas every slave is single connected and inscribed by the addressing telegram. This is also working, if a slave is substituted.

AS-I – additional energy

16

If an AS-I slave is consuming more than 100 mA or total consumption of AS-I slaves together is over 2 A of auxiliary energy for each AS-I string, then an additional power supply is to provide. Also AS-I output slaves are supplied by external voltage, in control technology normally 24 V DC. This is being connected over the AS-I power cable (black) to the auxiliary energy contacts of the slaves. For the auxiliary energy, the AS-I mains is connected as unshielded black two-core wire. Connection to auxiliary energy is done by throughput technique. The AS-I wire is profiled to avoid wiring errors by installation.

© Festo Didactic GmbH & Co. • MPS

Introduction

AS-I – run of communication If the AS-I Master is switched on, it is interrogating all possible addresses (1-31) during its setup. If a slave replies, its address and its profile is saved in a table. The profile of a slave is a combination of numbers, which determines its kind. For example, the 4 input-board has 0.0, an inductive sensor 1.1. After interrogation of all addresses, the AS-I Master has installed a complete list of all participants. Also it is possible to stipulate a project list; the AS-I Master is comparing its actual list with the stipulated one and is reporting differences to the PLC, as for example "wrong address" or "participant not available". This communication is occuring cyclically and is lasting 5 ms in a full expanded system. All existing addresses are interrogated at each AS-I-cycle, which contains slave reports, parameter reports as well as a diagnosis report. The AS-I Master is sending a message to one bus participant after the other (transfer of output data). The requested addresses are provided from its list, which was installed during his setup. If there is no reply on its interrogation, it is immediately repeated by the AS-I Master. If then there is also no reply, he starts working on the other addresses. During the next two cycles, the AS-I Master is trying to interrogate the missing address again, if the reply is still not coming, a configuration error bit is set, which may be interrogated and processed by the PLC. Furthermore, a parameter interrogation of an address is possible each cycle and enables adjustment of switching area of a sensor. Additionally a diagnosis interrogation is done at each cycle, which means, the AS-I Master is demanding an address, which is not on its list. Caused by this, it is possible to recognize a new participant after 30 cycles maximum (150 ms) and to respond it over the PLC and the AS-I Master. Furthermore, sensors, actuators and slaves may be changed during operation without roughly disturbing of the sequence or crash of a running program.

© Festo Didactic GmbH & Co. • MPS

17

Introduction

AS-I – data transfer and transmission security

Data transfer is taking place over unshielded and oil-resistant two-core AS-I data line, which is connected to a power supply of 30 V DC. The signal is being modulated on this voltage level.

master call

0 SB

masterbreak

slave answer

A3 A2 A1 A0 I4 I3 I2 I1 I0 PB 1

ST

IB

slavebreak

I3 I2 I1 I0 PB ST

IB

In this case, the following bits are relevant for data transfer: ST SB Q4 ... Q0 I4 ..... I0 I3 ..... I0 PB EB

= = = = = =

starter bit control bit address of the slave (5 bit ) information from master to the slave (5 bit ) information from slave to the master (4 bit ) parity bit end bit

Because only the master can start a call, the telegram is very short including less protocol overhead. Caused by this and also by a limited number of slaves, the input/output data may be updated very quickly and the AS-Interface must not be operated by a high data stream. This is also the reason, why the AS-Interface is less sensible for interferences caused by electro-magnetic fields. Besides a cheap price, this robustness is one of the decisive advantages compared with other systems, which have to carry much more of protocol overhead, like for example the PROFIBUS with ist variety of communication opportunities.

18

© Festo Didactic GmbH & Co. • MPS

Introduction

A master call with answer of the slave is executed by the AS-Interface like follows: Master call • The starter bit ST is marking the start of a master call (ST = 0). • The control bit SB qualifies the data- (SB = 0), address- (SB = 0), parameter- (SB = 0) and command call (SB = 1). • The address of the called slave is content of the 5 bits A4 ... A0. • The part of information from the master to the slave is transmitted in the 5 bits I4 ... I0. • The parity bit PB ensures, that the total sum of the „1‘s“ of the master call is even. Now the slave is able to recognize, if the transmission of the call has been executed without errors. • The end bit is marking the end of a master call (EB = 1). • The master break between 3 .. 10 bit times is intercalated for ensuring of transmission security. Slave answer • The starter bit ST is marking the start of the slave answer (ST = 0). • The part of information from slave to master is transferred in the 4 bits I3 ... I0. • The parity bit PB ensures, that the total sum of all „1‘s“ of the slave answer is even. Now the master is able to recognize, if the transmission of the answer was executed without errors. • The end bit is marking the end of the slave answer (EB = 1). • The slave break between 3 .. 10 bit times is intercalated for ensuring of transmission security. By means of this procedure of transmission, a very high transmission security is ensured. Single, double and triple errors are recognized in any case. Errors of 4-5 times are recognized by a probability of 99,9999%. Because all slaves are being called by the master at every cycle, the failure of a component is recognized immediately. Maintenance errors, like for example wrong addressing are recognized and indicated by a permanent comparison of the nominal and actual configuration in the master.

© Festo Didactic GmbH & Co. • MPS

19

Introduction

AS-I – economical installation

If one is comparing the costs of an installation for controlling a machine by AS-I Bus or by conventional parallel wiring, the results are amazing: • costs for AS-I installation are 5 % less • assembly costs are 75 % less • material costs are ca. 20 % more Furthermore, mounting time may be decisively reduced, because mounting of electrical and mechanical components can be done together. Further costs are to be saved by reduction of production depth and variety of parts by using standardized and pre-fabricated elements (stock-keeping). Above all, by using of the AS-I cable probability of wiring error is reduced. If all these costs are added and calculated, it comes out, that an application of AS-I is reaching the "break-even-point" at ca. 4 actuators. Further benefits, arising of the specific features of the AS-I Bus system: • Complete pre-assembly of construction elements • Simple test procedure • Increase of flexibility (expandability) • Reduction of total complexity • Reduction of planning and projecting expediture • Opportunity to upgrade planning forecast Reduction of the entire manufacturing process

20

© Festo Didactic GmbH & Co. • MPS

Introduction

AS-I – connection example with slaves 4 bit, 8 bit

The following graphics shows an example of a PLC-configuration with AS-I-Master a CP 342-2 and a CPU 313C-2 DP, as well as a standard 24 VDC power supply and a 30VDC AS-I power supply.

© Festo Didactic GmbH & Co. • MPS

21

Introduction

AS-I – input/output The connection of inputs and outputs to the different kind of slaves is as follows: connection to the slave M12 (4 bit) and clamp (8 bit) AS-I-M12-plug – View upon screw-/clamp side

Allocation listing (input signal) of a 3-wire sensor: 1 = + = brown 2 = signal = black 3 = = blue Allocation listing (input signal) of a vacuum switch: 1 = + = brown 2 = signal = black 3 = = blue Allocation listing (input signal) of a 2-wire-reed switch, Festo SMEO-4U-K-LED-230: 1 = + = black 2 = signal = brown Allocation listing (input signal) of a 3-wire- reed switch, Festo SME-8-K-LED-24: 1 = + = brown 2 = signal = black 3 = = blue Allocation listing (input signal) of a micro switch: 1 = + = brown 2 = signal = green Allocation listing (output signal) of lights/motors: 3 = = brown/red 4 = signal = blue/black

22

© Festo Didactic GmbH & Co. • MPS

Introduction

AS-I-Slave 8 bit with clamps (example connection to IN1 and OUT1 each)

Allocation listing (input signal) of a 3-wire sensor: 5 = + = brown 6 = signal = black 7 = = blue Allocation listing (input signal) of a vacuum switch: 5 = + = brown 6 = signal = black 7 = = blue Allocation listing (input signal) of a 2-wire-reed switch, Festo SMEO-4U-K-LED-230: 5 = + = black 6 = signal = brown Allocation listing (input signal) of a 3-wire- reed switch, Festo SME-8-K-LED-24: 5 = + = brown 6 = signal = black 7 = = blue Allocation listing (input signal) of a micro switch: 5 = + = brown 6 = signal = green Allocation listing (output signal) of lights/motors: 8 = = brown/red 9 = signal = blue/black

© Festo Didactic GmbH & Co. • MPS

23

Introduction

AS-I – input/output connection to the pneumatic valve interface

To see the connection of the pneumatic valve terminal please refer to the following graphicss:

1 2 3 4

24

connection of the two inputs In1 and In2 as well as 24 VDC power supply connection of external power supply for the output AS-I-data line connection of the output (valve Y 20.1)

© Festo Didactic GmbH & Co. • MPS

Introduction

The functions of the LED´s of the pneumatic valve interface are: LED display ASI-LED (green)

Fault-LED (red)

Description

On

Off

Asi-Interface voltage applied, no fault

Off

Off

No Asi-Interface voltage on bus

Flashing

On

Asi-Interface address not set (equals zero)

On

Flashing

Short circuit / overload at inputs

Off

Flashing

Short circuit / overload at outputs

flashing

On

Failure of bus communication (Watchdog expired)

AUX PWR-LED (green)

Description

On

Load voltage applied

Off

Load voltage applied

Status-LED (green/yellow)

Description

on

1- Signal at In/Output

off

0- Signal at In/Output

The function of the dip-switches on the pneumatic valve interface are: Setting

DIP switch setting *

With load voltage **

1,2: off

(factory setting)

3,4: on

With load voltage *** (seal the “24V DC” connection with blanking plug type ASI-SD-FK-BL))

1,2: on 3,4: off

* Black = pressed ** The outputs/valves are provided with power via the additional supply (standard FMS50 setting) *** The outputs/valves are provided with power via the AS-I-Interface bus

© Festo Didactic GmbH & Co. • MPS

25

Introduction

AS-I – slave addressing with programming and service device

Each slave has to be identified within the AS-I-network by an address between 1-31 for each master (CP 342-2) before connecting the slave into the AS-I-network. To define the slave adress, there are different possibilities and devices. The following graphics shows the possibility to define the address using the Programming and Service Device (PSG) from Siemens.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

26

switch on PSG (START) confirm indication (ENTER) choose Master (F3) choose individual operation (F1) choose new address (F1) confirm AS-I-address (ENTER) input new address (2) confirm entry (ENTER) back to main menue (2x ESC) switch off (F4)

© Festo Didactic GmbH & Co. • MPS

Introduction

AS-I – slave addressing with addressing device

The following graphics shows the possibility to define the address using the AS-I addressing device.

The handling of this addressing device is so easy and clear, that there is no need of explanation to do it. Just the connection, especially of the 4I/4O-module is interesting.

© Festo Didactic GmbH & Co. • MPS

27

Introduction

The following graphics shows the possibility to define the address using the AS-I addressing device.

The handling of this addressing device is so easy and clear, that there is no need of explanation to do it. Just the connection, especially of the 4I/4O-module is interesting.

28

© Festo Didactic GmbH & Co. • MPS

Introduction

AS-I – absolute hardwareaddresses within the S7 PLC program

Addressing of the AS-I slaves inputs and outputs is depending on the installation of the PLC hardware and on the setup of the PLC-modules. The following example is referring to the standard configuration of hardware installation at Festo FMS50 conveyor with AS-I.

The address range of the AS-I slaves, resulting from this installation of the PLC hardware is: • Input byte addresses from 256….271 • Output byte addresses from 256…271 This address range depends on the cord location of the AS-I master and can be checked within the hardware configuration, which is part of the chapter Programming

© Festo Didactic GmbH & Co. • MPS

29

Introduction

The AS-I slaves are not directly addressable within the program, because AS-I slaves are treated as periphery. This is the reason, why the following program part inside of the organization block is absolutely necessary, in order to address the slaves. Within the following example we use the addresses, which are standardized used with a Siemens S5 PLC – byte 64 – 79 in total per one master. This is facilitating the change from the S5 world - in which this address range is fix determined - to the world of the S7, where this address range is actually free choosable: L T L T L T L T

PID256 ID64 PID260 ID68 QD64 PQD256 ID68 PID260

load peripheral-input-double word 256 transfer to input-double word 64 load peripheral-input-double word 260 transfer to input-double word 68 load output-double word 64 transfer to peripheral-output-double word 256 load output-double word 68 transfer to peripheral-output-double word 260

In order to facilitate the programming in the Organization Block, double words are being transformed – every program line needs time (relatively!). The input-/output double words are consisting of 4 bytes: ID 64 = IB 64, IB 65, IB 66, IB 67 ID 68 = IB 68, IB 69, IB 70, IB 71 QD 64 = QB 64, QB 65, QB 66, QB 67 QD 68 = QB 68, QB 69, QB 70, QB 71 Single bytes also may be loaded and transferred, for example:

30

L T L T a.s.o.

PIB IB PIB IB

256 64 257 65

T L T L a.s.o.

QB PQB QB PQB

64 256 65 257

© Festo Didactic GmbH & Co. • MPS

Introduction

AS-I – peripheral addresses The peripheral address of the inputs and output-bits are concerning the slave regarding the slave address address which the sensors and/or actuators are connected to. Please refer to the following list of a the maximum in- and outputs used within one master. 7

6

PLC-Address

5

4

3

2

1

Bit

Bit

PIB/PQB 256

Flags

slave address 1

PIB/PQB 257

slave address 2

slave address 3

PIB/PQB 258

slave address 4

slave address 5

PIB/PQB 259

slave address 6

slave address 7

PIB/PQB 260

slave address 8

slave address 9

PIB/PQB 261

slave address 10

slave address 11

PIB/PQB 262

slave address 12

slave address 13

PIB/PQB 263

slave address 14

slave address 15

PIB/PQB 264

slave address 16

slave address 17

PIB/PQB 265

slave address 18

slave address 19

PIB/PQB 266

slave address 20

slave address 21

PIB/PQB 267

slave address 22

slave address 23

PIB/PQB 268

slave address 24

slave address 25

PIB/PQB 269

slave address 26

slave address 27

PIB/PQB 270

slave address 28

slave address 29

PIB/PQB 271

slave address 30

slave address 31

0

Regarding our definition to use the same addresses than with a S5 PLC (refer to one page before), and transformation from peripheral to usable addresses, the list looks like: 7

© Festo Didactic GmbH & Co. • MPS

6

5

4

3

2

1

PLC-Address

Bit

Bit

IB/QB 64

Flags

slave address 1

IB/QB 65

slave address 2

slave address 3

IB/QB 66

slave address 4

slave address 5

IB/QB 67

slave address 6

slave address 7

IB/QB 68

slave address 8

slave address 9

IB/QB 69

slave address 10

slave address 11

IB/QB 70

slave address 12

slave address 13

IB/QB 71

slave address 14

slave address 15

IB/QB 72

slave address 16

slave address 17

IB/QB 73

slave address 18

slave address 19

IB/QB 74

slave address 20

slave address 21

IB/QB 75

slave address 22

slave address 23

IB/QB 76

slave address 24

slave address 25

IB/QB 77

slave address 26

slave address 27

IB/QB 78

slave address 28

slave address 29

IB/QB 79

slave address 30

slave address 31

0

31

Introduction

Example 1: A microswitch is connected to a slave number 3 at IN4: • search for slave address 3 (2nd column/2nd line) • IN4 means, the 4th possible bit of together 4 bit (bit 0 -bit 3) = bit 3 consequently the absolute address = I 65.1 Example 2: A DC-motor is connected to a slave number 4 at OUT2: • search for slave address 4 (1st column/3rd line) • OUT2 means, the 2nd possible bit of together 4 bit (bit 4 -bit 7) = bit 5 consequently the absolute address = Q66.5 Example 3: A 3-wire sensor is connected to a slave number 4 at IN2: • search for slave address 4 (1st column/3rd line) • IN2 means, the 2nd possible bit of together 4 bit (bit 4 -bit 7) = bit 5 consequently the absolute address = I66.5 Example 4: A light is connected to a slave number 5 at OUT3: • search for slave address 5(2nd column/3rd line) • OUT3 means, the 3rd possible bit of together 4 bit (bit 0 -bit 3) = bit 2 consequently the absolute address = Q66.2 32

© Festo Didactic GmbH & Co. • MPS

Introduction

Frequency converter – general informations

Frequency converters are transforming the alternate current net with a fixed voltage supply and frequency into a new threee-phases net. Voltage supply and frequency are changeable within the new net. By changing the frequency the rotation speed will be changed and therefore the speed of the actuator. The frequency converter controls the acceleration and deceleration of the closed loop conveyor as you can see within the following graphicss:

t0…t1 acceleration t1…t2 maximum speed t2…t3 deceleration

© Festo Didactic GmbH & Co. • MPS

33

Introduction

The frequency converter Micromaster 420 is available with different control panels. The Basic Operator Panel – BOP is the standard which enables the user to adjust all neccessary parameters.

34

© Festo Didactic GmbH & Co. • MPS

Introduction

Main features • • • • • • • •

easy to install, parametise and commission short and reproduceable activation time on controlling signals extensive offer of parameters to configure for a wide range of applications easy cabling modular structure for flexible configurations high control frequency for noiseless motor movement external options for PC-data transmission, basic control panel a.s.o. advanced operator panel (AOP) and Profibus-data transmission module

Functional features • • • • • •

Field Current Control (FCC) for a better dynamics and better motor control Fast Current Limitation (FCL) for non-switch-off operation mechanics integrated direct current break system system brake for better braking power acceleration and deceleration time with programmable smoothness closed loop control with Proportional/Integral function (PI)

Safety features • • • • • •

© Festo Didactic GmbH & Co. • MPS

complete safety for motor and converter saftey agains too high/too low voltage power temperature saftety system for the converter ground connection safety system short circuit safety system I2 t-motor temperature safety system

35

Introduction

Description of the Control Panel functions Button

Function

Description

Display of conditions

the LCD is showing the actual settings of the converter

Converter Start

start of the converter. The pre-condition of the Startbutton is inactive. To activate, please change the parameter P0700 = 1

Converter Stop

Stop 1: by pressing the button once, the converter stops with the actual deceleration speed. The precondition of the Stop-button is inactive. To activate, please change the parameter P0700 = 1. Stop 2: by pressing the button twice oder pressing and holding longer than 3 seconds, the motor decelerates freely

Changing direction

by pressing this button, the direction of the motor will be changed. The opposite direction will be shown by a minus or a blinking decimal point. The pre-condition is inactive. To activate, please change the parameter P0700 = 1

Motor jog mode

by pressing and holding this button and if the converter has no output voltage signal, the motor is running with the pre-selected Jog-frequence. After the button will be released, the motor will stop. Pressing this button if the motor is running, has no influence

Functions

This button can be used to display additional informations. This button has to be pushed and hold and the display is showing the following informations, based on any defined parameter: 1.

voltage of the direct current circuit (d)

2.

output current (A)

3.

output freuquence (Hz)

4. output voltage (o) 5.

36

the value pre-selected in P0005

Functions

see the example changing of the speed

Increase/de crease value

by pressing this buttons, the displayed value can be increased or decreased. To change the frequency debit value via the BOP please change the parameter P1000 = 1

© Festo Didactic GmbH & Co. • MPS

Introduction

Company settings The following table shows the company settings of the parameters. Any parameter has an allocated value which can be changed by the user.

© Festo Didactic GmbH & Co. • MPS

37

Introduction

Example reduce of the speed (from company setting 50 to 35) Button

38

Description

Display

press to access to the parameters

r0000

press as long as P1082 appears

P1082

press to reach the level to parametise P1082

50.00

press as long as reaching the maximum frequence

35.00

press to save the parameter and exit

P1082

press as long as r0000 appears

r0000

press to exit

35.00

the LCD is changing between the debit and the actual frequence

00.00

© Festo Didactic GmbH & Co. • MPS

Introduction

Parameters of the motor The first step of commissioning is to adapt the parameters of the used motor into the converter. Please refer to the data sheet or data plate of the motor to see the parameters: • • • • • • •

© Festo Didactic GmbH & Co. • MPS

Parameter P0304 motor nominal voltage Parameter P0305 motor nominal current Parameter P0307 motor nominal power Parameter P0308 motor nominal power factor Parameter P0309 motor nominal efficiency Parameter P0310 motor nominal frequency Parameter P0311 motor nominal speed

39

Introduction

Additional user defined parameters A sudden acceleration or deceleration of the motor can be avoided by using ramp parameters. This achieves a reduced start and stop movement of the motor. This is neccessary for an exact positioning of the motor and is used mostly to reduce the start-up current of the motor. • Parameter P1120 (function refer to the graphicss)

• Parameter P1121 (function refer to the graphicss)

40

© Festo Didactic GmbH & Co. • MPS

Introduction

• • • •

Parameter P1130 (function refer to the graphicss) Parameter P1131 (function refer to the graphicss) Parameter P1132 (function refer to the graphicss) Parameter P1133 (function refer to the graphicss)

tup total = ½ P1130 + X*P1120 + ½ P1131 tdown total = ½ P1132 + X*P1121 + ½ P1133 X = x * fmax Another parameter is for the movemement speed. It can be adjusted by changing the parameters P1080 and P1082 changing the frequency. Both parameters are related to a fixed frequency band and can be changed only within this band. • • • •

© Festo Didactic GmbH & Co. • MPS

Parameter P1002 fixed frequency minimal Parameter P1003 fixed frequency maximum Parameter P1080 minumim frequency Parameter P1082 maximum frequency

41

Introduction

Adjustments for the conveyor Parameter description

Param.number

User adjustm.

Company adjustm.

User access level

P0003

3

1

Parameter filter

P0004

3

21

Parameter group for commissioning

P0010

0 = no adjustment possible

1 = changing of parameters possible

Motor nominal voltage [V]

P0304

230

***

Motor nominal current [A]

P0305

0,68

***

Motor nominal power [W]

P0307

0,11

***

Motor nominal speed [1/min]

P0311

3100

Fixed frequency [Hz]

P1001

50

0

Minimum frequency [Hz]

P1080

50

0

Maximum frequency [Hz]

P1082

60

50

Ramp-up time [s]

P1120

3

10

Ramp-down time [s]

P1121

3

10

The parameters P1001 until P1005 (fixed frequency) representing a frequency frame, where the parameters P1080 and P1082 can be changed within.

42

© Festo Didactic GmbH & Co. • MPS

Introduction

Example to adjust the conveyor speed 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

© Festo Didactic GmbH & Co. • MPS

switch on the power supply main switch press P on the converter control panel choose parameter P0010 with the ∧/∨ button on the control panel press P choose the value 1 with the ∧/∨ buttons press P choose parameter P1080 with the ∧/∨ buttons press P choose the value 50 Hz with the ∧/∨ buttons press P choose the parameter P0010 with the ∧/∨ buttons press P choose the value of 0 with the ∧/∨ buttons press P switch off the power supply main switch and on again

43

Commissioning

1.1

Analysis – Components identification

Please list up all the “sensors” and “actuators” shown in the picture below (1 – 3). Name the elements with identification in the wiring diagram/pneumatic plan and describe shortly their function generally (not the function within the system). Information Please use the technical manual-data sheets, pneumatic plan and wiring diagrams. Please refer to the examples (Ex.1 – Ex.3) mentioned below in the table of the execution work-sheet. Please follow the numbers (1 – 3) shown in the pictures below (Ex.1 is not shown in the graphicss). NOTICE:

Planning Please plan your project within the whole team carefully. Use the technical manual and the real station to do this project. Please describe the function of the element in general, not within the signal- and materialflow of the station. To find the data-sheet of the elements, please see the list of components first and check the order no. printed on the element itself. The time to finish this project should be around 1,5 hours.

© Festo Didactic GmbH & Co. • MPS

44

Commissioning

Execution/Documentation Please complete the list regarding the elements shown and numbered in the pictures above. No.

Name

Ident.

Description

Ex.1

Start-button

S1

Push button with light on the control panel, no data sheet normally open contact, connected to a PLC-

Page #

Panel: inputs

input

Ex.2

Inductive switch, normally open contact,

SIEN-M8NB-PS-S-L

switch,

Proximity

Bx0.1

activated by metal workpiece, nominal

Station: inputs

inductive

switch distance 2,5 mm, maximum

PLC-board: inputs

switching frequenz 900 Hz

Ex.3

Proximity

Bx0.5

Inductive switch, normally open contact,

SME-8-S-LED-24

switch,

activated by a magnet ring in the piston rod Station: inputs

inductive

of the short storke cylinder 2, send the

PLC-board: inputs

information “piston rod of the cylinder is in front position” to the PLC-input

No.

© Festo Didactic GmbH & Co. • MPS

Name

Ident.

Description

Page #

45

Commissioning

1.2

Analysis – Emergency Stop system

Please analyze the connections of the Emergency Stop system within your station and complete the drawing on the next page (Execution and Documentation). Information Please fill out all F in the graphics and draw the connections. Use the real station to check the connections. NOTICE:

Planning Please follow the explanations of the instructor first and then plan your activities step-by-step. Use the real station to find out all connections and identifications. Use also the technical documentation. Please refer to the following graphicss to see the Emergency Stop system. The time to finish this project should be around 2,0 hours.

46

© Festo Didactic GmbH & Co. • MPS

Commissioning

© Festo Didactic GmbH & Co. • MPS

47

Commissioning

Execution/Documentation

48

© Festo Didactic GmbH & Co. • MPS

Commissioning

1.3

Analysis – Input and Output adresses

Please complete the below mentioned list of input- and output adresses of the PLC regarding the definition, to use the Siemens S5-addresses from 64-…79. Please define your own symbol adress using max. 8 characters. Information To find out the adresses, please refer to the technical manual-wiring diagram of the station and the Control Panel and the theoretical part of AS-I within this documentation. The pneumatic components can be activated by the manual detection button on the valve. The standard configuration of the station numbers and the connected MPS-stations are defined as follow (please refer to the drawing on the next page): (the configuration of the connected MPS-stations can be redefined, but the station numbers are fixed. To redefine the stations, please refer to 1.7 Commissioning – Download Project and Test). Please use the following table to define the hardware addresses: 7 PLC-Address

© Festo Didactic GmbH & Co. • MPS

6

5

4

3

2

1

Bit

Bit

IB/QB 64

Flags

slave address 1

IB/QB 65

slave address 2

slave address 3

IB/QB 66

slave address 4

slave address 5

IB/QB 67

slave address 6

slave address 7

IB/QB 68

slave address 8

slave address 9

IB/QB 69

slave address 10

slave address 11

IB/QB 70

slave address 12

slave address 13

IB/QB 71

slave address 14

slave address 15

IB/QB 72

slave address 16

slave address 17

IB/QB 73

slave address 18

slave address 19

IB/QB 74

slave address 20

slave address 21

IB/QB 75

slave address 22

slave address 23

IB/QB 76

slave address 24

slave address 25

IB/QB 77

slave address 26

slave address 27

IB/QB 78

slave address 28

slave address 29

IB/QB 79

slave address 30

slave address 31

0

49

Commissioning

Standard configuration of the FMS50:

1. Conveyor station number 1 2. Conveyor station number 2 3. Conveyor station number 3 4. Conveyor station number 4 5. Conveyor station number 5 6. Conveyor station number 6 1.1 MPS-station 1 - Distribution and Testing station 2.1 MPS-station 2 - Processing and Handling station 3.1 MPS-station 3 - Vision system 4.1 MPS-station 4 - Robotassemby station 5.1 MPS-station 5 - Automatic Storage and Retrieval System (ASRS) 6.1 MPS-station 6 - Sorting and Handling station (1.1…6.1 are mentioned from outside to the conveyor) For further informations regarding the numbers of the MPS-stations and the conveyor-stations, please refer to 1.7.1 Commissioning – Driver Control

50

© Festo Didactic GmbH & Co. • MPS

Commissioning

NOTICE:

Planning Please plan your activities within your team. Check the inputs in the wiring diagram and at the slaves directly. The time to finish this project should be around 1,0 hour. Execution/Documentation Please complete the list of the inputs and outputs of your station. I/O Station 1 Slave 02

03

04

Module

Ident.

Addr.

IN2

B10.2

I65.5

01_Cong

Station 1- congestion sensor inductive

IN3

B10.3

I65.6

01_Wpav

Station 1- workp.on pallet sensor optical

IN4

B10.4

I65.7

01_Wpcou

Station 1- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

B10.5

I65.0

01_Strel

Station 1- stopper is released

pneumatic valve interface

IN2

X

X

OUT1

Y10.1

Q65.2

ASI-4E-B, 4 Inputs M12

Funct.

Symbol

IN1

Description Station 1- pallet at stopper

X 01Stopre

Not used Station 1- release stopper

3RG9002-0DB00, 4 Inputs,

IN1

4 Outputs, terminal screw

IN2

I66.5

01_Co_I2

Station 1- Comm.input 2

IN3

I66.6

01_Co_I3

Station 1- Comm.input 3

IN4

I66.7

01_Co_I4

Station 1- Comm.input 4

OUT1

Q66.4

01_Co_Q1

Station 1- Comm.output 1

OUT2

Q66.5

01_Co_Q2

Station 1- Comm.output 2

OUT3

Q66.6

01_Co_Q3

Station 1-Comm. output 3

OUT4

Q66.7

01_Co_Q4

Station 1- Comm.output 4

© Festo Didactic GmbH & Co. • MPS

Station 1- Comm.input 1

51

Commissioning

I/O Station 2 Slave 05

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

IN1

B20.1

I66.0

Symbol

Description

02_Palav

Station 2- pallet at stopper

IN2

06

07

Station 2- congestion sensor inductive

IN3

B20.3

I66.2

02_Wpav

Station 2- workp.on pallet sensor optical

IN4

B20.4

I66.3

02_Wpcou

Station 2- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

B20.5

I67.4

02_Strel

Station 2- stopper is released

pneumatic valve interface

IN2

X

X

OUT1

Y20.1

Q67.6

02Stopre

Station 2- release stopper

I67.0

02_Co_I1

Station 2- Comm.input 1

3RG9002-0DB00, 4 Inputs,

IN1

4 Outputs, terminal screw

IN2

X

Not used

Station 2- Comm.input 2

IN3

I67.2

02_Co_I3

Station 2- Comm.input 3

IN4

I67.3

02_Co_I4

Station 2- Comm.input 4

OUT1

Q67.0

02_Co_Q1

Station 2- Comm.output 1

OUT2

Q67.1

02_Co_Q2

Station 2- Comm.output 2

OUT3

Q67.2

02_Co_Q3

Station 2-Comm. output 3

OUT4

Q67.3

02_Co_Q4

Station 2- Comm.output 4

Symbol

Description

I/O Station 3 Slave 08

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

IN1

B30.1

I68.4

03_Palav

Station 3- pallet at stopper

IN2

B30.2

I68.5

03_Cong

Station 3- congestion sensor inductive

IN3

09

10

Station 3- workp.on pallet sensor optical

IN4

B30.4

I68.7

03_Wpcou

Station 3- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

B30.5

I68.0

03_Strel

Station 3- stopper is released

pneumatic valve interface

IN2

X

X

OUT1

Y30.1

X

Q68.2

03Stopre

Station 3- release stopper

3RG9002-0DB00, 4 Inputs,

IN1

I69.4

03_Co_I1

Station 3- Comm.input 1

4 Outputs, terminal screw

IN2

I69.5

03_Co_I2

Station 3- Comm.input 2

IN3

52

Not used

Station 3- Comm.input 3

IN4

I69.7

03_Co_I4

Station 3- Comm.input 4

OUT1

Q69.4

03_Co_Q1

Station 3- Comm.output 1

OUT2

Q69.5

03_Co_Q2

Station 3- Comm.output 2

OUT3

Q69.6

03_Co_Q3

Station 3-Comm. output 3

OUT4

Q69.7

03_Co_Q4

Station 3- Comm.output 4

© Festo Didactic GmbH & Co. • MPS

Commissioning

I/O Station 4 Slave 11

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

Symbol

Description

IN1

B40.1

I69.0

04_Palav

Station 4- pallet at stopper

IN2

B40.2

I69.1

04_Cong

Station 4- congestion sensor inductive

IN3

B40.3

I69.2

04_Wpav

IN4 12

13

Station 4- workp.on pallet sensor optical Station 4- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

B40.5

I70.4

04_Strel

pneumatic valve interface

IN2

X

X

OUT1

Y40.1

Q70.6

04Stopre

Station 4- release stopper

X

Station 4- stopper is released Not used

3RG9002-0DB00, 4 Inputs,

IN1

I70.0

04_Co_I1

Station 4- Comm.input 1

4 Outputs, terminal screw

IN2

I70.1

04_Co_I2

Station 4- Comm.input 2

IN3

I70.2

04_Co_I3

Station 4- Comm.input 3

OUT1

Q70.0

04_Co_Q1

Station 4- Comm.output 1

OUT2

Q70.1

04_Co_Q2

Station 4- Comm.output 2

OUT3

Q70.2

04_Co_Q3

Station 4-Comm. output 3

OUT4

Q70.3

04_Co_Q4

Station 4- Comm.output 4

Addr.

Symbol

Description

IN4

Station 4- Comm.input 4

I/O Station 5 Slave 14

15

16

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

IN1

Station 5- pallet at stopper

IN2

B50.2

I71.5

05_Cong

Station 5- congestion sensor inductive

IN3

B50.3

I71.6

05_Wpav

Station 5- workp.on pallet sensor optical

IN4

B50.4

I71.7

05_Wpcou

Station 5- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

B50.5

I71.0

05_Strel

Station 5- stopper is released

pneumatic valve interface

IN2

X

X

OUT1

Y50.1

X

Not used

Q71.2

05Stopre

Station 5- release stopper

3RG9002-0DB00, 4 Inputs,

IN1

I72.4

05_Co_I1

Station 5- Comm.input 1

4 Outputs, terminal screw

IN2

I72.5

05_Co_I2

Station 5- Comm.input 2

IN3

I72.6

05_Co_I3

Station 5- Comm.input 3

IN4

I72.7

05_Co_I4

Station 5- Comm.input 4

OUT1

© Festo Didactic GmbH & Co. • MPS

Station 5- Comm.output 1

OUT2

Q72.5

05_Co_Q2

Station 5- Comm.output 2

OUT3

Q72.6

05_Co_Q3

Station 5-Comm. output 3

OUT4

Q72.7

05_Co_Q4

Station 5- Comm.output 4

53

Commissioning

I/O Station 6 Slave 17

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

IN1

B60.1

I72.0

Symbol

Description

06_Palav

Station 6- pallet at stopper

IN2

18

19

Station 6- congestion sensor inductive

IN3

B60.3

I72.2

06_Wpav

Station 6- workp.on pallet sensor optical

IN4

B60.4

I72.3

06_Wpcou

Station 6- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

B60.5

I73.4

06_Strel

Station 6- stopper is released

pneumatic valve interface

IN2

X

X

OUT1

Y60.1

Q73.6

06Stopre

Station 6- release stopper

X

Not used

3RG9002-0DB00, 4 Inputs,

IN1

I73.0

06_Co_I1

Station 6- Comm.input 1

4 Outputs, terminal screw

IN2

I73.1

06_Co_I2

Station 6- Comm.input 2

IN3

I73.2

06_Co_I3

Station 6- Comm.input 3

IN4

I73.3

06_Co_I4

Station 6- Comm.input 4

OUT1

Q73.0

06_Co_Q1

Station 6- Comm.output 1

OUT2

Station 6- Comm.output 2

OUT3

Q73.2

06_Co_Q3

Station 6-Comm. output 3

OUT4

Q73.3

06_Co_Q4

Station 6- Comm.output 4

Addr.

Symbol

Description

I/O Control Panel Slave

Module

direct

Control panel inside the control

SH4

I0.0

AUTOON

Automatic on button

cabinet

SH5

i0.1

AUTOOF

Automatic off button

LSH4

Q0.0

L_AUTOON

Light inside Automatic on button

LSH5

Q0.1

L_AUTOOF

Light inside Automatic off button

Q0.7

Conveyor

Motor conveyor

54

Funct.

Ident.

© Festo Didactic GmbH & Co. • MPS

Commissioning

1.4

Analysis – Please complete the below mentioned list of input- and output adresses of the PLC Input and Output regarding the definition, to use the Siemens S5-addresses from 64-…79. Please adresses expanded define your own symbol adress using max. 8 characters. Information To find out the adresses, please refer to the technical manual-wiring diagram for the station and the Control Panel and the theoretical part of AS-I within this documentation. The pneumatic components can be activated by the manual detection button on the valve. The standard configuration of the station numbers and the connected MPS-stations are defined as follows (please refer to the drawing on the next page): (the configuration of the connected MPS-stations can be redefined, but the station numbers are fixed. To redefine the stations, please refer to 1.7 Commissioning – Download Project and Test). Please use the following table to define the hardware addresses: 7 PLC-Address

© Festo Didactic GmbH & Co. • MPS

6

5

4

3

2

1

Bit

Bit

IB/QB 64

Flags

slave address 1

IB/QB 65

slave address 2

slave address 3

IB/QB 66

slave address 4

slave address 5

IB/QB 67

slave address 6

slave address 7

IB/QB 68

slave address 8

slave address 9

IB/QB 69

slave address 10

slave address 11

IB/QB 70

slave address 12

slave address 13

IB/QB 71

slave address 14

slave address 15

IB/QB 72

slave address 16

slave address 17

IB/QB 73

slave address 18

slave address 19

IB/QB 74

slave address 20

slave address 21

IB/QB 75

slave address 22

slave address 23

IB/QB 76

slave address 24

slave address 25

IB/QB 77

slave address 26

slave address 27

IB/QB 78

slave address 28

slave address 29

IB/QB 79

slave address 30

slave address 31

0

55

Commissioning

Standard configuration of the FMS50:

1. Conveyor station number 1 2. Conveyor station number 2 3. Conveyor station number 3 4. Conveyor station number 4 5. Conveyor station number 5 6. Conveyor station number 6 1.1 MPS-station 1 - Distribution and Testing station 2.1 MPS-station 2 - Processing and Handling station 3.1 MPS-station 3 - Vision system 4.1 MPS-station 4 - Robotassemby station 5.1 MPS-station 5 - Automatic Storage and Retrieval System (ASRS) 6.1 MPS-station 6 - Sorting and Handling station (1.1…6.1 are mentioned from outside to the conveyor) For further informations regarding the numbers of the MPS-stations and the conveyor-stations, please refer to 1.7.1 Commissioning – Driver Control

56

© Festo Didactic GmbH & Co. • MPS

Commissioning

NOTICE:

Planning Please plan your activities within your team. Check the inputs in the wiring diagram and at the slaves directly. The time to finish this project should be around 1,5 hour. Execution/Documentation Please complete the list of the inputs and outputs of your station. I/O Station 1 Slave 02

03

04

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

Symbol

IN2

B10.2

I65.5

01_Cong

Station 1- congestion sensor inductive

IN3

B10.3

I65.6

01_Wpav

Station 1- workp.on pallet sensor optical

IN4

B10.4

I65.7

01_Wpcou

Station 1- workp. counter

IN1

Description Station 1- pallet at stopper

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

Station 1- stopper is released

pneumatic valve interface

IN2

X

X

OUT1

Y10.1

Q65.2

X 01Stopre

Not used Station 1- release stopper

3RG9002-0DB00, 4 Inputs,

IN1

4 Outputs, terminal screw

IN2

I66.5

01_Co_I2

Station 1- Comm.input 2

IN3

I66.6

01_Co_I3

Station 1- Comm.input 3

IN4

I66.7

01_Co_I4

Station 1- Comm.input 4

OUT1

Q66.4

01_Co_Q1

Station 1- Comm.output 1

OUT2

Q66.5

01_Co_Q2

Station 1- Comm.output 2

OUT3

Q66.6

01_Co_Q3

Station 1-Comm. output 3

OUT4

Q66.7

01_Co_Q4

Station 1- Comm.output 4

© Festo Didactic GmbH & Co. • MPS

Station 1- Comm.input 1

57

Commissioning

I/O Station 2 Slave 05

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

IN1

B20.1

I66.0

Symbol

Description

02_Palav

Station 2- pallet at stopper

IN2

06

Station 2- congestion sensor inductive

IN3

B20.3

I66.2

02_Wpav

Station 2- workp.on pallet sensor optical

IN4

B20.4

I66.3

02_Wpcou

Station 2- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

B20.5

I67.4

02_Strel

Station 2- stopper is released

pneumatic valve interface

IN2

X

X

X

OUT1 07

3RG9002-0DB00, 4 Inputs,

IN1

4 Outputs, terminal screw

IN2

Not used Station 2- release stopper

I67.0

02_Co_I1

Station 2- Comm.input 1 Station 2- Comm.input 2

IN3

I67.2

02_Co_I3

IN4

I67.3

02_Co_I4

OUT1

Station 2- Comm.input 3 Station 2- Comm.input 4 Station 2- Comm.output 1

OUT2

Q67.1

02_Co_Q2

Station 2- Comm.output 2

OUT3

Q67.2

02_Co_Q3

Station 2-Comm. output 3

OUT4

Q67.3

02_Co_Q4

Station 2- Comm.output 4

Symbol

Description

I/O Station 3 Slave 08

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

IN1

B30.1

I68.4

03_Palav

Station 3- pallet at stopper

IN2

B30.2

I68.5

03_Cong

Station 3- congestion sensor inductive

IN3 IN4 09

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

pneumatic valve interface

IN2

Station 3- workp.on pallet sensor optical B30.4

I68.7

03_Wpcou

Station 3- stopper is released X

X

X

OUT1 10

Not used Station 3- release stopper

3RG9002-0DB00, 4 Inputs,

IN1

I69.4

03_Co_I1

Station 3- Comm.input 1

4 Outputs, terminal screw

IN2

I69.5

03_Co_I2

Station 3- Comm.input 2

IN3

I69.6

03_Co_I3

Station 3- Comm.input 3

IN4

58

Station 3- workp. counter

Station 3- Comm.input 4

OUT1

Q69.4

03_Co_Q1

Station 3- Comm.output 1

OUT2

Q69.5

03_Co_Q2

Station 3- Comm.output 2

OUT3

Q69.6

03_Co_Q3

Station 3-Comm. output 3

OUT4

Q69.7

03_Co_Q4

Station 3- Comm.output 4

© Festo Didactic GmbH & Co. • MPS

Commissioning

I/O Station 4 Slave 11

12

13

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

Symbol

Description

IN1

B40.1

I69.0

04_Palav

Station 4- pallet at stopper

IN2

B40.2

I69.1

04_Cong

Station 4- congestion sensor inductive

IN3

B40.3

I69.2

04_Wpav

Station 4- workp.on pallet sensor optical

IN4

Station 4- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

Station 4- stopper is released

pneumatic valve interface

IN2

X

X

OUT1

Y40.1

Q70.6

04Stopre

Station 4- release stopper

X

Not used

3RG9002-0DB00, 4 Inputs,

IN1

I70.0

04_Co_I1

Station 4- Comm.input 1

4 Outputs, terminal screw

IN2

I70.1

04_Co_I2

Station 4- Comm.input 2

IN3

I70.2

04_Co_I3

Station 4- Comm.input 3

IN4

Station 4- Comm.input 4

OUT1

Station 4- Comm.output 1

OUT2

Q70.1

04_Co_Q2

Station 4- Comm.output 2

OUT3

Q70.2

04_Co_Q3

Station 4-Comm. output 3

OUT4

Q70.3

04_Co_Q4

Station 4- Comm.output 4

Symbol

Description

I/O Station 5 Slave 14

15

Module

Funct.

Ident.

Addr.

IN1

B50.1

I71.4

05_Palav

Station 5- pallet at stopper

IN2

B50.2

I71.5

05_Cong

Station 5- congestion sensor inductive

IN3

B50.3

I71.6

05_Wpav

Station 5- workp.on pallet sensor optical

IN4

B50.4

I71.7

05_Wpcou

Station 5- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

B50.5

I71.0

05_Strel

Station 5- stopper is released

pneumatic valve interface

IN2

X

X

ASI-4E-B, 4 Inputs M12

X

OUT1 16

Not used Station 5- release stopper

3RG9002-0DB00, 4 Inputs,

IN1

I72.4

05_Co_I1

Station 5- Comm.input 1

4 Outputs, terminal screw

IN2

I72.5

05_Co_I2

Station 5- Comm.input 2

IN3

I72.6

05_Co_I3

Station 5- Comm.input 3

IN4

I72.7

05_Co_I4

Station 5- Comm.input 4

OUT1

Q72.4

05_Co_Q1

Station 5- Comm.output 1

OUT2

Q72.5

05_Co_Q2

Station 5- Comm.output 2

OUT3

Q72.6

05_Co_Q3

Station 5-Comm. output 3

OUT4

© Festo Didactic GmbH & Co. • MPS

Station 5- Comm.output 4

59

Commissioning

I/O Station 6 Slave 17

18

Module ASI-4E-B, 4 Inputs M12

Funct.

Ident.

Addr.

Symbol

Description

IN1

B60.1

I72.0

06_Palav

Station 6- pallet at stopper

IN2

B60.2

I72.1

06_Cong

Station 6- congestion sensor inductive

IN3

B60.3

I72.2

06_Wpav

Station 6- workp. counter

EVA-MF-2E1A-Z, 2 Inputs, 1 Output,

IN1

Station 6- stopper is released

pneumatic valve interface

IN2

X

X

X

OUT1 19

Station 6- workp.on pallet sensor optical

IN4

Not used Station 6- release stopper

3RG9002-0DB00, 4 Inputs,

IN1

Station 6- Comm.input 1

4 Outputs, terminal screw

IN2

I73.1

06_Co_I2

Station 6- Comm.input 2

IN3

I73.2

06_Co_I3

Station 6- Comm.input 3

IN4

I73.3

06_Co_I4

Station 6- Comm.input 4

OUT1

Q73.0

06_Co_Q1

Station 6- Comm.output 1

OUT2

Q73.1

06_Co_Q2

Station 6- Comm.output 2

OUT3

Q73.2

06_Co_Q3

Station 6-Comm. output 3

OUT4

Q73.3

06_Co_Q4

Station 6- Comm.output 4

Addr.

Symbol

Description

AUTOON

Automatic on button

I/O Control Panel Slave

Module

direct

Control panel inside the control

Funct.

Ident. SH4

I0.0

cabinet

Automatic off button LSH4

Q0.0

L_AUTOON

Light inside Automatic on button

LSH5

Q0.1

L_AUTOOF

Light inside Automatic off button Motor conveyor

60

© Festo Didactic GmbH & Co. • MPS

Commissioning

1.5

Commissioning – Adjustment of the Station

Please check the adjustment of all sensors, mechanical and pneumatical components and the Emergency Stop wiring of your station to prepare the test of the whole process. Information To find out the function and location of the sensors, please use the technical manual. The inputs can also be checked directly at the AS-I-slave. To move pneumatic actuators, please switch off the air-pressure and move them manually by hand. Please refer to the following graphicss to see the position of the workpiece on the pallet.

1

direction of movement NOTICE:

© Festo Didactic GmbH & Co. • MPS

61

Commissioning

Planning Please plan your activities within your team. Check the inputs in the wiring diagram and at the AS-I-slaves. Check the adjustment of the mechanical components first. Check the connection of the Emergency Stop system. The time to finish this project should be around 3,0 hour. Execution/Documentation Write down the single steps and all useful informations. Write down your single steps you did to proceed. Step No.:

62

Description

Check

1

check the adjustment of mechanical components

2

check the adjustment of mechanical actuators holder

3

check the mechanical position of hand over to the next station

4

cable connections (Emergency, I/O-communication…)

5

connect all power supplies

6

check the adjustment of sensor holders

7

check the adjustment of sensors in the holders

8

check the adjustment of sensitivity of sensor

9

tubing connections

10

connect all air-pressure supplies (careful! turn pressure down)

11

check the adjustment of the speed of pneumatic actuators

12

connect the stations together

13

communication connection

© Festo Didactic GmbH & Co. • MPS

Commissioning

1.6

Commissioning – Adjustment of the Station expanded

Please check the adjustment of all sensors, mechanical and pneumatical components and the Emergency Stop and I/O-communication wiring of your station to prepare the test of the whole process. Information To find out the function and location of the sensors, please use the technical manual. The inputs can also be checked directly at the AS-I-slave. To move pneumatic actuators, please switch off the air-pressure and move them manually by hand. Please refer to the following graphicss to see the position of the workpiece on the pallet and see the I/O-communication from the conveyor to the MPS-stations on the next pages.

1 direction of movement

© Festo Didactic GmbH & Co. • MPS

63

Commissioning

I/O-communication Æ Distribution station – Testing station – Conveyor station 1

Distribution Station

Testing Station

PART AV

Transport System PART ON PALLET

PART AV

TRANSPORT AS-i

IN 0.7

IN 0.1

OUT 0.7

IN 0.1

IN 0.7

IN ........

SYSLINK (AS-i)

IN 4 IN 5 OUT 4 OUT 5 0V

OUT 6 OUT 7 IN 6 IN 7 0V

Station 1 ready

IN 4 IN 5 OUT 4 OUT 5 0V

0V

OUT 6 OUT 7 IN 6 IN 7 0V

Stations ready Palette free 0V

IN 2 IN 3 OUT 2 OUT 3 0V IN 1 OUT 0 OUT 1

4mm Lab cable Signal 0V

64

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

IN 2 IN 3 OUT 3

SYSLINK

0V

© Festo Didactic GmbH & Co. • MPS

Commissioning

I/O-communication Æ Processing station – PICalfa station – Conveyor station 2

Processing Station PART AV

PIC alfa Station

Transport System

PART AV

Convert sensor to IN/OUTPUT-Position dissemble el. Push-out

PART ON PALLET

IN 0.7

IN 0.1

TRANSPORT AS-i OUT 0.7

IN 0.7

IN 0.1

OUT 0.7

No application for FMS50

IN ........ SYSLINK (AS-i)

Processing ready for part IN 4 IN 5 OUT 4 OUT 5 0V

OUT 6 OUT 7 IN 6 IN 7 0V

Rotation release 0V

OUT 6 OUT 7 IN 6 IN 7 0V

IN 4 IN 5 OUT 4 OUT 5 0V

Run release Stations ready Pending order 0V

IN 2 IN 3 OUT 2 OUT 3 0V

Part ready for IN 1 OUT 0 OUT 1

4mm Lab cable Signal 0V

© Festo Didactic GmbH & Co. • MPS

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

IN 2 IN 3 OUT 3

SYSLINK

0V

65

Commissioning

I/O-communication Æ Vision system – Conveyor station 3 Vision

Transport System PART ON PALLET

TRANSPORT AS-i IN ........

SIMATIC VS710 I/O-Terminal SYSLINK

SYSLINK (AS-i) OUT0 OUT1 OUT2 OUT3 IN 0 IN 1 IN 2 IN 4 0V 24V

Station ready Part IO/NIO (1/0) Quality evaluated Part NIO Pending order

IN 0 IN 1 IN 2 IN 3

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

OUT 0 OUT 1 OUT 2 OUT 3 0V 24V

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

I/O-cabel twisted with SYS-Link-plug (black marking Order Nr. 167 106)

66

© Festo Didactic GmbH & Co. • MPS

Commissioning

I/O-communication Æ Robot assembly – Conveyor station 4

Transport System

Robot assembly station

In FMS50 Mode the sensor signals PART AV and FOLLOWING STATION FREE are not transfered to the robot. The released input is used for coding of the stations´orders (In6, In7)

Foll.stat. PART B2 B1 AV (colour) (Orient.)FREE

I/O-Terminal Magazine

I/O-Terminal Robot

X1

PART ON PALLET

Operation panel

X3

X2

TRANSPORT AS-i IN 0 IN 2 IN 3 IN 4 IN 6 IN 7 IN 8 IN 10 IN 11 IN 12

IN ........

START STOP RESET

PART AV FOLl. stat. Free

01: Assembly 10: Sorting out 11: at bus: load part on palette

IN 14 IN 15 OUT 0

OUT 6 OUT 7 OUT 8 OUT 10 OUT 11 OUT 12 OUT 14 OUT 15

© Festo Didactic GmbH & Co. • MPS

X4

OUT 2 OUT 3 OUT 4

ERR CODE #0 ERR CODE #1 Order aktiv (busy) Station ready 0V

SYSLINK (AS-i)

OUT 0 OUT 1 OUT 2 OUT 3 IN 0 IN 1 IN 2 IN 3 0V

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

I/O-cabel twisted with SYS-Link-plug (Red marking Order Nr. 121 210 )

67

Commissioning

I/O-communication Æ ASRS – Conveyor station 5

Transport System

Station AS/RS

Pending order

0 1 1 1 1

Control panel new

Bit1 Bit0 X 0 0 1 1

X 0 1 0 1

PART ON PALLET

Order No processing Reserved Storage Retrieval, oldest part Retrieval, jungest part

TRANSPORT AS-i IN ........

SYSLINK (AS-i) 0V OUT 6

IN 4

Pending order

OUT 7 OUT 4

IN 6

OUT 5

IN 7

Order Bit0 Order Bit1 Stock is full Stock is empty Order aktiv (busy) Station ready

IN 0

0V OUT 0 OUT 1 OUT 2 OUT 3

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

IN 1 IN 2 IN 3

AS-I Addr: AS-I Addr: AS-I Addr: AS-I Addr:

Cabel

IN 1 IN 2 IN 3 OUT 0 OUT 1

SYSLINK - plug SYSLINK

OUT 2 OUT 3 0V

68

© Festo Didactic GmbH & Co. • MPS

Commissioning

I/O-communication Æ Sorting station PICalfa station – Conveyor station 6

PIC alfa station

Transport System

Sorting/Commissioning station PART AV

PART AV

OUT 0.7

IN 0.1

IN 0.7

AS-I Addr:

OUT 0.7

IN 0.7

IN 0.1

Transport System AS-i

SYSLINK (AS-i) OUT 2 OUT 3 IN 2 IN 3 0V

FOL Stat. FREE* Stations ready 0V

OUT 6 OUT 7 IN 6 IN 7 0V

IN 4 IN 5 OUT 4 OUT 5 0V

Sorting station ready 0V

OUT 0

IN 4 IN 5 OUT 4 OUT 5 0V

OUT 6 OUT 7 IN 6 IN 7 0V

Sorting Station not ready, if: - it was not started (START-Button activated) - slides are full with workpieces - no voltage supplied to the station - the station does not exist

IN 0 IN 1 IN 2 IN 3

SYSLINK

OUT 3 4mm Labor cable

0V Signal 0V

Expiry as in the case of MPS standard: if a palette with workpiece is in Ap6 and the PIC alfa set signal free, the transport control sets share AV* the signal . This signal must be evaluated in the program of the station PIC alfa instead of the signal share AV . PIC alfa station get the part and the signal share AV* disappears again, the pallet can drive on . AV* is a combination from the sensor share ON PALLET and the condition pallet IN position.

NOTICE:

© Festo Didactic GmbH & Co. • MPS

69

Commissioning

Planning Please plan your activities within your team. Check the inputs in the wiring diagram and at the AS-I-slaves. Check the adjustment of the mechanical components first. Check the connection of the Emergency Stop system and I/O-communication to the MPS-stations. The time to finish this project should be around 4,0 hour. Execution/Documentation Write down the single steps and all useful informations. Write down your single steps you did to proceed. Step No.:

70

Description

Check

1

check the adjustment of mechanical components

2

check the adjustment of mechanical actuators holder

3

check the mechanical position of hand over to the next station

4

cable connections (Emergency, I/O-communication…)

5

connect all power supplies

6

check the adjustment of sensor holders

7

check the adjustment of sensors in the holders

8

check the adjustment of sensitivity of sensor

9

tubing connections

10

connect all air-pressure supplies (careful! turn pressure down)

11

check the adjustment of the speed of pneumatic actuators

12

connect the stations together

13

communication connection

© Festo Didactic GmbH & Co. • MPS

Commissioning

1.7

Commissioning – Download Project and Test

Please download the full project into the PLC and test the full process without any connected MPS-stations. Information Please make sure that the PC is connected to the PLC with the communication cable, the power supply (main switch) of the station is on, air-pressure of around 5 bar is available , all emergency switches are deactivated and the CPU-switch is in STOP position. Make sure that the PLC memory is empty (delete) and the power supply of all connected MPS-stations is off and change the Emergency Stop connection to the MPS-stations with the connectors which are used if there is no MPS-station available (with the short cut between plug 3 and 4). The control elements of the control cabinet of the transport system are required for the start-up of the transport system and, as such, the complete system.

Main switch conveyor The main switch is located on the side of the control cabinet of the transport system station, supplying the control cabinet with voltage. The conveyor belts and the system can only be started, if the control cabinet receives voltage supply.

© Festo Didactic GmbH & Co. • MPS

71

Commissioning

Control elements of the Transport system Name

Element

Function

Error

H8

Flashes

Indicator Acknowledge error Automatic on is flashing

Flashes

Indicator Start-up request

Light on

Indicator system in operation

H5 Automatic on S5

Start up system

H6

Light on

S6

Switch off motors of the conveyor belts

H1

Light on

Indicator Automatic off

Automatic off

Controller off S1

STOP

Transport system is being completely de-activated (cp. EMERGENCY-STOP). Indicator Request Acknowledge EMERGENCY-STOP

H3

Light on

S3

Acknowledge EMERGENCY-STOP

S2

De-activate control / EMERGENCY-STOP function

Controller on

EMERGENCY-

Indicator Controller off

The table assists in operating the conveyor transport system station. All of the pushbuttons and lamps are described within. After downloading of the PLC-program, please switch the CPU to RUN first. Activate the controller by pressing the button Controller on once and after the light Automatic on is flashing, please press this button to run the conveyor. Please be aware, that if all connceted MPS-stations are off, the pallets don´t stop at the connected MPS-stations. After that, please connect the Emergency Stop connection to the MPS-stations and switch on the power supply of all MPS-stations and start the homing procedure. After that, the pallets must stop for a short time at each station where a MPS-station is connected.

72

© Festo Didactic GmbH & Co. • MPS

Commissioning

NOTICE:

Planning Please follow the description of the in instructor carefully step-by-step. Use the NOTICE field to write down the single steps to proceed. The time to finish this project should be around 2,0 hours.

© Festo Didactic GmbH & Co. • MPS

73

Commissioning

Execution/Documentation

File Æ Open Æ Browse Æ (select subdirectory – example here D:\Eigene Dateien\Eigene Daten\Teach_gb\Festo\MPS_Conveyor FMS50) Æ FMS50 Æ OK (left mouse button)

74

© Festo Didactic GmbH & Co. • MPS

Commissioning

(click with the left mouse button onto the project Conveyor)Æ PLC Æ Download Æ (follow the instructions on the screen to download the project – after download is finish, switch the CPU-switch to RUN and test the program)

© Festo Didactic GmbH & Co. • MPS

75

Commissioning

1.7.1

Commissioning – Driver Control

The Driver Control is very important to define which MPS-station is connected to which conveyor station. The entire conveyor program is done by using variables for each station. This allows us to be very flexible by changing MPS-stations to each conveyor station. If the Driver Control is not correct, let´s say the MPS-station number 1 (Distribution/Testing) is not activated within the Driver Control, the entire program will ignore the MPS-station. So this data, which is part of the DB1 (Data Block 1), are very important to be checked and to be correct. Please follow the screen shots and explanations in the following to get an idea about how to check and how to change this variables. Please be reminded, that the numbers in front of the stations and programs within the first screen shot on this page can be different within your solution. Its only important to open the Simatic 300-Station which is named as xxxxConveyorXXX.

+xxxConveyorxxx Æ +CPU313C-2DP Æ +S7 xxxConveyorxxx Æ BlocksBausteine

76

© Festo Didactic GmbH & Co. • MPS

Commissioning

DB1 (double click) Æ View Æ Data View

© Festo Didactic GmbH & Co. • MPS

77

Commissioning

(Move to the top end of the list and refer to the numbers mentioned at IX1…IX8). This list is for an example FMS50 configuration as follows: Adress

78

Name

Type

Initial value

Actual value

Comment

108

IX1

Byte

B#16#0

B#16#1

MPS-stat.1 connected to conv.stat.1

109

IX2

Byte

B#16#0

B#16#0

no MPS-stat.connected

110

IX3

Byte

B#16#0

B#16#0

no MPS-stat.connected

111

IX4

Byte

B#16#0

B#16#4

MPS-stat.4 connected to conv.stat.4

112

IX5

Byte

B#16#0

B#16#5

MPS-stat.5 connected to conv.stat.5

113

IX6

Byte

B#16#0

B#16#6

MPS-stat.6 connected to conv.stat.6

114

IX7

Byte

B#16#0

B#16#0

no MPS-stat.connected

115

IX8

Byte

B#16#0

B#16#0

no MPS-stat.connected

© Festo Didactic GmbH & Co. • MPS

Commissioning

This above mentioned list is just an example of a possible FMS50 configurationlike:

1 4 5 6

MPS-station 1 - Distribution/Testing is connected to conveyor station 1 MPS-station 4 - Robot/Robotassembly is connected to conveyor station 4 MPS-station 5 - ASRS is connected to conveyor station 5 MPS-station 6 - Sorting/Handling is connected to conveyor station 6

Basically, the MPS-stations have the following numbers: 1 2 3 4 5 6

Distribution/Testing Processing/Handling Vision system Robot/Robotassembly ASRS Sorting/Handling

and can be connected to each conveyor station you want. So please understand, that the MPS-station number 1…6 has nothing to do with the conveyor station number IX1…IX8

© Festo Didactic GmbH & Co. • MPS

79

Commissioning

Another example of a system and the list of the DB1:

Adress

80

Name

Type

Initial value

Actual value

Comment

108

IX1

Byte

B#16#0

B#16#1

MPS-stat.1 connected to conv.stat.1

109

IX2

Byte

B#16#0

B#16#0

no MPS-stat.connected

110

IX3

Byte

B#16#0

B#16#4

MPS-stat.4 connected to conv.stat.3

111

IX4

Byte

B#16#0

B#16#5

MPS-stat.5 connected to conv.stat.4

112

IX5

Byte

B#16#0

B#16#0

no MPS-stat.connected

113

IX6

Byte

B#16#0

B#16#6

MPS-stat.6 connected to conv.stat.6

114

IX7

Byte

B#16#0

B#16#0

no MPS-stat.connected

115

IX8

Byte

B#16#0

B#16#0

no MPS-stat.connected

© Festo Didactic GmbH & Co. • MPS

Commissioning

(If you changed the variables, which you should not do within the entire conveyor program, please save the DB1) Æ File Æ Save

© Festo Didactic GmbH & Co. • MPS

81

Commissioning

(and download the new DB1 into the PLC) Æ PLC Æ Download (follow the messages on the screen)

82

© Festo Didactic GmbH & Co. • MPS

Commissioning

(and close the window) Æ File Æ Exit

© Festo Didactic GmbH & Co. • MPS

83

Commissioning

1.7.2

Commissioning – Online check of the Driver Control

After downloading of the entire project (1.7 Commissioning – Download Project and Test) or changing of the DB1 (1.7.1 Commissioning – Driver Control) you are able to check the Driver Control variables online. Please make sure, that you are still connected to the PLC and the CPU is switched to STOP. Please proceed as follows:

PLC Æ Monitor/Modify Variables

84

© Festo Didactic GmbH & Co. • MPS

Commissioning

Table Æ Open

© Festo Didactic GmbH & Co. • MPS

85

Commissioning

(make sure that the BlocksBausteine of the Conveyor station is open – left window) Æ TreiberDriver Control Æ OK

86

© Festo Didactic GmbH & Co. • MPS

Commissioning

(here you can see which MPS-station is connected to which conveyor station. After viewing, please exit the window) Æ Table Æ Exit

© Festo Didactic GmbH & Co. • MPS

87

Programming

2.1

Programming – Hardwareconfiguration

Please define the PLC-hardware used within your station with the STEP 7 software. After the configuration, please download it into the PLC. Information Please make sure that the PC is connected to the PLC with the communication cable, the power supply of the station is on, the emergency switch is deactivated and the CPU-switch is in STOP position. Make sure that the PLC memory is empty (delete). Use the screen shots (execution) to proceed. Open a new project and name it P2_01_Co. It´s not necessary to add the station name into the hardware configuration name, because the configuration is the same for all stations. NOTICE:

Planning Please follow the description (screen shots) carefully step by step. Please make sure, that every member of your team did the hardware configuration at least once. The time to finish this project should be around 1,0 hours.

© Festo Didactic GmbH & Co. • MPS

88

Programming

Execution Screen shots of the hardware configuration, the bold words are commands to click on, the ( ) are only comments (ENTER) means click left mouse button once or press ENTER, (double click) means double click the left mouse button:

File Æ New Æ (type Name: P2_01_Co) Æ OK

© Festo Didactic GmbH & Co. • MPS

89

Programming

Insert Æ Station Æ SIMATIC 300 Station

90

© Festo Didactic GmbH & Co. • MPS

Programming

+ P2_01_Co Æ SIMATIC 300(1) Æ Hardware (double click)

© Festo Didactic GmbH & Co. • MPS

91

Programming

+ SIMATIC 300 Æ + RACK-300 Æ Rail Æ (double click)

92

© Festo Didactic GmbH & Co. • MPS

Programming

(Click on Slot 2) Æ - RACK 300 Æ + CPU-300 Æ + CPU 313C-2DP Æ 6ES7 3136CE00-0AB0 (depends on the CPU you use – check the order no. on the front left below corner of the CPU) Æ (double click) Æ (we don’t use any networking like MPI or Profibus-DP at the moment, that’s why – not networked is ok) Æ OK

© Festo Didactic GmbH & Co. • MPS

93

Programming

CPU 313C-2DP (at the Slot 2 – double click) Æ Cycle/Clock Memory Æ Clock Memory Æ 100 (Memory Byte – free definition)

94

© Festo Didactic GmbH & Co. • MPS

Programming

Retentive Memory Æ 0 (Number of Memory Bytes Starting with MB0) Æ 0 (Number of S7 Timers Starting with T0) Æ 0 Number of S7 Counters Starting with C0) Æ OK

© Festo Didactic GmbH & Co. • MPS

95

Programming

(Click on Slot 4) Æ - CPU-300 Æ + CP-300 Æ + AS-Interface Æ CP 342-2 AS-I (6GK7 342-2AH01-0XA0 depends module you use – refer to the left below corner of the module to find the right number) Æ (double click)

96

© Festo Didactic GmbH & Co. • MPS

Programming

- SIMATIC 300 Æ Station Æ Save and Compile

© Festo Didactic GmbH & Co. • MPS

97

Programming

(Distinguished to the S5 PLC-family of Siemens, you could change the AS-I peripheral addresses if you want – for example we want to change the input and output peripheral byte 256…271 to the standardized addresses 64…79 used within the S5 PLC´s, you please proceed like shown into the screen shot) Æ CP 342-2 (Slot 4 double click) Æ Addresses Æ (change the address of the Inputs Start to 64 and the Outputs Start also to 64 and deactivate the System selection of in- and outputs) Æ OK PLEASE DON´T PROCEED TO CHANGE THE ADDRESSES TO 64…79

98

© Festo Didactic GmbH & Co. • MPS

Programming

PLC Æ Download (follow the instructions on the screen to download the hardware configuration)

© Festo Didactic GmbH & Co. • MPS

99

Programming

(After download without an error message switch the CPU to RUN - no red light SF/BF - switch the CPU to STOP again) Station Æ Exit

100

© Festo Didactic GmbH & Co. • MPS

Programming

Controll If there will be no error message after saving and compiling your hardware configuration and no error message while or after downloading, the hardware configuration have been done properly. Change the switch on the CPU to RUN-position-if there is no read light SF/BF the configuration was successful and then change the switch to STOP again. Documentation Please add your own comments to the screen shots.

© Festo Didactic GmbH & Co. • MPS

101

Programming

2.1.1

Programming – Transfer of the peripheral AS-Iadresses within OB1

Please edit the OB1 within the project P2_01 to transfer the peripheral AS-Iaddresses into addressable addresses used by Simatic S5 (64…79). Information The AS-I slaves are not directly addressable within the program, because AS-I slaves are treated as periphery. This is the reason, why the following program part inside of the organization block is absolutely necessary, in order to address the slaves. Within the following example we use the addresses, which are standardized used with a Siemens S5 PLC – byte 64 – 79 in total per one master. This is facilitating the change from the S5 world - in which this address range is fix determined - to the world of the S7, where this address range is actually free choosable: L T L T … L T

PID256 ID64 PID260 ID68

load peripheral-input-double word 256 transfer to input-double word 64 load peripheral-input-double word 260 transfer to input-double word 68

PID268 ID76

load peripheral-input-double word 268 transfer to input-double word 76

L T L T … L T

QD64 PQD256 QD68 PQD260

load output double word 64 transfer to peripheral output-double word 256 load output double word 68 transfer to peripheral output-double word 260

QD76 PQD268

load output double word 76 transfer to peripheral output-double word 268

Please make sure that the PC is connected to the PLC with the communication cable, the power supply of the station is on, the Emergency Stop switch is deactivated and the CPU-switch is in STOP position. Make sure that the PLC memory is empty (delete). Use the screen shots (Execution) to proceed. NOTICE:

Planning Please follow the description (screen shots) carefully step by step. Please make sure, that every member of your team did the hardware configuration at least once. The time to finish this project should be around 1, 0 hours.

102

© Festo Didactic GmbH & Co. • MPS

Programming

Execution

(After closing the Hardware configuration window) +SIMATIC 300(1) Æ +CPU 313C-2DP Æ +S7 Program(1) Æ Blocks Æ (double click on OB1)

© Festo Didactic GmbH & Co. • MPS

103

Programming

OK

104

© Festo Didactic GmbH & Co. • MPS

Programming

(Edit the program like shown within the screen shot)

© Festo Didactic GmbH & Co. • MPS

105

Programming

File Æ Save Æ File Æ Exit

106

© Festo Didactic GmbH & Co. • MPS

Programming

2.2

Programming – Basics in Digital Technology – AND

Please edit the PLC-program concerning the following description: as long as an Automatic on-button AND an Automatic off-button are pressed, the piston rod of the cylinder move. The cylinder is actuated by a 5/2-way single solenoid valve. Please use the pneumatic cylinder of the conveyor station 3 for this and all following exercises. Information Use FC5 to edit the program. Save the project P2_01_Co as the new project P2_02_Co (see screen shots). We didn’t close the project P2_01_Co, because we have to save this project with a new name. Please use symbol addresses for this and all following projects (see the screen shots on the following pages how to edit the symbol table). The programming language of FC5 should be FBD (Function Block Diagram), in OB1 STL (Statement List). FC5 starts unconditional (UC). NOTICE:

© Festo Didactic GmbH & Co. • MPS

107

Programming

108

© Festo Didactic GmbH & Co. • MPS

Programming

In the following please find some important information regarding pneumatic actuators and their triggering. These informations are basically. NOTICE:

• 5 = number of connections (1, 3, 4, 2 and 5) • 2 = 2 switching positions (2 rectangles) The connections have the following functions: 1(P) = air connection (supply) 2(B) = output B for backward stroke 3(S) = connection exhaust air of forward stroke 4(A) = output A for forward stroke 5(S) = connection exhaust air of backward stroke In the following drawing you can find letters in brackets behind the standardized designation of the connections (1, 3, 4, 2 and 5). These letters are former designations, one can still find them on old elements.

Single solenoid

4(A)

Double solenoid

2(B)

14 y1

4(A) 14

5(S)

3(R) 1(P)

y2

2(B) 12

5(S)

3(R) y3 1(P)

Activation of single/double solenoid valve:

© Festo Didactic GmbH & Co. • MPS

109

Programming

4(A)

2(B)

14 y1

5(S)

power (24VDC) connected to Y1

3(R) 1(P)

4(A)

2(B)

14 y1 5(S)

3(R) 1(P)

Activation of a single solenoid valve:

4(A) 2(B) short 14 power signal y2 5(S) 3(R) (24VDC) 1(P) connected to y2

4(A)

12 14 y3

y2

2(B)

short power signal 3(R) y3 5(S) (24VDC) 1(P) connected to y3 12

Activation of a double solenoid valve:

110

© Festo Didactic GmbH & Co. • MPS

Programming

Planning Please plan your project step by step first within the group. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructor. Before programming, don’t forget to delete the contents of the PLC using the CPU-switch. Follow the screen shots to save the project P2_01 with a new name, edit the symbol table and OB1 and insert and edit FC5. The time to finish this project should be around 3,0 hour including theory.

There are two possibilities to structure a project where four Programs are parallel to the Station SIMATIC 300(1) Æ this structure is used for education, because there is mostly more than only one different exercise (Programs) for one station. Struc02 shows a typical industrial structure, because there is mostly only one Program for one station or application. All the following projects have to be done in this structure.

© Festo Didactic GmbH & Co. • MPS

111

Programming

Execution “Copy” the project P2_01 into the new project P2_02 with the command Save as….

(Click on P2_01_Co) Æ File Æ Save as Æ (type the new name P2_02_Co) Æ OK

112

© Festo Didactic GmbH & Co. • MPS

Programming

© Festo Didactic GmbH & Co. • MPS

113

Programming

Edit the symbol table with the symbol editor

+P2_02_Co Æ +SIMATIC 300(1) Æ +CPU 313C-2DP Æ S7 Program(1) Æ Symbols Æ (double click) Æ (edit all symbols and hardware addresses for all stations)

114

© Festo Didactic GmbH & Co. • MPS

Programming

(After editing all stations) ÆFile Æ Save Æ File Æ Exit

© Festo Didactic GmbH & Co. • MPS

115

Programming

Insert a Function FC5 into the project P2_02 and expand the OB1 with the unconditional call of the FC5

+S7 Program(1) Æ Blocks Æ Insert Æ Function

116

© Festo Didactic GmbH & Co. • MPS

Programming

(Type in the name of the FC) FC5 Æ (choose the correct programming language) FBD Æ OK

© Festo Didactic GmbH & Co. • MPS

117

Programming

(Double click onto OB1) Æ (click on Network 2) Æ Insert Æ Network

118

© Festo Didactic GmbH & Co. • MPS

Programming

(Edit Network 3 like shown in the screen shot) Æ File Æ Save Æ File Æ Exit

© Festo Didactic GmbH & Co. • MPS

119

Programming

Editing the FC5 with the AND-function

(After editing) File Æ Save Æ (no error message) File Æ Exit This procedure is always the same after editing a program Æ it´s not mentioned anymore!!!

120

© Festo Didactic GmbH & Co. • MPS

Programming

Block Æ PLC Æ Download (it´s not necessary to download the System data again, so please choose no if this question appears and follow the instructions on the screen) This procedure to download a project is always the same after editing a program Æ it´s not mentioned anymore!!! Controll After editing and downloading the project into the CPU, please test the function according the project description. Please use the Online function also like shown on the next screen

© Festo Didactic GmbH & Co. • MPS

121

Programming

(Re-open FC5 by double click on it) Æ Debug Æ Monitor Æ (you can see the function of the logic online on the monitor. Please switch the monitor mode off again before exit the program) Æ Debug Æ Monitor Æ File Æ Exit

122

© Festo Didactic GmbH & Co. • MPS

Programming

2.3

Programming – Basics in Digital Technology – OR

Please edit the PLC-program concerning the following description: as long as an Automatic on button OR an Automatic off button is activated, the piston rod of the cylinder moves. The cylinder is actuated by a 5/2-way single solenoid valve. Information Use FC1 to edit the program. Save project P2_02 as the new project P2_03. Please use the symbol addresses shown in the list of inputs and outputs of Project 1.3 to edit the program. The programming language for FC1 should be FBD, for OB1 STL. The FC1 shall start unconditional. The following screen shows the project structure and the symbol editor. NOTICE:

© Festo Didactic GmbH & Co. • MPS

123

Programming

124

© Festo Didactic GmbH & Co. • MPS

Programming

Planning Please plan your project step by step first within the group. Use the list of inputs and outputs of the Project 1.3. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructor. Before programming, don’t forget to delete the contents of the PLC using the CPU-switch again. After editing OB1 and FC1, please download the Blocks into the CPU and test the program. The time to finish this project should be around 1,0 hour including theory. Execution/Documentation Program OB1:

© Festo Didactic GmbH & Co. • MPS

125

Programming

Program FC1:

If you click the right mouse button on an input or output and click on Insert Symbol., you will get a list of all defined inputs and outputs within the Symbol Editor. Controll Edit the project and download it. Test the function according the project description.

126

© Festo Didactic GmbH & Co. • MPS

Programming

2.4

Programming – Basics in Digital Technology – RSFlip-Flop

Please edit the PLC-program concerning the following description: if an Automatic on button is pressed shortly, the piston rod of the cylinder with single solenoid shall move as long as an Automatic off button is pressed shortly. If the Automatic on- and the Automatic off button are pressed at the same time, the piston rod shall not move out. Information Use FC1 to edit the program. Save the old project P2_03_Co as the new project P2_04_Co. Please use symbol addresses. The programming language of FC1 should be FBD, for OB1 STL. NOTICE:

© Festo Didactic GmbH & Co. • MPS

127

Programming

128

© Festo Didactic GmbH & Co. • MPS

Programming

Planning Please plan your project step by step first within the group. Use the list of inputs and outputs of the Project 1.3. Work out the informations of truth table, wiring diagram, logic plan and stepping diagram first together with the Instructors. Before programming, don’t forget to delete the contents of the PLC using the CPU-switch. The time to finish this project should be around 1,5 hour including theory. Execution/Documentation Program OB1 is the same than for project before. Program FC1

© Festo Didactic GmbH & Co. • MPS

129

Programming

Controll Edit the project and download it. See the function of the project online on your computer. Test the function according the project description.

130

© Festo Didactic GmbH & Co. • MPS

Programming

2.5

Programming – Basics in Digital Technology – AND NOT

Please edit the PLC-program concerning the following description: as long as an Automatic on button is pressed AND an Automatic off button is NOT activated, the piston rod of the cylinder with single solenoid shall move. Information Use FC10 to edit the program. Please use symbol addresses. The programming language for FC10 should be FBD, for OB1 STL. The FC10 shall start unconditional. Work out the Truth Table together with the instructor first. Instructor: Please work out the Truth table together with the participants. Show how to negate an input in the program with FBD. Explain that within the program they shall use the cylinder with single solenoid valve not the light H1.

Planning Please plan your project step by step first within the group. The time to finish this project should be around 0,5 hour.

© Festo Didactic GmbH & Co. • MPS

131

Programming

Execution/Documentation Program OB1

132

© Festo Didactic GmbH & Co. • MPS

Programming

Program FC10

Controll Edit the project and download it. Test the function according the project description. Watch FC10 with the online-function (description see Project 2.4).

© Festo Didactic GmbH & Co. • MPS

133

Programming

2.6

Programming – Basics in Digital Technology – IDENTITY

Please edit the PLC-program concerning the following Truth table. Reduce the logic as much as possible. Use the Automatic on button (S) and the Automatic off button (R) and the cylinder with single solenoid valve (H1).

Information Use FC1 to edit the program. Name the project P2_06_Co. Please use symbol addresses. The programming language for FC1 and for OB1 should be STL. The FC1 shall start unconditional. NOTICE:

Planning Please plan your project step by step first within the group. The time to finish this project should be around 0,5 hour.

134

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program OB1

© Festo Didactic GmbH & Co. • MPS

135

Programming

Program FC1

Controll Edit the project and download it. Test the function according the project description. Watch FC1 with the online-function.

136

© Festo Didactic GmbH & Co. • MPS

Programming

2.7

Programming – Condition Call of a Program

After a short actuation of an Automatic on button, the piston rod of the cylinder with single solenoid shall move as long as an Automatic off button is pressed shortly. The cylinder shall not move, if both buttons are pressed at the same time. The program shall only be active, if a pallet is at the stopper, the program FC8 is not running if no pallet is in place. Information Use FC8 to edit the program. The project name is P2_07_Co. Please use symbol addresses. The programming language for FC8 is FBD, for OB1 STL. NOTICE:

Planning Please plan your project step by step first within the team. Discuss the differences to call a function (FC) with and without a condition. The command for conditional call is CC. Before the action of CC, you have to edit a condition-which condition is this? The time to finish this project should be around 1,0 hour.

© Festo Didactic GmbH & Co. • MPS

137

Programming

Execution/Documentation Program OB1

138

© Festo Didactic GmbH & Co. • MPS

Programming

Program FC8

Controll Edit the project and download it. Test the function according the project description. Watch the function of the FC with the online-function. This control step will be the same for all the following projects, so it´s not mentioned in each project anymore.

© Festo Didactic GmbH & Co. • MPS

139

Programming

2.8

Programming – Condition Call of a Program expanded

Expand the Project 2.7 (P2_07_Co) after a short actuation of an Automatic on button, the piston rod of the cylinder with solenoid valve shall move as long as an Automatic off button is pressed shortly. The cylinder shall not move, if both buttons are pressed at the same time. The program shall only be active, if a pallet is at the stopper, the program FC8 is not running if no pallet is in place with the additional function Æ the piston rod move to the starting position if no pallet is in place during running of the program in. Information Use FC8 to edit the program. Please use symbol addresses. The programming language for FC8 should be FBD, for OB1 STL. NOTICE:

Planning Please plan your project step by step first within the team. Before programming, don’t forget to delete the contents of the PLC from the computer. Edit the project (programs) on a sheet of paper first. The time to finish this project should be around 1,0 hour.

140

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program OB1

Program FC8 is the same than for the project before.

© Festo Didactic GmbH & Co. • MPS

141

Programming

2.9

Programming – On-Delay-Timer function

If an Automatic on button is pressed and hold, the light inside the Automatic on button shall be on after 5,0 seconds and stay on as long as the button is pressed. The timer is only running while the Automatic button is pressed. If the button will be released before 5 seconds, the timer starts new. Information Use FC1 to edit the program. The programming language for FC1 should be FBD, for OB1 STL. Use the Hardware catalog (Overviews) to edit the program in FBD and use the help-function to get further informations (see the screen shots "Help function for an On-Delay-Timer"). Use Timer 1 for this project. NOTICE:

Planning Please plan your project step by step first within the team. Check out the function of all timers with the help function and choose the right timer for your project. May be it´s helpful, to print the help-functions of the timers for further projects. Edit on a sheet of paper first. The time to finish this project should be around 2,0 hour including theory and print out of the different timers.

142

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program OB1

© Festo Didactic GmbH & Co. • MPS

143

Programming

Help functions in Step 7

+ Timers Æ S_ODT Æ (F1 opens the help function and you can see a description of the timer)

144

© Festo Didactic GmbH & Co. • MPS

Programming

Program FC1

© Festo Didactic GmbH & Co. • MPS

145

Programming

2.10

Programming – Off-Delay-Timer function

If an Automatic off button is pressed, the light inside the Automatic off button shall be on as long as the button is pressed. If you release Automatic off, the light will be on for another 3 seconds. Information Use FC1 to edit the programs. Please use symbol addresses. The programming language for FC1 should be FBD, for OB1 STL. Use Timer 2 for this project. Planning Please plan your project step by step first within the team. Check out the function of all timers and choose the right timer for your project. Edit on a sheet of paper first. The time to finish this project should be around 1,0 hour.

146

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program FC1, the program OB1 is the same than for the project before

© Festo Didactic GmbH & Co. • MPS

147

Programming

2.11

Programming – Counter Down function

If an Automatic on button is pressed, the piston rod of the cylinder move until reaching the sensor for the front/back position depending on the hardware and then move back to starting condition automatically. After starting 5 times, the light inside the Automatic on button must be on and the piston rod can not move again. Set the counter by pressing the Automatic off button once. Information Use FC1 to edit the programs. Please use symbol addresses. The programming language for FC1 should be FBD, for OB1 STL. Use Counter 1 for this project. NOTICE:

Planning Please plan your project step by step first within the team. Check out the function of all counters as shown for the timers in the Project 2.9 and choose the right counter for your project. Edit on a sheet of paper first. The time to finish this project should be around 2,0 hour including theory and print out of the different counters.

148

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program FC1, the program OB1 is the same than for the project before

The logic module P (M10.0) is an edge memory this means, even you hold Startbutton down, only a short pulse will come through to the input. Some contact shatter or bounce even you press them only once.

© Festo Didactic GmbH & Co. • MPS

149

Programming

2.12

Programming – Programming of a Flashlight

As long as an Automatic on button is pressed, the light inside the Automatic on button flashes with 500 ms on and 500 ms off. The program of FC1 should be done with only one Network. Information Use FC1 to edit the programs. Please use symbol addresses. The programming language for FC1 should be FBD, for OB1 STL. There is a Memory byte (Clock Memory) defined within the Hardware configuration which automatically flashes with different frequencies or different time periods. Please see the following time periods for the 8 Bits of the Memory byte 100 (100 is free defined within the Hardware configuration). A time period is the time the Memory is on and the time the Memory is off: M100.0 = 0,1 sec. M100.1 = 0,2 sec. M100.2 = 0,4 sec. M100.3 = 0,5 sec. M100.4 = 0,8 sec. M100.5 = 1,0 sec. M100.6 = 1,6 sec. M100.7 = 2,0 sec NOTICE:

Planning Please plan your project step by step first within the team. Check out the Hardware configuration in Project 2.1 again how to define and activate the Clock Memory . The time to finish this project should be around 0,5 hour.

150

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program FC1, the program OB1 is the same than for the project before

© Festo Didactic GmbH & Co. • MPS

151

Programming

2.13

Programming – Programming of a Auto/Manu sequence

The starting condition for this project is to press the Automatic on button shortly. After the Automatic on button was pressed shortly, the light inside the Automatic on button is on for 1 second. After the Automatic on light is off, the light inside the Automatic off is on for 3 seconds Æ cycle end. Restart of the cycle can be done in two different ways: no pallet is at the stopper (I72.0 is off), the cycle has to be restarted by pressing the Automatic on button again (Manu-cycle) or a pallet is at the stopper (I72.0 is on) restarts the cycle automatically (Auto-cycle). Information Even there is a pallet at the stopper, the very first cycle has to be started by pressing the Automatic on button, the following cycles starts automatically (if a pallet is still at the stopper, or by pressing the Automatic on button again, if the pallet is no more available at the stopper position.) Use FC1 to edit the program. Please use symbol addresses. The programming language for FC1 should be FBD, for OB1 STL. The first start of the cycle must be by pressing Start-button, not with Auto/Manu-switch. NOTICE:

Planning Please plan your project step by step first within the team. The time to finish this project should be around 2,0 hour.

152

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program FC1, the program OB1 is the same than for the project before

© Festo Didactic GmbH & Co. • MPS

153

Programming

2.14

Programming – Conveyor movement

A pallet should be detected at station 6 of the conveyor. The Automatic on button starts the process (start conveyor) and the Automatic on light is on. The process is active until the CPU switch is in RUN position. CPU switch to Stop position ends the cycle. If a pallet will reach the station, the pallet stops for 2 seconds and will be released after the time is finish. Information For this exercise, we have to change the starting position of all stopper cylinders excluding station 6, which means, the position have to be changed from front to back position. Please use only one pallet on the conveyor. FC1 in FBD, OB1 in STL. NOTICE:

Planning Please plan your project step by step first within the team. Discuss the possibilities to change the piston rod position of the stopper cylinders of station 1-5 first. Define the programming sequence first step by step on a paper first. The time to finish this project should be around 2,0 hour.

154

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program FC1, the program OB1 is the same than for the project before

© Festo Didactic GmbH & Co. • MPS

155

Programming

2.15

Programming – Conveyor movement expanded

A workpiece on a pallet should be detected at station 6 of the conveyor and indicated by the light inside the Automatic off button. The Automatic on button starts the process (start conveyor and check of the workpieces) and the Automatic on light is on. The process is active until the CPU switch is in RUN position. CPU switch to Stop position ends the cycle. If a pallet reaches the station, the pallet stops and the light barrier checks if there is a workpiece in place. If yes, the Automatic on light is on and the pallet can be released by pressing the Automatic off button once and the process restarts again automatically. If there is no workpiece available, the pallet will be released. Information For this exercise, we have to change the starting position of all stopper cylinders excluding station 6, which means, the position have to be changed from front to back position. The position of the workpiece on the pallet is shown in the following graphics. Please use only one pallet on the conveyor. FC1 in FBD, OB1 in STL.

NOTICE:

Planning Please plan your project step by step first within the team. Discuss the possibilities to change the piston rod position of the stopper cylinders of station 1-5 first. Define the programming sequence first step by step on a paper first. The time to finish this project should be around 3,0 hour.

156

© Festo Didactic GmbH & Co. • MPS

Programming

Execution/Documentation Program FC1, the program OB1 is the same than for the project before

© Festo Didactic GmbH & Co. • MPS

157

Programming

158

© Festo Didactic GmbH & Co. • MPS

Programming

2.16

Project – Basics of I/O– communication

Please complete the following graphics according the description. Information Work out the basics of input/output communication together with the instructor first. Planning Please plan your project step by step first within the team. The time to finish this project should be around 1,0 hour. Execution/Documentation Please define a 1 Bit bidirectional communication network:

PLC

PLC

PNP 24 VDC Input: 0-12 VDC=0-Sig. 12-30 VDC=1-Sig. Output: 1-Sig.=24 VDC

PNP 24 VDC Input: 0-12 VDC=0-Sig. 12-30 VDC=1-Sig. Output: 1-Sig.=24 VDC

24 VDC 0 V

Input

© Festo Didactic GmbH & Co. • MPS

Output

24 VDC 0 V

Input

Output

159

Programming

Please define a 1 Bit unidirectional communication network from PLC to RobotController:

PLC

Robot-Controller

PNP 24 VDC Input: 0-12 VDC=0-Sig. 12-30 VDC=1-Sig. Output: 1-Sig.=24 VDC

PNP 12 VDC Input: 0- 6 VDC=0-Sig. 6-12 VDC=1-Sig. max.volt.30 VDC Output: 1-Sig.=12 VDC

24 VDC 0 V

160

Input

Output

12 VDC 0 V

Input

Output

© Festo Didactic GmbH & Co. • MPS

Programming

Please define a 1 Bit bidirectional communication network:

PLC

Robot-Controller

PNP 24 VDC Input: 0-12 VDC=0-Sig. 12-30 VDC=1-Sig. Output: 1-Sig.=24 VDC

PNP 12 VDC Input: 0- 6 VDC=0-Sig. 6-12 VDC=1-Sig. max.volt.30 VDC Output: 1-Sig.=12 VDC

24 VDC 0 V

Input

© Festo Didactic GmbH & Co. • MPS

Output

12 VDC 0 V

Input

Output

161

Programming

Please define a 1 Bit bidirectional communication network:

PLC

Robot-Controller

PNP 24 VDC Input: 0-12 VDC=0-Sig. 12-30 VDC=1-Sig. Output: 1-Sig.=24 VDC

NPN 12 VDC Input: 0- 6 VDC=1-Sig. 6-12 VDC=0-Sig. Output: 1-Sig.=0 VDC

24 VDC 0 V

162

Input

Output

12 VDC 0 V

Input

Output

© Festo Didactic GmbH & Co. • MPS

Programming

2.17

Project – Test the I/O– communication

Please test the input/output-communication between the conveyor and one of your connected MPS-stations by a PLC-program. Complete the drawing shown in the Execution step first. Information Please use only one program FC1 in FBD which starts without any condition to solve this problem. The OB1 is in STL. Fill out all F in the drawing. The binary communication like input/output communication is very important basic knowledge to understand the next level of communication – Fieldbus Technology! NOTICE:

Planning Please plan your project step by step first within your team and communicate with the team of the connected station also to complete your drawing. Finish the drawing first and then work out which button, lights or actuators you will use for this project and write it into the drawing. The time to finish this project should be around 1,5 hour.

© Festo Didactic GmbH & Co. • MPS

163

Programming

Execution/Documentation

This drawing is an example for the communication between the Testing station and the conveyor.

164

© Festo Didactic GmbH & Co. • MPS

Programming

Program FC1, OB1 is the same than in the project before

Controll Edit the project and download it. Test the function according the project description and your planning. Watch FC1 with the online-function.

© Festo Didactic GmbH & Co. • MPS

165

Programming

2.18

Project – Communication via Profibus-DP

This project combines two PLC´s via Profibus-DP, if corresponding PLC´s are available. The communication shall be based on a 1-bit bidirectional communication which means that as long as a button is pressed on the Master PLC station control panel, a light at the slave PLC control panel is and opposite. Information Please define the inputs (button) and outputs (lights) by yourself. Please edit the program FC1 in FBD which starts without any condition. The OB1 is in STL. Please follow the screen shots shown within the Execution step. The following solution is based on the configuration shown in the graphics:

NOTICE:

166

© Festo Didactic GmbH & Co. • MPS

Programming

Planning Please work out the theory of Fieldbus technology together with the Instructor first. Please connect both Profibus-DP interfaces and the PC´s with the PLC´s like shown in the graphics above. Normally the programming of a Profibus network is done by only one PC, but because we are working out the projects by teams, the Master and the Slave solution should be done by both teams. The Master team is downloading the Master solution into the Master PLC and the Slave team is downloading the Slave solution into the Slave PLC. Please plan by yourself who is corresponding for which PLC. Please follow the screen shots very carefully and discuss your solution steps within the whole team. . The time to finish this project should be around 3,0 hour.

© Festo Didactic GmbH & Co. • MPS

167

Programming

Execution/Documentation The following description is based on the definition of 1 Byte with the address field of input/output byte 40. This means, that there is a Profibus-DP address field of I40.0 – I40.7 and Q40.0 – Q40.7. As you can see, from the program-controlled point of view Profibus-DP is nothing else but an I/O-communication. Insert a Subnet and two Simatic-300 Stations

File Æ New Æ (type in the name P2_18_Co) Æ OK Æ Insert Æ Subnet Æ 2 PROFIBUS

168

© Festo Didactic GmbH & Co. • MPS

Programming

Insert Æ Station Æ 2 SIMATIC S7-300 Æ (change the name to Slave)

© Festo Didactic GmbH & Co. • MPS

169

Programming

(Click on the project P2_18_Co) Æ Insert Æ Station Æ 2 SIMATIC S7-300 Æ (change the name to Master)

170

© Festo Didactic GmbH & Co. • MPS

Programming

Hardware configuration of the DP-Slave

(Click on Slave) Æ Hardware (double click) Æ +SIMATIC 300 Æ +RACK-300 Æ Rail (double click)

© Festo Didactic GmbH & Co. • MPS

171

Programming

(Click on Slot 2) Æ -RACK-300 Æ +CPU-300 Æ +CPU 313C-2DP Æ 6ES7 3136CE00-0AB0 (double click) Æ PROFIBUS(1) Æ 4 (Profibus-DP address) Æ OK

172

© Festo Didactic GmbH & Co. • MPS

Programming

CPU 313C-2DP (Slot 2 double click) Æ Cycle/Clock Memory Æ (click on Clock memory) Æ 100 (Memory Byte)

© Festo Didactic GmbH & Co. • MPS

173

Programming

Retentive Memory Æ (type in 0 like shown within the screen shot) Æ OK

174

© Festo Didactic GmbH & Co. • MPS

Programming

DP (Slot X2 double click) Æ DP-Slave (type in the name)

© Festo Didactic GmbH & Co. • MPS

175

Programming

Operating Mode Æ (click on DP-Slave)

176

© Festo Didactic GmbH & Co. • MPS

Programming

Configuration Æ New Æ (Address type choose Input) Æ 40 (Address) Apply

© Festo Didactic GmbH & Co. • MPS

177

Programming

New Æ (Address type choose Output) Æ 40 Æ Apply Æ Close

178

© Festo Didactic GmbH & Co. • MPS

Programming

Station Æ Save and Compile Æ (follow the screen) Æ Station Æ Exit The Slave team must download the hardware configuration into the Slave PLC before exit.

© Festo Didactic GmbH & Co. • MPS

179

Programming

Insert OB82 and FC1 into the Slave

+Slave Æ +CPU 313C-2DP Æ +S7 Program(1) Æ Blocks Æ Insert Æ S7-Block Æ Organisation Block Æ OB82 (type in the Name) Æ (choose STL) Æ OK There is no need to program the OB82, but the Profibus-DP communication use this OB to transfer data to start-up the communication.

180

© Festo Didactic GmbH & Co. • MPS

Programming

Insert Æ S7-Block Æ Function Æ FC1 (type in the name) Æ (choose FBD) Æ OK

© Festo Didactic GmbH & Co. • MPS

181

Programming

Edit FC1 of the Slave

(Edit the program like shown within the screen shot) Æ File Æ Save Æ File Æ Exit

182

© Festo Didactic GmbH & Co. • MPS

Programming

Hardware configuration of the Master

(Click on the Master station) Æ Hardware (double click) Æ +SIMATIC 300 Æ +RACK-300 Æ Rail (double click)

© Festo Didactic GmbH & Co. • MPS

183

Programming

(Click on Slot 2) Æ -RACK-300 Æ +CPU-300 Æ +CPU 313C-2DP Æ 6ES7 313-6CE00-0AB0 (double click) Æ PROFIBUS(1) Æ 2 (type in the address) Æ OK

184

© Festo Didactic GmbH & Co. • MPS

Programming

CPU 313C-2DP (Slot 2 double click) Æ Cycle/Clock Memory Æ (click on Clock memory) Æ 100 (type in the Memory Byte)

© Festo Didactic GmbH & Co. • MPS

185

Programming

Retentive Memory Æ (type in 0 like shown within the screen shot) Æ OK

186

© Festo Didactic GmbH & Co. • MPS

Programming

DP (Slot X2 double click) Æ DP-Master (type in the name)

© Festo Didactic GmbH & Co. • MPS

187

Programming

Operating Mode Æ (check if the DP-Master is active) Æ OK

188

© Festo Didactic GmbH & Co. • MPS

Programming

(Click on the line PROFIBUS(1) DP master system(1)) Æ - SIMATIC 300 Æ +PROFIBUS DP Æ +Configured Stations Æ CPU 31x (double click) Æ Connect Æ OK

© Festo Didactic GmbH & Co. • MPS

189

Programming

(Double click on the symbol of the Slave CPU) Æ Configuration Æ (click onto line 1) Æ Edit

190

© Festo Didactic GmbH & Co. • MPS

Programming

(Choose address type Output) Æ 40 (type in the address) Æ Apply

© Festo Didactic GmbH & Co. • MPS

191

Programming

(Click on line 2) Æ Edit Æ (choose address type Input) Æ 40 (type in the address) Æ Apply Æ Close Æ Station Æ Save and Compile Æ Station Æ Exit The Master team must download the hardware configuration into the Master PLC before exit.

192

© Festo Didactic GmbH & Co. • MPS

Programming

Copy Symbols and OB1 from the project before and insert OB82

File Æ Open Æ (choose the project P2_17_Co) Æ OK Æ +P2_17_Co Æ +SIMATIC 300(1) Æ +CPU 313C-2DP Æ S7 Program(1) Æ +P2_18_Co Æ +Master Æ +CPU 313C-2DP Æ Symbols (right mouse button in the project P2_17_Co) Æ Copy

© Festo Didactic GmbH & Co. • MPS

193

Programming

S7 Program(2) (in the project P2_18_Co) Æ (right mouse button) Æ Paste

194

© Festo Didactic GmbH & Co. • MPS

Programming

+S7 Program(1) (in the project P2_17_Co) Æ Blocks Æ (right mouse button click onto OB1) Æ Copy

© Festo Didactic GmbH & Co. • MPS

195

Programming

+S7 Program(2) (in the project P2_18_Co) Æ (right mouse button) Æ Paste Æ OK

196

© Festo Didactic GmbH & Co. • MPS

Programming

Insert Æ S7-Block Æ Organisation Block Æ OB82 (type in the name) Æ (choose STL) Æ OK

© Festo Didactic GmbH & Co. • MPS

197

Programming

Insert Æ S7-Blocks Æ Function Æ FC1 (type in the name) Æ (choose FBD) Æ OK

198

© Festo Didactic GmbH & Co. • MPS

Programming

Edit of FC1, the OB1 is the same than in the project before

(Edit the program like shown within the screen shot) Æ File Æ Save Æ File Æ Exit After editing, the Slave team shall download the full Slave project into the Slave PLC and the Master team into the Master PLC. Test the project.

© Festo Didactic GmbH & Co. • MPS

199

Trouble Shooting

3.1

Program – Trouble Shooting

In the following exercises there are some programming errors which have to be detected, located and eliminated. Information The programs have been part of the programming projects. NOTICE:

Planning Please follow the steps: error detection (what is not working) , error location (where can the error be logically), error elimination (find out the error location, change the program and test the sequence). Controll Test the program according the short description given by the instructor on the board.

© Festo Didactic GmbH & Co. • MPS

200

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

201

Trouble Shooting

Original Project

202

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

203

Trouble Shooting

Original Project

204

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

205

Trouble Shooting

Original Project

206

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

207

Trouble Shooting

Original Project

208

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

209

Trouble Shooting

Original Project

210

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

211

Trouble Shooting

Original Project

212

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

213

Trouble Shooting

Original Project

214

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

215

Trouble Shooting

Original Project

216

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

217

Trouble Shooting

Original Project

218

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

219

Trouble Shooting

Original Project

220

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

221

Trouble Shooting

Original Project

222

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Error description:

© Festo Didactic GmbH & Co. • MPS

223

Trouble Shooting

Original Project

224

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

The following error within a program was not part of the programming projects. The Project-description is: If the Auto/Manu-switch is off a program FC1 shall be active, if the Auto/Manuswitch is on, a program FC2 shall be active. FC1 is a NOR-function with the Start-light (H1), the FC2 is a NAND-function with the Reset-light (H2). Use the Start- and Resetbutton as inputs. Error description:

© Festo Didactic GmbH & Co. • MPS

225

Trouble Shooting

Original Project

226

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

© Festo Didactic GmbH & Co. • MPS

227

Trouble Shooting

228

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

3.2

Process – Trouble Shooting

Please test the full process including all conditions. Find out which part of the process is not working properly and proceed with the steps: error detection, error limitation and error elimination. Please don’t forget to fill out the working-sheet of the part Execution and Documentation. The original project shall be Project 2.18. Information Besides Commissioning and Programming, the Trouble Shooting and Maintenance is one of the most important tasks in reality, because non-operating manufacturing units are causing high costs. It is much more important than in installation&commissioning or programming, to train operational steps to detect, limitate and eliminate an error as quick as possible. At Trouble Shooting there is one difference between so called “Commissioning Errors“ and “Maintenance Errors”. Both of them could be different in a way, there are NO wrong wirings, tubing’s as well as programming errors within the Maintenance Errors, because the system already has been running perfectly and an operational error had happened. Such operational errors could be: • • • •

break of wire defect of elements like valves, cylinders, motors, sensors, etc. ... break of program mechanical reasons

Procedure of error elimination divides into three important fields: • error detection • error limitation • error elimination which have to be documented respectively by the trainee on the attached work sheet. An example helps with the further procedure. Usually maintenance errors are easier to transform into manual training, therefore this Teachware is referring only on this field regarding the solutions of its exercises.

© Festo Didactic GmbH & Co. • MPS

229

Trouble Shooting

NOTICE:

230

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

/6.4 /6.4

9 8

-A2DI1

O6 -XG2

7

/6.4 /6.4 /6.4

-A2DI1

7 6 5

-A2DI1

I4 -XG2 I3

16 4

3

-XMG2

-XG2

-XMG2

4

-S5

3

17

-XK1

/6.4 /6.4 /6.4

-A2DI1

4 3

-A2DI1 -A2DI1

I2 -XG2 I1

14 -XMG2

4

3 -S2

-XG2

-XMG2

4

-S3

3

15

-S4

-A2DI1

24NA

COM/5.7

-S6

-XMG2

4

3

-A2DI1

0V/8.1

24V/8.1

In the following, there is a step-by-step explanation of a sample trouble shooting. This wiring diagram is not part of the technical documentation of the Distribution Station, but show a very good example how to measure an error step by step with different measuring methods.

© Festo Didactic GmbH & Co. • MPS

0V/6.8

24NA/6.8 24V/6.8

2

I0 -XG2

13 4

-XMG2

-S1

3

21

24VB -XG2

-XMG2

24V -XK1

Disconnection at START-Button S1

231

Trouble Shooting

Although the program is loaded to the PLC and normal position is reached (RESETLight flashing) the Station may not be started (RESET-Light not change to off). The starting condition is, that the Station is in normal position, which is indicated by flashing of the RESET-light. The reason for malfunction must be the START-button itself. Measuring of the current path No. 1 may be proceeded in different ways. In the following, two examples may be described, and both of them are leading to result. • measuring of voltage • measuring of continuity For better understanding, the current path No. 1 may be shown as an equivalent diagram:

disconnection XMG2 21

XMG2 13 A2DI1 2

XK1 24V 24V 0V 0V

232

R

PLC input

0V-clamp PLC-board

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Voltage test procedure 1. step:

0V

XMG2 21

XMG2 13 A2DI1 2

XK1 24V 24V

R

0V

PLCinput

0V-clamp PLC-board

0V

Voltage test procedure 2. step:

12V

XMG2 21

XMG2 13 A2DI1 2

XK1 24V 24V 0V 0V

R

PLCinput

0V-clamp PLC-board

Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken wiring

© Festo Didactic GmbH & Co. • MPS

233

Trouble Shooting

Continuity test 1. step:

R>

no continuity

XMG2 21

XMG2 13 A2DI1 2

XK1 24V

Attention: disconnect power supply !

R

PLCinput

0V

Continuity test 2. step:

0

continuity

disconnection XMG2 21

XMG2 13 A2DI1 2

XK1 24V

Attention: disconnect power supply !

R

PLCinput

0V

Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken wiring

234

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

The work-sheet for this example looks like: Order of Maintenance Name: Hellmich

Order-No: 001 310800

Location of Error: Distribution Station

Date: 31.08.2001 Sheet: 1 # 1

Error Detection After switch-on theair pressure and the PLC, the RESET-light is flashing, which means, that the system is in normal position Æ starting condition OK However, the station cannot be started by the Start-Button (RESET-light not change to off).

Error Limitation MECHANICAL: 1.

Is there a mechanical defect on the Start-button?

ELECTRICAL 1. Is the Start-button switching regularly? - Continuity test of switching contacts. 2. Is the signal of the button reaching the PLC? - Control by sight and voltage test.

Error Elimination REASON Break of wire (end sleeve) at the button at connection X. Attach new end sleeve to the wire and connect again. Control of total sequence = error eliminated.

Planning Please follow the description of the in instructor carefully step-by-step. Make a detailled plan of how you want to check the error location step-by-step.

© Festo Didactic GmbH & Co. • MPS

235

Trouble Shooting

Execution/Documentation Follow the three steps of Trouble Shooting carefully. Write down the single steps and all useful informations into the work-sheet. Please show your result first to the instructor before removing the error!!!!! Please ask your instructor for copies of this work-sheets!!! Order of Maintenance Name:

Order-No:

Date:

Location of Error:

Sheet: Error Detection

Error Limitation MECHANICAL:

ELECTRICAL

PNEUMATICAL

Error Elimination REASON

236

© Festo Didactic GmbH & Co. • MPS

Trouble Shooting

Controll After error elimination, please check the process again step-by-step carefully, there might be another error within the system.

© Festo Didactic GmbH & Co. • MPS

237