Festo

FMS50 Conveyor
MPS 2000
Trainee Edition
Festo Didactic GmbH & Co. MPS
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: did@festo.com
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
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
2.1
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
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
3.1
Program Trouble Shooting_________________________________200
3.2
Process Trouble Shooting _________________________________229
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:
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
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.
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)
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 technologyAND:
programming of the basic function AND
Basics in digital technologyOR:
programming of the basic function OR
Basics in digital technologyRS-Flip-Flop:
programming of the basic function RS-Flip-Flop
Basics in digital technologyAND NOT:
programming of the basic function AND NOT
Basics in digital technologyIDENTITY:
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 time for each approx.
3.1
198
Trouble Shooting
Process
Maintenance Trouble Shooting14 Process-Errorstime for each approx.
3.2
227
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
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
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.
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
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.
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 Frderung busfhiger Interfaces fr binre 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
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 mm) 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.
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.
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.
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
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 1s 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 1s 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.
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
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.
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
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
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)
Introduction
The functions of the LEDs 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
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)
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.
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
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 256271
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
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 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
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
PLC-Address
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
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
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
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
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:
t0t1 acceleration
t1t2 maximum speed
t2t3 deceleration
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
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
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
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.
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
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:
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)
40
Introduction

tup total = P1130 + X*P1120 + P1131

tdown total = P1132 + X*P1121 + 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.
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
Parameter filter
P0004
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
Minimum frequency [Hz]
P1080
50
Maximum frequency [Hz]
P1082
60
50
Ramp-up time [s]
P1120
10
Ramp-down time [s]
P1121
10
The parameters P1001 until P1005 (fixed frequency) representing a frequency frame,
where the parameters P1080 and P1082 can be changed within.
42
Introduction
Example to adjust the conveyor speed

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
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.
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.
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.
46
Commissioning
47
Commissioning
48
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
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
49
Commissioning
Standard configuration of the FMS50:
1.
Conveyor station number 1
2.
3.
4.
5.
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
(1.16.1 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
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.
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
IN2
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
IN4
I66.7
01_Co_I4
OUT1
Q66.4
01_Co_Q1
Station 1- Comm.output 1
OUT2
Q66.5
01_Co_Q2
OUT3
Q66.6
01_Co_Q3
Station 1-Comm. output 3
OUT4
Q66.7
01_Co_Q4
51
Commissioning
I/O Station 2
Slave
05
Module
Funct.
Ident.
Addr.
IN1
B20.1
I66.0
Symbol
Description
02_Palav
IN2
06
07
IN3
B20.3
I66.2
02_Wpav
IN4
B20.4
I66.3
02_Wpcou
IN1
B20.5
I67.4
02_Strel
IN2
OUT1
Y20.1
Q67.6
02Stopre
I67.0
02_Co_I1
IN1
IN2
Not used
IN3
I67.2
02_Co_I3
IN4
I67.3
02_Co_I4
OUT1
Q67.0
02_Co_Q1
OUT2
Q67.1
02_Co_Q2
OUT3
Q67.2
02_Co_Q3
OUT4
Q67.3
02_Co_Q4
Symbol
Description
I/O Station 3
Slave
08
Module
Funct.
Ident.
Addr.
IN1
B30.1
I68.4
03_Palav
IN2
B30.2
I68.5
03_Cong
IN3
09
10
IN4
B30.4
I68.7
03_Wpcou
IN1
B30.5
I68.0
03_Strel
IN2
OUT1
Y30.1
Q68.2
03Stopre
IN1
I69.4
03_Co_I1
IN2
I69.5
03_Co_I2
IN3
52
Not used
IN4
I69.7
03_Co_I4
OUT1
Q69.4
03_Co_Q1
OUT2
Q69.5
03_Co_Q2
OUT3
Q69.6
03_Co_Q3
OUT4
Q69.7
03_Co_Q4
Commissioning
I/O Station 4
Slave
11
Module
Funct.
Ident.
Addr.
Symbol
Description
IN1
B40.1
I69.0
04_Palav
IN2
B40.2
I69.1
04_Cong
IN3
B40.3
I69.2
04_Wpav
IN4
12
13

IN1
B40.5
I70.4
04_Strel
IN2
OUT1
Y40.1
Q70.6
04Stopre

Not used
IN1
I70.0
04_Co_I1
IN2
I70.1
04_Co_I2
IN3
I70.2
04_Co_I3
OUT1
Q70.0
04_Co_Q1
OUT2
Q70.1
04_Co_Q2
OUT3
Q70.2
04_Co_Q3
OUT4
Q70.3
04_Co_Q4
Addr.
Symbol
Description
IN4
I/O Station 5
Slave
14
15
16
Module
Funct.
Ident.
IN1
IN2
B50.2
I71.5
05_Cong
IN3
B50.3
I71.6
05_Wpav
IN4
B50.4
I71.7
05_Wpcou
IN1
B50.5
I71.0
05_Strel
IN2
OUT1
Y50.1
Not used
Q71.2
05Stopre
IN1
I72.4
05_Co_I1
IN2
I72.5
05_Co_I2
IN3
I72.6
05_Co_I3
IN4
I72.7
05_Co_I4
OUT1
OUT2
Q72.5
05_Co_Q2
OUT3
Q72.6
05_Co_Q3
OUT4
Q72.7
05_Co_Q4
53
Commissioning
I/O Station 6
Slave
17
Module
Funct.
Ident.
Addr.
IN1
B60.1
I72.0
Symbol
Description
06_Palav
IN2
18
19
IN3
B60.3
I72.2
06_Wpav
IN4
B60.4
I72.3
06_Wpcou
IN1
B60.5
I73.4
06_Strel
IN2
OUT1
Y60.1
Q73.6
06Stopre
Not used
IN1
I73.0
06_Co_I1
IN2
I73.1
06_Co_I2
IN3
I73.2
06_Co_I3
IN4
I73.3
06_Co_I4
OUT1
Q73.0
06_Co_Q1
OUT2
OUT3
Q73.2
06_Co_Q3
OUT4
Q73.3
06_Co_Q4
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.
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
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
55
Commissioning
Standard configuration of the FMS50:
1.
2.
3.
4.
5.
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
(1.16.1 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
Commissioning
NOTICE:
Planning
and at the slaves directly.
Please complete the list of the inputs and outputs of your station.
I/O Station 1
Slave
02
03
04
Module
Funct.
Ident.
Addr.
Symbol
IN2
B10.2
I65.5
01_Cong
IN3
B10.3
I65.6
01_Wpav
IN4
B10.4
I65.7
01_Wpcou
IN1
Description
IN1
IN2
OUT1
Y10.1
Q65.2
X
01Stopre
Not used
IN1
IN2
I66.5
01_Co_I2
IN3
I66.6
01_Co_I3
IN4
I66.7
01_Co_I4
OUT1
Q66.4
01_Co_Q1
OUT2
Q66.5
01_Co_Q2
OUT3
Q66.6
01_Co_Q3
OUT4
Q66.7
01_Co_Q4
57
Commissioning
I/O Station 2
Slave
05
Module
Funct.
Ident.
Addr.
IN1
B20.1
I66.0
Symbol
Description
02_Palav
IN2
06
IN3
B20.3
I66.2
02_Wpav
IN4
B20.4
I66.3
02_Wpcou
IN1
B20.5
I67.4
02_Strel
IN2
OUT1
07
IN1
IN2
Not used
I67.0
02_Co_I1
IN3
I67.2
02_Co_I3
IN4
I67.3
02_Co_I4
OUT1
OUT2
Q67.1
02_Co_Q2
OUT3
Q67.2
02_Co_Q3
OUT4
Q67.3
02_Co_Q4
Symbol
Description
I/O Station 3
Slave
08
Module
Funct.
Ident.
Addr.
IN1
B30.1
I68.4
03_Palav
IN2
B30.2
I68.5
03_Cong
IN3
IN4
09
IN1
IN2

B30.4
I68.7
03_Wpcou

X
OUT1
10
Not used
IN1
I69.4
03_Co_I1
IN2
I69.5
03_Co_I2
IN3
I69.6
03_Co_I3
IN4
58
OUT1
Q69.4
03_Co_Q1
OUT2
Q69.5
03_Co_Q2
OUT3
Q69.6
03_Co_Q3
OUT4
Q69.7
03_Co_Q4
Commissioning
I/O Station 4
Slave
11
12
13
Module
Funct.
Ident.
Addr.
Symbol
Description
IN1
B40.1
I69.0
04_Palav
IN2
B40.2
I69.1
04_Cong
IN3
B40.3
I69.2
04_Wpav
IN4
IN1
IN2
OUT1
Y40.1
Q70.6
04Stopre
Not used
IN1
I70.0
04_Co_I1
IN2
I70.1
04_Co_I2
IN3
I70.2
04_Co_I3
IN4
OUT1
OUT2
Q70.1
04_Co_Q2
OUT3
Q70.2
04_Co_Q3
OUT4
Q70.3
04_Co_Q4
Symbol
Description
I/O Station 5
Slave
14
15
Module
Funct.
Ident.
Addr.
IN1
B50.1
I71.4
05_Palav
IN2
B50.2
I71.5
05_Cong
IN3
B50.3
I71.6
05_Wpav
IN4
B50.4
I71.7
05_Wpcou
IN1
B50.5
I71.0
05_Strel
IN2
OUT1
16
Not used
IN1
I72.4
05_Co_I1
IN2
I72.5
05_Co_I2
IN3
I72.6
05_Co_I3
IN4
I72.7
05_Co_I4
OUT1
Q72.4
05_Co_Q1
OUT2
Q72.5
05_Co_Q2
OUT3
Q72.6
05_Co_Q3
OUT4
59
Commissioning
I/O Station 6
Slave
17
18
Module
Funct.
Ident.
Addr.
Symbol
Description
IN1
B60.1
I72.0
06_Palav
IN2
B60.2
I72.1
06_Cong
IN3
B60.3
I72.2
06_Wpav
IN1
IN2
OUT1
19
IN4
Not used
IN1
IN2
I73.1
06_Co_I2
IN3
I73.2
06_Co_I3
IN4
I73.3
06_Co_I4
OUT1
Q73.0
06_Co_Q1
OUT2
Q73.1
06_Co_Q2
OUT3
Q73.2
06_Co_Q3
OUT4
Q73.3
06_Co_Q4
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
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.
direction of movement
NOTICE:
61
Commissioning
Planning
and at the AS-I-slaves. Check the adjustment of the mechanical components first.
Check the connection of the Emergency Stop system.
Write down the single steps and all useful informations. Write down your single
steps you did to proceed.
Step No.:
62
Description
Check
check the adjustment of mechanical components
check the adjustment of mechanical actuators holder
check the mechanical position of hand over to the next station
cable connections (Emergency, I/O-communication)
connect all power supplies
check the adjustment of sensor holders
check the adjustment of sensors in the holders
check the adjustment of sensitivity of sensor
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
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
63
Commissioning
I/O-communication 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
Commissioning
I/O-communication 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
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 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
Commissioning
I/O-communication 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 stationsorders (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
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 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
Commissioning
I/O-communication 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:
69
Commissioning
Planning
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.
Write down the single steps and all useful informations. Write down your single
steps you did to proceed.
Step No.:
70
Description
Check
check the adjustment of mechanical components
check the adjustment of mechanical actuators holder
check the mechanical position of hand over to the next station
cable connections (Emergency, I/O-communication)
connect all power supplies
check the adjustment of sensor holders
check the adjustment of sensors in the holders
check the adjustment of sensitivity of sensor
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
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.
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 dont 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
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.
73
Commissioning
File Open Browse (select subdirectory example here D:\Eigene

Dateien\Eigene Daten\Teach_gb\Festo\MPS_Conveyor FMS50) FMS50 OK (left
mouse button)
74
Commissioning
(click with the left mouse button onto the project Conveyor) PLC Download
(follow the instructions on the screen to download the project after download is
finish, switch the CPU-switch to RUN and test the program)
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, lets 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 +CPU313C-2DP +S7 xxxConveyorxxx BlocksBausteine
76
Commissioning
DB1 (double click) View Data View
77
Commissioning
(Move to the top end of the list and refer to the numbers mentioned at IX1IX8).
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
111
IX4
Byte
B#16#0
B#16#4
112
IX5
Byte
B#16#0
B#16#5
113
IX6
Byte
B#16#0
B#16#6
114
IX7
Byte
B#16#0
B#16#0
115
IX8
Byte
B#16#0
B#16#0
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 16 has nothing to do with the conveyor station
number IX1IX8
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
109
IX2
Byte
B#16#0
B#16#0
110
IX3
Byte
B#16#0
B#16#4
111
IX4
Byte
B#16#0
B#16#5
112
IX5
Byte
B#16#0
B#16#0
113
IX6
Byte
B#16#0
B#16#6
114
IX7
Byte
B#16#0
B#16#0
115
IX8
Byte
B#16#0
B#16#0
Commissioning
(If you changed the variables, which you should not do within the entire conveyor
program, please save the DB1) File Save
81
Commissioning
(and download the new DB1 into the PLC) PLC Download (follow the messages
on the screen)
82
Commissioning
(and close the window) File Exit
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 Monitor/Modify Variables
84
Commissioning
Table Open
85
Commissioning
(make sure that the BlocksBausteine of the Conveyor station is open left window)
TreiberDriver Control OK
86
Commissioning
(here you can see which MPS-station is connected to which conveyor station. After
viewing, please exit the window) Table Exit
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
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. Its 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.
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 New (type Name: P2_01_Co) OK
89
Programming
Insert Station SIMATIC 300 Station
90
Programming
+ P2_01_Co SIMATIC 300(1) Hardware (double click)
91
Programming
+ SIMATIC 300 + RACK-300 Rail (double click)
92
Programming
(Click on Slot 2) - RACK 300 + CPU-300 + CPU 313C-2DP 6ES7 3136CE00-0AB0 (depends on the CPU you use check the order no. on the front left
below corner of the CPU) (double click) (we dont use any networking like MPI
or Profibus-DP at the moment, thats why not networked is ok) OK
93
Programming
CPU 313C-2DP (at the Slot 2 double click) Cycle/Clock Memory Clock
Memory 100 (Memory Byte free definition)
94
Programming
Retentive Memory 0 (Number of Memory Bytes Starting with MB0) 0 (Number

of S7 Timers Starting with T0) 0 Number of S7 Counters Starting with C0) OK
95
Programming
(Click on Slot 4) - CPU-300 + CP-300 + AS-Interface 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) (double click)
96
Programming
- SIMATIC 300 Station Save and Compile
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 256271 to the standardized addresses 6479 used within
the S5 PLCs, you please proceed like shown into the screen shot) CP 342-2 (Slot
4 double click) Addresses (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)
OK
PLEASE DONT PROCEED TO CHANGE THE ADDRESSES TO 6479
98
Programming
PLC Download (follow the instructions on the screen to download the hardware
configuration)
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 Exit
100
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.
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 (6479).
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

PID268
ID76

L
T
L
T
L
T
QD64
PQD256
QD68
PQD260
load output double word 64

transfer to peripheral output-double word 256
QD76
PQD268

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
Programming
Execution
(After closing the Hardware configuration window) +SIMATIC 300(1)

+CPU 313C-2DP +S7 Program(1) Blocks (double click on OB1)
103
Programming
OK
104
Programming
(Edit the program like shown within the screen shot)
105
Programming
File Save File Exit
106
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 didnt 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:
107
Programming
108
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:
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
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, dont 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) 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.
111
Programming
Execution
Copy the project P2_01 into the new project P2_02 with the command Save as.
(Click on P2_01_Co) File Save as (type the new name P2_02_Co) OK
112
Programming
113
Programming
Edit the symbol table with the symbol editor
+P2_02_Co +SIMATIC 300(1) +CPU 313C-2DP S7 Program(1) Symbols

(double click) (edit all symbols and hardware addresses for all stations)
114
Programming
(After editing all stations) File Save File Exit
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) Blocks Insert Function
116
Programming
(Type in the name of the FC) FC5 (choose the correct programming language) FBD
OK
117
Programming
(Double click onto OB1) (click on Network 2) Insert Network
118
Programming
(Edit Network 3 like shown in the screen shot) File Save File Exit
119
Programming
Editing the FC5 with the AND-function
(After editing) File Save (no error message) File Exit

This procedure is always the same after editing a program its not mentioned
anymore!!!
120
Programming
Block PLC Download (its 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
its 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
121
Programming
(Re-open FC5 by double click on it) Debug Monitor (you can see the
function of the logic online on the monitor. Please switch the monitor mode off again
before exit the program) Debug Monitor File Exit
122
Programming
2.3
Programming
Basics in Digital
Technology OR

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:
123
Programming
124
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, dont 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.
Program OB1:
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
Programming
2.4
Programming
Basics in Digital
Technology RSFlip-Flop

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:
127
Programming
128
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, dont forget to delete the contents of the PLC using the CPU-switch.
Program OB1 is the same than for project before. Program FC1
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
Programming
2.5
Programming
Basics in Digital
Technology AND
NOT

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.
131
Programming
Program OB1
132
Programming
Program FC10
Controll
Watch FC10 with the online-function (description see Project 2.4).
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.
134
Programming
Program OB1
135
Programming
Program FC1
Controll
Watch FC1 with the online-function.
136
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?
137
Programming
Program OB1
138
Programming
Program FC8
Controll
Watch the function of the FC with the online-function.
This control step will be the same for all the following projects, so its not
mentioned in each project anymore.
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 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,
dont forget to delete the contents of the PLC from the computer. Edit the project
(programs) on a sheet of paper first.
140
Programming
Program OB1
Program FC8 is the same than for the project before.
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
its 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
Programming
Program OB1
143
Programming
Help functions in Step 7
+ Timers S_ODT (F1 opens the help function and you can see a description of
the timer)
144
Programming
Program FC1
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
all timers and choose the right timer for your project. Edit on a sheet of paper first.
146
Programming
Program FC1, the program OB1 is the same than for the project before
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
language for FC1 should be FBD, for OB1 STL. Use Counter 1 for this project.
NOTICE:
Planning
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
Programming
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.
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
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 .
150
Programming
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 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.
152
Programming
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
Programming
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
156
Programming
157
Programming
158
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
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
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
Programming
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
Output
12 VDC 0 V
Input
Output
161
Programming
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
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.
163
Programming
This drawing is an example for the communication between the Testing station
and the conveyor.
164
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.
165
Programming
2.18
Project
Communication via
Profibus-DP
This project combines two PLCs via Profibus-DP, if corresponding PLCs 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
Programming
Planning
Please work out the theory of Fieldbus technology together with the Instructor first.
Please connect both Profibus-DP interfaces and the PCs with the PLCs 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. .
167
Programming
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 New (type in the name P2_18_Co) OK Insert Subnet

2 PROFIBUS
168
Programming
Insert Station 2 SIMATIC S7-300 (change the name to Slave)
169
Programming
(Click on the project P2_18_Co) Insert Station 2 SIMATIC S7-300

(change the name to Master)
170
Programming
Hardware configuration of the DP-Slave
(Click on Slave) Hardware (double click) +SIMATIC 300 +RACK-300 Rail

(double click)
171
Programming
(Click on Slot 2) -RACK-300 +CPU-300 +CPU 313C-2DP 6ES7 3136CE00-0AB0 (double click) PROFIBUS(1) 4 (Profibus-DP address) OK
172
Programming
CPU 313C-2DP (Slot 2 double click) Cycle/Clock Memory (click on Clock

memory) 100 (Memory Byte)
173
Programming
Retentive Memory (type in 0 like shown within the screen shot) OK
174
Programming
DP (Slot X2 double click) DP-Slave (type in the name)
175
Programming
Operating Mode (click on DP-Slave)
176
Programming
Configuration New (Address type choose Input) 40 (Address) Apply
177
Programming
New (Address type choose Output) 40 Apply Close
178
Programming
Station Save and Compile (follow the screen) Station Exit

The Slave team must download the hardware configuration into the Slave PLC before
exit.
179
Programming
Insert OB82 and FC1 into the Slave
+Slave +CPU 313C-2DP +S7 Program(1) Blocks Insert S7-Block

Organisation Block OB82 (type in the Name) (choose STL) 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
Programming
Insert S7-Block Function FC1 (type in the name) (choose FBD) OK
181
Programming
Edit FC1 of the Slave
(Edit the program like shown within the screen shot) File Save File Exit
182
Programming
Hardware configuration of the Master
(Click on the Master station) Hardware (double click) +SIMATIC 300

+RACK-300 Rail (double click)
183
Programming
(Click on Slot 2) -RACK-300 +CPU-300 +CPU 313C-2DP

6ES7 313-6CE00-0AB0 (double click) PROFIBUS(1) 2 (type in the address)
OK
184
Programming
CPU 313C-2DP (Slot 2 double click) Cycle/Clock Memory (click on Clock

memory) 100 (type in the Memory Byte)
185
Programming
Retentive Memory (type in 0 like shown within the screen shot) OK
186
Programming
DP (Slot X2 double click) DP-Master (type in the name)
187
Programming
Operating Mode (check if the DP-Master is active) OK
188
Programming
(Click on the line PROFIBUS(1) DP master system(1)) - SIMATIC 300

+PROFIBUS DP +Configured Stations CPU 31x (double click) Connect
OK
189
Programming
(Double click on the symbol of the Slave CPU) Configuration (click onto line 1)
Edit
190
Programming
(Choose address type Output) 40 (type in the address) Apply
191
Programming
(Click on line 2) Edit (choose address type Input) 40 (type in the address)
Apply Close Station Save and Compile Station Exit
The Master team must download the hardware configuration into the Master PLC
before exit.
192
Programming
Copy Symbols and OB1 from the project before and insert OB82
File Open (choose the project P2_17_Co) OK +P2_17_Co

+SIMATIC 300(1) +CPU 313C-2DP S7 Program(1) +P2_18_Co +Master
+CPU 313C-2DP Symbols (right mouse button in the project P2_17_Co)
Copy
193
Programming
S7 Program(2) (in the project P2_18_Co) (right mouse button) Paste
194
Programming
+S7 Program(1) (in the project P2_17_Co) Blocks (right mouse button click
onto OB1) Copy
195
Programming
+S7 Program(2) (in the project P2_18_Co) (right mouse button) Paste OK
196
Programming
Insert S7-Block Organisation Block OB82 (type in the name) (choose

STL) OK
197
Programming
Insert S7-Blocks Function FC1 (type in the name) (choose FBD) OK
198
Programming
Edit of FC1, the OB1 is the same than in the project before
(Edit the program like shown within the screen shot) File Save File 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.
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.
200
Trouble Shooting
Error description:
201
Trouble Shooting
Original Project
202
Trouble Shooting
Error description:
203
Trouble Shooting
Original Project
204
Trouble Shooting
Error description:
205
Trouble Shooting
Original Project
206
Trouble Shooting
Error description:
207
Trouble Shooting
Original Project
208
Trouble Shooting
Error description:
209
Trouble Shooting
Original Project
210
Trouble Shooting
Error description:
211
Trouble Shooting
Original Project
212
Trouble Shooting
Error description:
213
Trouble Shooting
Original Project
214
Trouble Shooting
Error description:
215
Trouble Shooting
Original Project
216
Trouble Shooting
Error description:
217
Trouble Shooting
Original Project
218
Trouble Shooting
Error description:
219
Trouble Shooting
Original Project
220
Trouble Shooting
Error description:
221
Trouble Shooting
Original Project
222
Trouble Shooting
Error description:
223
Trouble Shooting
Original Project
224
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:
225
Trouble Shooting
Original Project
226
Trouble Shooting
227
Trouble Shooting
228
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 dont 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, tubings 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.
229
Trouble Shooting
NOTICE:
230
Trouble Shooting
/6.4
/6.4
9
8
-A2DI1
O6
-XG2
/6.4
/6.4
/6.4
-A2DI1
7
6
5
-A2DI1
I4
-XG2
I3
16
4
-XMG2
-XG2
-XMG2
-S5
17
-XK1
/6.4
/6.4
/6.4
-A2DI1
4
3
-A2DI1
-A2DI1
I2
-XG2
I1
14
-XMG2
3
-S2
-XG2
-XMG2
-S3
15
-S4
-A2DI1
24NA
COM/5.7
-S6
-XMG2
-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.
0V/6.8
24NA/6.8
24V/6.8
I0
-XG2
13
4
-XMG2
-S1
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
PLC
input
0V-clamp
PLC-board
Trouble Shooting
Voltage test procedure 1. step:
0V
XMG2
21
XMG2
13
A2DI1
2
XK1
24V
24V
0V
PLCinput
0V-clamp
PLC-board
0V
Voltage test procedure 2. step:
12V
XMG2
21
XMG2
13
A2DI1
2
XK1
24V
24V
0V
0V
PLCinput
0V-clamp
PLC-board
Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken
wiring
233
Trouble Shooting
Continuity test 1. step:
R>
no continuity
XMG2
21
XMG2
13
A2DI1
2
XK1
24V
Attention:
disconnect
power supply !
PLCinput
0V
Continuity test 2. step:
continuity
disconnection
XMG2
21
XMG2
13
A2DI1
2
XK1
24V
Attention:
disconnect power supply !
PLCinput
0V
Result: disconnection must be located between clamp XMG2 and A2DI1-2= broken
wiring
234
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
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.
235
Trouble Shooting
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
Trouble Shooting
Controll
After error elimination, please check the process again step-by-step carefully, there
might be another error within the system.
237

Festo

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Festo

Загружено:

Авторское право:

Доступные форматы

FMS50 Conveyor

Festo Didactic GmbH & Co. MPS

Mechatronics Teachware FMS50 Conveyor MPS 2000

Wolfgang Eckart, Intercon-Asia

Wolfgang Eckart, Festo Didactic GmbH & Co

Festo Didactic GmbH & Co

Festo Didactic GmbH & Co., D-73770 Denkendorf, 2004

Table of Contents _______________________________________________________ 1

Festo Didactic GmbH & Co. MPS

Frequency converter general informations _____________________________ 33

Analysis Components identification__________________________44

Analysis Emergency Stop system ____________________________46

Analysis Input and Output adresses __________________________49

Analysis Input and Output adresses expanded _________________ 55

Commissioning Adjustment of the Station _____________________ 61

Commissioning Adjustment of the Station expanded ____________ 63

Commissioning Download Project and Test ___________________ 71

Commissioning Driver Control ______________________________ 76

Commissioning Online check of the Driver Control______________84

Programming Hardware-configuration ________________________ 88

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

Programming Basics in Digital Technology AND ______________107

Programming Basics in Digital Technology OR _______________123

Programming Basics in Digital Technology RS-Flip-Flop _______127

Programming Basics in Digital Technology AND NOT__________131

Programming Basics in Digital Technology IDENTITY __________134

Programming Condition Call of a Program ____________________137

Programming Condition Call of a Program expanded ___________140

Programming On-Delay-Timer function ______________________142

Festo Didactic GmbH & Co. MPS

Programming Off-Delay-Timer function ______________________146

Programming Counter Down function________________________148

Programming Programming of a Flashlight ___________________150

Programming Programming of a Auto/Manu sequence__________152

Programming Conveyor movement__________________________154

Programming Conveyor movement expanded _________________156

Project Basics of I/O communication _______________________159

Project Test the I/O communication ________________________163

Project Communication via Profibus-DP _____________________166

Trouble Shooting _____________________________________________________200

Festo Didactic GmbH & Co. MPS

Program Trouble Shooting_________________________________200

Process Trouble Shooting _________________________________229

Mechatronics is a comprehensive combination of Technologies and is mostly

Festo Didactic GmbH & Co. MPS

Totally Integrated System

Partly Integrated Systems

Festo Didactic GmbH & Co. MPS

Analyse a system, Installation&Commissioning

Programming single Station, Communication with other Stations

Trouble Shooting: Programming Errors, Trouble Shooting in the Process

which are covered within the following projects.

Festo Didactic GmbH & Co. MPS

Analysis (Analyse a system) and

Programming (Programming single Station and

Trouble Shooting: Program (Programming Errors) and

Festo Didactic GmbH & Co. MPS

Project overview Commissioning and Programming

Error in Project 2.2 2.13 time for each approx.

Maintenance Trouble Shooting14 Process-Errorstime for each approx.

Festo Didactic GmbH & Co. MPS

Theory of Actuator Sensor

Festo Didactic GmbH & Co. MPS

Nowadays, in complex systems with big amounts of input/output signals, it is no