MPS500_Manual_AS_RS_S7_A003.pdf

MPS 500
Manual
AS-RS
Order-NR.:
Type: Manual MPS500
Designation MPS500_AS_RS_S7_A003
Printed: 11.05.2006
Autor: Schober
Graphics: Schober
Layout: Schober
© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2006
Internet: www.festo.com/didactic
e-mail: did@festo.com
This manual, all text and illustrations contained included, is protected by copyright. Any utilization
outside the limits of the copyright law and other than training purposes are not permissible without
our definite approval. This applies in particular to reproductions, operations, translations, micro
filming and the storing and processing into electronic systems. Parts of this manual may be copied by
the authorized user, exclusively for teaching purposes. Distribution of this documentation, as well as
reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences
are liable to compensation. All rights reserved, especially the right to execute registrations concerning
patents, designs for use and patterns.
2 © Festo Didactic GmbH & Co.KG • MPS500

1. Intended use
The User Manual must be to hand at all times. Keep it close to the machine.
This installation was developed and manufactured only for use in basic and further
training in the fields of automation and communications. The training company
and/or the training staff must ensure that the trainees observe the safety
precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations.
It contains all information and data required for commissioning, maintenance and
operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training
company and/or any third parties occurring when the installation is used for any
purpose apart from training, except Festo Didactic has caused such injury or harm
intentionally or by grossly negligence.
The manual is divided into four parts:
• Part A
In addition to technical data, Part A contains an overview of the possible uses of
the stations.
• Part B
Part B contains some exercises and the solutions for this exercises (Not available
for each station).
• Part C
Part C contains the pneumatic and electrical diagrams for the station and the
listing of the control programs (Not available for each station).
• Part D
Part D contains data sheets and technical information about the electrical and
electronic modules used.
© Festo Didactic GmbH & Co.KG • MPS500 3

List of applicable standards The list below provides an overview of the most important standards and
and regulations regulations relating to mechanical, electrical and safety-engineering design and
production.
• DIN EN 292 -Machine safety

• DIN EN 60204 - Electrical equipment of industrial machines
• DIN VDE 0113 - See DIN EN 60204
• DIN 40719 - Circuit documentation
• VDI 2853 - Technical safety requirements concerning the building, equipping and
operation of industrial robots
• VDI 2853 - Technical safety requirements concerning automated production
systems
• VDI 2411 - Terms and explanations in conveying and handling
• VDI 2860 - Assembly and robotics - terms
• VDI 2861 - Assembly and robotics - characteristic quantities
• DIN 19245 - PROFIBUS Part 1-3
As far as possible, the System is maintenance-free. All bearings are lubricated for
life. The installation was designed in such a way as to keep the number of wearing
parts to a minimum. This does not include machines that are part of optional
expansions (such as industrial robots).
At this point we would like to point out that this manual and the concept of the
operating instructions for a Flexible Training System of this type are regularly
updated. To ensure that the instructions are ever more user-friendly, you would help
us a great deal by passing on your suggestions for improvement. Please let us know
of your suggestions, corrections or ideas, either in writing or via telephone:
+49(711-3467-0)

Contents
1. Intended use ___________________________________________________ 3
2. Introduction ____________________________________________________ 9
2.1. General______________________________________________________ 9
2.2. AS-RS station________________________________________________ 10
2.3. Didactic structure ____________________________________________ 11
2.4. Scope of tasks of the stations __________________________________ 12
2.4.1. Mechanics ______________________________________________ 12
2.4.2. Pneumatics _____________________________________________ 12
2.4.3. Electrics ________________________________________________ 12
2.4.4. Informatics______________________________________________ 12
2.4.5. Bus technology __________________________________________ 12
3. General safety instructions _______________________________________ 13
3.1. Use according to regulations ___________________________________ 13
3.2. Handling the system __________________________________________ 13
3.2.1. Dangers in handling the machine ____________________________ 13
3.2.2. Safety precautions in standard operation _____________________ 13
3.2.3. Dangers due to electric current _____________________________ 14
3.2.4. Dangers due to pneumatic energy ___________________________ 14
3.2.5. Maintenance – Servicing – Malfunction removal ________________ 15
3.2.6. Organisational measures __________________________________ 15
3.3. Personnel___________________________________________________ 15

Contents
3.3.1. Notes on personnel _______________________________________ 15
3.3.2. Training operations _______________________________________ 15
3.3.3. Outside training operations ________________________________ 15
3.3.4. Safety symbols __________________________________________ 16
4. Commissioning ________________________________________________ 17
4.1. Transport ___________________________________________________ 17
4.2. Set up______________________________________________________ 18
4.2.1. General information ______________________________________ 18
4.3. Commissioning ______________________________________________ 21
4.3.1. Pneumatic commissioning _________________________________ 21
4.3.2. Electric commissioning ____________________________________ 21
4.3.3. Establishing communication connections _____________________ 22
4.3.4. EMERGENCY-STOP system _________________________________ 23
4.4. Start-up process general_______________________________________ 24
5. Operation_____________________________________________________ 25
5.1. General operation notes _______________________________________ 25
5.1.1. Behaviour rules __________________________________________ 25
5.1.2. Operation rules __________________________________________ 25
5.2. Process description___________________________________________ 26
5.2.1. AS-RS station____________________________________________ 26
5.3. Operation panel______________________________________________ 27
5.4. Reset mode _________________________________________________ 28

Contents
5.5. Automatic mode _____________________________________________ 28
5.5.1. Start automatic mode _____________________________________ 28
5.5.2. Stop automatic mode _____________________________________ 28
5.6. Commissioning – homing and Reference position of the X- and Z-axis _ 29
5.7. Teach mode _________________________________________________ 35
5.7.1. Example teach a position __________________________________ 42
5.7.2. Load positions into controller_______________________________ 42
6. Technology ___________________________________________________ 43
6.1. drawings ___________________________________________________ 43
6.2. Modules in use ______________________________________________ 44
6.2.1. workpiece reception ______________________________________ 44
6.2.2. Handling________________________________________________ 46
6.3. Technical datas ______________________________________________ 47
7. Electrical system _______________________________________________ 49
7.1. Power supply ________________________________________________ 49
7.2. Controller ___________________________________________________ 50
7.2.1. Controller design S7 ______________________________________ 50
7.3. Wiring______________________________________________________ 51
7.3.1. I/O-Components _________________________________________ 51

Contents

2. Introduction
2.1. General This manual describes the handling of a MPS 500 system. It contains explanations
and descriptions of all the processes required for operation. Facts are partly
described with the help of graphics or images subserving an easier understanding.
The MPS 500 system is a successively expandable system consisting of individual

stations. However, the central unit is always the transport system.
Operation is not dependant on the operating position the material flow is being
started from conveyor system. Still, the sequential order of the stations requires
adherence, as it is pre-defined in the SPS-program.
The MPS 500 system is designed in such a way, that the amount and kind of
attached MPS-stations attached is not important. A complete processing cycle of the
work-piece is always warranted. Therefore, the transport system is required under
any circumstances.
In complete set-up, the work-piece is seperated from the distribution station to be

transfered to the testing station. The testing station checks the condition of the
work-pieces, ejects junk in case of occurrence and transfers the faultless pieces to
the transport system. Consequently, the product input into the system takes place
from the distribution station. In case the distribution station does not exist in the
system, the work-piece can be placed onto a work-piece carrier, anywhere in the
system. It is to be noted that no work-piece carriers should be extracted/removed
from the system.
The processing station is loaded a PIC-alfa station. The work-piece receives
processing, followed by testing. The PIC-alfa station returns the work-piece to the
transport system.
The work-piece is tested for shape tolerance in the vision station.
The robot station assembles a model cylinder from a basic body.
The AS/RS station is able to store work-pieces and, on demand, returns them to the
system.
In the sorting/commissioning station the work-pieces can be re-retrieved from the
system. The work-pieces are transported from the transport system to the sorting
station by a PIC-alfa station, where the work-pieces are arranged according to
colour, ready for product output. From the commissioning station the work-pieces
are not released by colour, but by the number of pieces. Each time 18 pieces are
commissioned. The three upper slides are on stand-by for the work-pieces, the
fourth slide is for parts storage in the adjustment process.

Introduction
2.2. AS-RS station The automatic storage/retrieval system is designed to store, retrieve and relocate
workpieces.
The operation of the AS/RS is possible at the controlpanel at the basic rack of the
station.
The automaticmode is started with the Start push button, the process controll is
done by the transport system.
The storage system must be empty before starting the station.
The control for the station is put in the basic rack of the station.

Introduction
2.3. Didactic structure The installation is structured, to enable methodical learning, i.e. from single use of
modules to the complex and complete installation. Perhaps even in combination
with further systems.
For example, it is possible to pick out a single module to start with the first steps,
e.g. the robot.
• First the mechanical assembly is considered. The robot’s radius of action

requires integration into the location of the robot.
• The following step could be the connection of all cables required for operation
and the set-up of the robot.
• Moving the robot and teaching the required positions are the first real operations
with the robot, which introduces the user how to deal with the teach-box.
• The robot’s programming can be started, as soon as the robot can be moved by
the teach-box. Small programs, which can be created by using the
Cosimir/Cosirob software, are expandable for the complex programs.
• Orders to further stations and from other controls can be installed in the
programs.
Once the learning process of this module has been concluded, these learning steps
can be transferred to the next module. As soon as all of the modules have been
processed individually, the modules can be interconnected and the programs can be
adapted. A complete production process can be simulated.
This is an ideal training area for the professional practice of mechatronis, as well as
all of the technical ranges (mechanical, electrical and pneumatic processes) are
represented in a simple and clearly way, concerning each one of the modules and
the complete system.

Introduction
2.4. Scope of tasks of the The stations are possessing a varied range of functions. A small extraction of the
stations various possibilities of the stations follows.
2.4.1. Mechanics
• Obtaining basic mechanical skills about the assembly of basic modules

• Obtaining complex mechanical skills about the assembly of a complete station or
complex modules
• Assembly provides instructions about the technical connections between the
various components
2.4.2. Pneumatics
• Understanding of a pneumatic circuit by set-up and pipe connection of the

cylinders and valves
2.4.3. Electrics
• Obtaining electrical knowledge of reading a circuit diagram, concerning the

wiring of sensors and valves
• Functional understanding of the individual modules e.g. in case of error
detection, by means of a circuit diagram and a measuring device
2.4.4. Informatics
• Understanding of programs receiving an insight by controlling the individual

components of the programs
• Changing and improving programs recognising and removing errors in a
complete program
• Writing new programs new programs can be written by combination of the skills
obtained in the steps before.
2.4.5. Bus technology
• Instructions in the various bus technologies avoidance to gain intimate

knowledge about the various bus technologies is made impossible by working
with the programs

3. General safety instructions
3.1. Use according to This installation has been developed and produced exclusively for training purposes
regulations in the fields of automation and communication. The training company, as well as the
instructors have to ensure, that the trainees pay strict attention to the safety
precautions, as described in the accompanying manuals.
Festo Didactic accepts no liability charges for possible damages to any trainee of the
training company and/or further third parties, which might occur during
use/operation of the installation, if it is not part of a real training situation; except
Festo Didactic caused such damages deliberately or by negligence.
Due to the product liability law and various EC-directives, the following directions
are required and are to be strictly observed by the operator.
3.2. Handling the system 3.2.1. Dangers in handling the machine
The installation has been constructed technologically up to date and in conformance

with the recognized rules of safety engineering. Nevertheless, during operation it is
possible that harm might be caused to the user or third parties or that the
installation or other property might get damaged. Therefore, the installation has to
be handled according to specified operational use in perfect technical condition
only.
Safety endangering malfunctions can not be tolerated during training and have to be
removed immediately.
3.2.2. Safety precautions in standard operation
Put the installation into operation only, once all of the protection settings are
completely functional.
At least, before starting operation, check the installation for externally visible
damages and for the reliability of the safety devices.
Do not grip into the installation while in operation.
Before circuit construction, circuit disassembly and circuit modification: switch off
air pressure and power supply.
General safety regulations are to be observed: DIN 58126 and VDE 0100.

General safety instructions
3.2.3. Dangers due to electric current
As soon as maintenance is completed, check the function reliability of the safety

devices.
Only trained experts in electric or electronic engineering are permitted to carry out
work on the electric supply system.
The terminal boxes are to be kept closed at all times. Access must be permitted only
under supervision of a member of the training staff.
Do not activate electric limit switches manually during fault search. Tools are to be
used.
Only low voltage 24VDC is to be used.
3.2.4. Dangers due to pneumatic energy
Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt
air pressure supply immediately.
Caution! When the air pressure supply is activated, cylinders may move in or out.
Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In
this case, keep on holding the end of the tube.
Do not exceed the permitted operating pressure. See data sheets.

3.2.5. Maintenance – Servicing – Malfunction removal
Carry out adjustments and inspections as instructed, in accordance with the

specified intervals.
Secure the compressed air and electricity supplies to prevent unintentional start-up.
During inspections, maintenance and repair work, the machine must be de-
energised, de-pressurised and secured against unexpected restart.
All screw connections released during maintenance, inspection or repair work must
be checked to ensure correct re-tightening.
3.2.6. Organisational measures
All existing safety devices must be checked at regular intervals.
3.3. Personnel 3.3.1. Notes on personnel
Basically two situations have to be considered, concerning matters on personnel.
• Activities during training operations

• Activities outside training operations
3.3.2. Training operations
Trainees are permitted to work with the machine only under strict supervision of an
experienced person or an instructor.
Activities of trouble-shooting and fault correction are to be checked by the

instructor. Special care should be taken regarding safety aspects.
3.3.3. Outside training operations
Activities in the areas of maintenance, service and repair are to be carried out by
only persons with appropriate technical qualifications.

3.3.4. Safety symbols
In this manual the following danger designations and signs are being used:
This symbol indicates an immediate

threat to a persons health or life.
DANGER !
Failure to pay attention to this symbol may result in serious health damage, which
may even lead to life-threatening injuries.
This symbol emphasises important

information for correct machine
handling.
IMPORTANT
Failure to pay attention to this symbol may result in damages to the machine or to
its surroundings.
This symbol indicates operational tips

and especially useful directions.
i
INFORMATION
This symbol assists you to make optimal use of all of your machine’s functions.

4. Commissioning
4.1. Transport Care is to be taken that the transport of the stations is to be executed only by a
suitable transport vehicle. The weight amounts up to 500 kg, depending on the
station.
The route of transport is to be cleared in advance, to be accessible to the transport

vehicle. Installation of warning signs or barriers may be required.
i The transport boxes are to be opened with care, as additional components, such as
computers may be contained in the delivery, which are to be protected from falling
out.
Once the transport box has been opened and the possibly contained additional
components removed, the station can be taken out to be transported to its
destination by means of two fork-lifts or one fork-lift truck.
Please check the stability of all of the profile connectors by means of an Allen key
size 6. The connectors may have come loose during transport, due to inevitable
vibration.
Pay special attention to all overhanging components. Sensors and similar small
parts are very easily damaged in case of improper transport.
The stations are not to be picked up by or even under the mounted feet – increased
risk of becoming trapped or contused.

Commissioning
4.2. Set up 4.2.1. General information
The installation is to be set up in a frost-free room with maximum relative air

humidity of 70%.
In countries with an atmospheric humidity over 70% and temperatures above 25

degrees Celsius, the premise is to provide an air-conditioning system for constant
surrounding conditions.
To comply with the levels of the regulatory guidelines, sources of electrical

interference such as welding plants, large motors and contactors are to be checked
for electromagnetic compatibility in advance and screened where necessary.
To ensure faultless operation a load-bearing floor is required to avoid settling.
Allow sufficient distance between the installation and the wall of the room.
Any dust originating from construction work has to be kept off the installation (by
covering).

Commissioning
For a more simple room planning the complete installation design is shown in the
following. The AS-RS station is to line up that a fault-free workpiece handing over
can take place.
Set-up situation MPS 500 example

Commissioning
Dimensional drawing of set-up MPS 500 example

Commissioning
4.3. Commissioning The AS-RS station can be built up only if the transport system stands on its final
position and the commissioning for the transport system has been carried out.
The AS/RS station has to be mounted at the transport system, utilising the included
profiles. Afterwards, the distance of the AS/RS station is fixed in such a way, that the
handling is able to move in extended status over operating position. At this point,
screw and lean the profiles lightly onto the basic frame of the transport system
station, by means of the angles. Align the AS/RS station by means of a spirit-level
and tighten the connector profiles afterwards.
It may be possible, that the transfer position must be taught corrected.
4.3.1. Pneumatic commissioning
The mechanical construction must be finished. At the beginning the stations have to
be attached to the pneumatic system of the room. In most cases the maintenance
unit is on the profile plate of the station. The coupling has a 5 mm nominal diameter.
If the available system is equipped with 7.9 mm nominal diameter, it is possible to
change the coupling of the maintenance unit with a greater one. (reducer 1/8 on 1/4
necessary). If this has been carried out, the stations can be provided with 6 bar and
the pneumatic commissioning is realised.
4.3.2. Electric commissioning
The station must be provided with electrical voltage now.

The basic rack is provided with a power supply unit witch is provided with a voltage
of 110/230 V. The delivered cable has a completely protected norm plug, this must
be plugged into an electrical socket protected sufficiently. Distribution strips are,
enclosed to this also for the connection of other stations. If an extension for the
cable is necessary for the distribution strip, this can to be executed only by a trained
expert. The electrical socket must be protected, corresponding to the customer.
The power supply unit (24 VDC) of the sensoric and the actuators of the station is
provided in each case by means of a 2-pin cable.

Commissioning
4.3.3. Establishing communication connections
The communication connections to the transports system is to be set up according

to the following example.
In order that the system “knows” that the station is present and processing can
occur station, it has to be connected to the system by I/O-connectors. At each case,
the connections are established the control panel.
For more detailed information, the connection possibilities are listed below:
Connection by I/O – one side cable 4 mm plug / one side SYS-link plug
between transport system and MPS–stations

Commissioning
Station AS/RS Transport System
PART ON
Pending PALLET
order Bit1 Bit0 Order
0 X X No processing
1 0 TRANSPORT
0 Reserved
AS-i
Control panel new 1 0 1 Storage
1 1 0 Retrieval, oldest part
IN ........
1 1 1 Retrieval, jungest part
SYSLINK (AS-i)
0V 0V
OUT 6 Pending order
IN 4 OUT 0 AS-I Addr:
OUT 7 OUT 1 AS-I Addr:
Order Bit0
OUT 2 AS-I Addr:
OUT 4 IN 6 Order Bit1 OUT 3 AS-I Addr:
OUT 5 IN 7
Stock is full
AS-I Addr:
Stock is empty IN 1 AS-I Addr:
Order aktiv (busy) IN 2 AS-I Addr:
Station ready IN 3 AS-I Addr:
IN 0
IN 1
Cabel
IN 2 SYSLINK - plug
IN 3
OUT 0 SYSLINK
OUT 1
OUT 2
OUT 3
0V
Connection AS/RS station - Transport system
4.3.4. EMERGENCY-STOP system
See transport system manual

Commissioning
4.4. Start-up process For the MPS500-installation the first start-up has been executed at the customer
general already.
For the installation to be ready for operation execute the following directions:
1. Mains supply 230 V AC for power supply unit, connect control cabinet of
transport system and commissioning station.
2. Power supply unit 24V DC with connections +24V/0V/earth are connected
correctly to the stations and activated (except for robot: only after adjustment of
the transport system).
3. Each station is supplied with ca. 6 bar compressed air.
4. I/O-communication connectors (laboratory plugs) are connected according to
communication plan.
5. All of the PLC-programs are loaded into the respective controls. The controls are
switched to RUN and the red error indicators of the controls are not on.
6. All of the EMERGENCY-STOP signal generators (push-buttons, door contact, light
barriers, a.s.o.) are not to be switched on, i.e. activated.
7. Activate the main switch of the transport system station.
8. Acknowledge the EMERGENCY-STOP of the control cabinet of the transport
system.
9. Remove all of the work-pieces from the installation, i.e. stations:
- Remove work-pieces from the palettes on the transport system
- Clear the storage shelves of the AS/RS station (HRL20)
- Clear the slides of the sorting/commissioning station
10. The magazines of all of the stations are to be stocked up:
- Magazines (piston, spring and cover) of the robot station with assembly
- Fill magazine of the distribution station with basic bodies
11. Now adjust the stations and the transport system (see chapter – Operation).

5. Operation
This chapter describes the necessary control units for starting and stopping the
system, as well as operating with the system.
5.1. General operation The stations require some rules of operation witch should be observed. If they are
notes not complied, faults in the processes are possible. Dangers for the physical health
also cannot be excluded.
It is recommended to observe the following rules strictly.
5.1.1. Behaviour rules
• During the operation of the stations it is forbidden to grip in by hand.

• With larger audience a mechanical protection of the stations is necessary.
• Removing any cable under tension is forbidden.
• Water has to be kept away from the plant.
5.1.2. Operation rules
• The stations only may be used by introduced persons.

• The operation has to be carried out according to the operating instructions.
• A pushing the different switches/push buttons of all control units uncheckedly
has to be stopped.
• No workpiece carriers may be taken by the system.

Operation
5.2. Process description 5.2.1. AS-RS station
Process description inside AS-RS station.
Example store a workpiece – on condition that sorting station is completely full
• Transportsystem is starting a store process

• Occupied workpiece carrier is stopping in front of the AS/RS
• The handling is gripping the workpiece from the pallet
• Workpiece is moved to the first not occupied workepieceplace in the AS/RS – the
AS/RS is equipped from the bottom to the top
• Gripper moves backwards and handling doesn’t move anymore.
• Workpiece carrier is released
Example restore a workpiece – on condition that sorting station is completely empty
• Transportsystem is starting a store process

• Empty workpiece carrier is stopping in front of the AS/RS
• The handling is gripping the oldest workpiece from the workpieceplace in the
AS/RS
• Workpiece is moved to the waiting pallet on the transportsystem
• Handling/gripper moves back to workpieceplace 4
• Workpiece carrier is released

Operation
5.3. Operation panel The AS-RS station is controlled by means of the operation panel shown below, which
is located at the right/left side of the switchgear cabinet. There are different
arrangements of the operation panel, so it is possible that the picture is different to
your system.
Operation panel
Name Element Function
H1 Lights up Ready for automatic

Start
S1 Start automatic
Move to reference position

H2 Lights up
Reset possible
S4 Start reference move
Chose Position Auto Automatic mode

Auto/Man S3
mode Position Man Teach/manual mode
Stop S2 Stop automatic at cycle end
Q2 H3 AS/RS occupied
Q2 H4 AS/RS empty

Operation
5.4. Reset mode The first start-up of the station is to be completed before the reset mode can be
executed. Retrieve all workpieces from stock. Electrical current and air are to be
available. All of the emergency-off switches are to be unlocked.
CAUTION: Handling motion – DANGER OF INJURY.
Operation from operation panel
• Turn key switch to MAN position

• If the RESET button at operation panel is pressed, the handling makes the
reference move.
• After reference move the START lamp lights up
5.5. Automatic mode 5.5.1. Start automatic mode
Once it has been successfully reset, the station is ready for the start signal to
activate automatic mode.
• Turn key switch to AUTO position

• Press START button to start automatic mode
• START lamp is going out
5.5.2. Stop automatic mode
• Press STOP button to stop automatic mode to cycle end

• After cycle is finished, RESET lamp lights up
• Station is ready for new start
For new automatic start, the reset move is necessary.

Operation
5.6. Commissioning – The active working range of the X- and Z-axis portal-robot is defined between the
homing and security switches of the linear drive units. To posit axis by using incremental
Reference position transducing system, it´s necessary to define a so called Home position and a so
of the X- and Z-axis called Reference position, using Reed-switches on each axes. This exercise include
the definition of the Home position and the Reference position of the X- and Z-axes.
Information
To move the axis by “hand”, you can use the Simulator module SM 374, coming with
the PLC-board of the ASRS. Please make sure, the switch on the Simulator module is
switched to 16 digital inputs (see no.: 1 at the picture below). Switch on the last
switch on the Simulator = I 1.7 activates the module (2).

Operation
Please refer to the following table regarding the functions of the single switches:
Adress Picture Description
I0.0 1 X-axes move to the left
I0.1 2 X-axes move to the right
I0.2 3 Z-axes move up
I0.3 4 Z-axes move down
I0.4 5 Solenoid of the Y-axes = 1 = move forward
I0.5 6 Solenoid of the gripper = 1 = gripper open
I0.6 7 Fast motion of the X-axes
I0.7 8 Fast motion of the Z-axes
I1.7 9 Activates the Simulator module

Operation
Before starting, please switch off the air-pressure supply. To activate the axis, you
must turn the key-operated switch to the position 1 first to reset the motor-
controller of the axis and then turn to position 3 as shown in the picture below (1)

Operation
The Homing position of the X- and Z-axis is defined in the right/down position of the
axis. Move the X- and Z-axis by using the Simulator switches carefully to the position
shown in the pictures below. The gripper should be closed and the Y-axes should be
moved out by hand without air-pressure.
After reaching the right/down position shown in the picture above, move the Reed-
switch of the Z-axes B13 (2) and the Reed-switch of the X-axes B10 (1) very carefully
from a lower/left position up/right until the sensor have a signal (LED = on). Fix the
Reed-switches in this position. Please refer to the picture below to proceed

Operation
The Reference position of the X- and Z-axis is defined in the left/up position of the
axis. Move the X- and Z-axis by using the Simulator switches carefully. The gripper
should be closed and the Y-axes should be moved out by hand without air-pressure.
Make sure to move both axis as left as possible (X-axes) and as up as possible
(Z-axes) both as short as possible before activating the security switches. Move the
Reed-switches as shown in the picture below (1 and 2) and fix them.

Operation
Finally switch on the air-pressure supply and move the Y-axes in and out, using the
Simulator switch. Please make sure, that there will be no crash moving this axes.
Please adjaust the speed of the axes with the one-way flow control valves.
Please deactivate the Simulator module by switching the input I1.7 off and turn the
CPU-switch to Stop position.

Operation
5.7. Teach mode The free programmable X- and Z-axis of the ASRS are equiped with an incremental
transducing system with each 2 signal outputs-pulse and direction-which can be
processed by the fast counter inputs of the PLC 314C 2DP. Within the standard
program solution, there is a Teach-In-routine implemented to define the positions of
the storage places. The solution have been done by relative positioning, this means,
by teaching 3 different positions at the ASRS, all other positions are calculated by
the program.
Information
Please make sure that the PC is connected to the PLC with the communication cable,
the power supply of the station is on, air-pressure of around 5 bar is available at
each station, the Emergency switch is deactivated (if available), the Auto/Manu-
switch is in Manu-position ( --- ) and switch the CPU to STOP and to RUN-P again. To
proceed with the teaching of the so called Reference positions (3 positions), the
buttons of the control panel are used as a Teach-In-Box. To activate the axis, you
must turn the key-operated switch to the position 1 first to reset the motor-
controller of the axis and then turn to position 3 as shown in the picture below (1)

Operation
Please proceed to reset the axis first before starting to teach the positions:
1. Switch CPU to StOP and RUN-P again Æ reset all outputs and memories
2. Check the air-pressure Æ = 5 bar
3. Check cable connection Æ plug should be locked
4. Remove all workpieces from the storage places and from the gripper
5. Make sure the Emergency switch is not activated
6. Switch the Auto/Manu switch to Manu ( ---) Æ this activates the Reset condition
7. Press the Reset button once Æ the X- and Z-axis are moving to the Reference
position and after reaching this position, the axis move to the Home position
8. After reaching the Home position of the X- and Z-axis, Start-light is flashing
9. Press the Start button once Æ the Teach-In-cycle starts Æ the Start-light is on
To move the Y-axes and the gripper, please use the manual detection buttons on the
valves. First of all put a black workpiece inside the gripper as shown in the picture
below. After gripping the workpiece, please switch off the air-pressure supply at the
station.

Operation
To teach the positions, the buttons and lights of the control panel are used as a
Teach-Box. The functions are:
1. Start-button to move the selected axes in positive direction (+)

2. Detection of the actual teaching position
3. Press shortly to choose between the axes, press longer than 5 seconds to store
the position
4. Reset-buttom to move the selected axes in negative direction (-)
5. Detection of the actual teaching position
6. Auto/Manu-switch to activate the Teach-In Æ position Manu
7. Q1-light, indicates that the X-axes is active
8. Q2-light, indicates that the Z-axes is active
for further details, please refer to the table on the next page.

Operation
Description of the control panel functions:
Operational Function within the Teach-In Additional Informations

Control
START-button: START- RESET-

Move the selected axes in positive (+) Teach-Position
light light
direction
START-light:
Indicates the actual Teach-Position
1 0 Transfer System
Start
RESET-button: Storage pos. 4
Move the selected axes in negative 0 1
(right/down)
(-) direction
RESET-light:
Indicates the actual Teach-Position Storage pos. 17
1 1
(left/up)
Reset
Tip: Direction X-Achse Z-Achse
Toggle between the axis (X/Z)
Press for 5s: + left up
Storage of the actual position
- right down
Stop
Light Q1:
Indicates if the X-axes have been
selected
Q1
Light Q2:
Indicates if the Z-axes have been
selected
Q2

Operation
After the Rest-procedure have been done (see Information) and the Start-light is on,
please proceed to store the 3 positions as follows:
1. Move to the first position by using the control panel buttons. The first position is
at the Transfer System and the y-axis is in front position. After reaching the
position, please remove the workpiece by hand from the gripper and move the
y-axis back to rear position
2. Store the first position by pressing the Stop-button for 5 seconds Æ both axis
move to the Reference position automatically. After reaching the Reference
position, the Start-light is flashing
3. By pressing the Start-button once more again, the second teach position will be
active Æ the axis move to the Home position Æ the Reset-light is on
4. Put back a black workpiece into the gripper like before and move to the second
position by using the control panel buttons. The second position is at the
storing place 4. After reaching the position, please remove the workpiece by
hand from the gripper and move the y-axis back to rear position

Operation
5. Store the second position by pressing the Stop-button for 5 seconds Æ both
axis move to the Reference position automatically. After reaching the Reference
position, the Start-light is flashing
6. By pressing the Start-button once more again, the third teach position will be
active Æ the axis move to the Home position Æ the Reset-light is on
7. Put back a black workpiece into the gripper like before and move to the third
position by using the control panel buttons. The third position is at the storing
place 17 (please be reminded, that the picture show the gripper above the real
position-please insert the workpiece into the workpiece mounting). After
reaching the position, please remove the workpiece by hand from the gripper
and move the y-axis back to rear position

Operation
8. Store the third position by pressing the Stop-button for 5 seconds Æ both axis
move to the Reference position automatically. After reaching the Reference
position, both lights-Reset and Start are off
Finally proceed the Reset condition of the axis again:
1. Switch the CPU-switch to STOP and to RUN-P again Æ reset all outputs and
memories
2. Check the air-pressure Æ = 5 bar
3. Check cable connection Æ plug should be locked
4. Remove all workpieces from the storage places and from the gripper
5. Make sure the Emergency switch is not avtivated
6. Switch the Auto/Manu switch to Manu ( --- ) position Æ this activates the
Reset condition
7. Press the Reset button once Æ the X- and Z-axis are moving to the Reference
position and after reaching this position, the axis move to the Home position
8. After reaching the Home position of the X- and Z-axis, the Start-light is flashing
9. Switch the Auto/Manu-switch to Auto ( | )position
10. Press the Start button once Æ the storage or retrieval cycle starts

Operation
5.7.1. Example teach a position
If the preteach positions are no longer present (e.g. new CPU), the basic positions (if
necessary, the complete project), must be reloaded. The positions are located as
follows:
Controller axis file
x-axis / z-axis
S7 DB 30
5.7.2. Load positions into controller
S7-300 1. Start simatic manager

2. Open project
3. Open controller online
4. Open module-reservoir in online and offline window
5. DB 30
6. Copy from offline window to online window (Data module is transmits into
controller)
7. Copy from online window to offline window (Data module is transmitted from
controller)

6. Technology
This chapter refers to the technology of the AS-RS station.
For better construction understanding of the station, the technical drawings should
be a very helpful data.
The rooms must be checked for their technical datas before built up the
station/system. The size of the door openings and the entrance must be big enough
for the measurements of the system. Even the load-capacity of the floor must be
high enough for the system.
6.1. drawings
Technical drawing AS-RS station

Technology
6.2. Modules in use The AS-RS station is made up of a number of different function modules.
• workpiece reception
• Handling
6.2.1. workpiece reception
On this module the palettes are stored in the AS-RS
Example workpiece reception
Performance
Inputs /
Outputs /
Max. reservation 4 workpieces

Technology
Position of all shelves
• Position conveyor (90):position at the transport system

Technology
6.2.2. Handling
The workpieces will submit with the help of the handling from the transport system
to the AS-RS - or the other way.
Handling example
Performance
Max. reservation 1 piece

Technology
6.3. Technical datas Pos. Designation / Criterion Measurements / Feature
1 Width: 710 mm
2 Max. width 710 mm
3 Length 1 100 mm
4 Max. length 1 100 mm
5 height 1 710 mm
6 Max. height 1 710 mm
7 Weight approx. 100 kg

Technology

7. Electrical system
To operate the station it is required to connect all of the supply cables and
communication lines included. The cables used to program the system are explained
additionally.
To give you a better survey of the being lines used in the plant, these are explained
in the following.
7.1. Power supply The devices are delivered together with the respective power supply plugs,
protectively contact covered, in case they require power supply.
The customer must ensure that the power supply is earthed correctly and is
equipped with a fault current monitor.
If it is required for several devices to be in operation at the same time, it is possible

to connect these to a switchboard containing distribution board, provided that the
permissible maximum rating is not exceeded.

Electrical system
7.2. Controller 7.2.1. Controller design S7
Card location Module Name Comment
2 Controller CPU-314C-2DP
3 Virtually occupied
4 I/O Card SM 374 Communication
S7 controller AS-RS station
The communication ensues by means of Ethernet, should the station be connected

to another station, as described under the point complete process, for example.
Two possibilities are available to program the Siemens controls. A MPI cable is
sufficient for programming, if a special programming unit is available. If a common
PC is used for programming, a MPI card needs to be installed into the PC. If such a
card containing PC is available, a common MPI cable may be used. A MPI cable
inclusive adapter box is required, if a PC without MPI card is used for programming.
The interface for programming is on the CPU–Card.

Electrical system
7.3. Wiring The wiring within the station and the wiring to the other stations are explained in the
following.
7.3.1. I/O-Components
The operation panel, the modules from station are pluggable connected via
I/O-terminals to the I/O-cards from the control.
So that a perfect communication can be ensured, the I/O interface is standardised.

The I/O terminal is at all work positions at the disposal.
I/O-Terminal
Technical data
Plug type IEEE 488 24 pins
Inputs 8
Outputs 8
Current consumption Max. 1A/PIN
Power supply 24 VDC

Electrical system
OUT BIT 0 1 13 IN BIT 0

POWER 24 VDC 9 21 POWER 24 VDC
syslink pin assignment

01 Bit 0 Output word white 13 Bit 0 Input word grey-pink
02 Bit 1 Output word brown 14 Bit 1 Input word red-blue
03 Bit 2 Output word green 15 Bit 2 Input word white-green
04 Bit 3 Output word yellow 16 Bit 3 Input word brown-green
05 Bit 4 Output word grey 17 Bit 4 Input word white-yellow
06 Bit 5 Output word pink 18 Bit 5 Input word yellow-brown
07 Bit 6 Output word blue 19 Bit 6 Input word white-grey
08 Bit 7 Output word red 20 Bit 7 Input word grey-brown
09 24 V Power supply black 21 24 V Power supply white-pink
10 22
11 0 V Power supply pink-brown 23 0 V Power supply white-blue
12 0 V Power supply purple 24
Allocation I/O- Terminal
Clamp Bit Function Color Clamp Bit Function Colour
01 0 Output White 13 0 Input Grey-pink
02 1 Output Brown 14 1 Input Red-blue
03 2 Output Green 15 2 Input White-green
04 3 Output Yellow 16 3 Input Brown-green
05 4 Output Grey 17 4 Input White-yellow
06 5 Output Pink 18 5 Input Yellow-brown
07 6 Output Blue 19 6 Input White-grey
08 7 Output Red 20 7 Input Grey-brown
09 Power
24V Power supply Black 21 24V White-pink
supply
10 22
11 Power
0V Power supply Pink-brown 23 0V White-blue
supply
12 0V Power supply purple 24

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MPS 500

Type: Manual MPS500

© Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2006

2 © Festo Didactic GmbH & Co.KG • MPS500

The manual is divided into four parts:

© Festo Didactic GmbH & Co.KG • MPS500 3

• DIN EN 292 -Machine safety

4 © Festo Didactic GmbH & Co.KG • MPS500

1. Intended use ___________________________________________________ 3

2.2. AS-RS station________________________________________________ 10

2.3. Didactic structure ____________________________________________ 11

2.4. Scope of tasks of the stations __________________________________ 12

2.4.1. Mechanics ______________________________________________ 12

2.4.2. Pneumatics _____________________________________________ 12

2.4.3. Electrics ________________________________________________ 12

2.4.5. Bus technology __________________________________________ 12

3. General safety instructions _______________________________________ 13

3.1. Use according to regulations ___________________________________ 13

3.2. Handling the system __________________________________________ 13

3.2.1. Dangers in handling the machine ____________________________ 13

3.2.2. Safety precautions in standard operation _____________________ 13

3.2.3. Dangers due to electric current _____________________________ 14

3.2.4. Dangers due to pneumatic energy ___________________________ 14

3.2.5. Maintenance – Servicing – Malfunction removal ________________ 15

3.2.6. Organisational measures __________________________________ 15

© Festo Didactic GmbH & Co.KG • MPS500 5

3.3.1. Notes on personnel _______________________________________ 15

3.3.2. Training operations _______________________________________ 15

3.3.3. Outside training operations ________________________________ 15

3.3.4. Safety symbols __________________________________________ 16

4.1. Transport ___________________________________________________ 17

4.2. Set up______________________________________________________ 18

4.2.1. General information ______________________________________ 18

4.3. Commissioning ______________________________________________ 21

4.3.1. Pneumatic commissioning _________________________________ 21

4.3.2. Electric commissioning ____________________________________ 21

4.3.3. Establishing communication connections _____________________ 22

4.3.4. EMERGENCY-STOP system _________________________________ 23

4.4. Start-up process general_______________________________________ 24

5.1. General operation notes _______________________________________ 25

5.1.1. Behaviour rules __________________________________________ 25

5.1.2. Operation rules __________________________________________ 25

5.2. Process description___________________________________________ 26

5.2.1. AS-RS station____________________________________________ 26

5.3. Operation panel______________________________________________ 27

5.4. Reset mode _________________________________________________ 28

6 © Festo Didactic GmbH & Co.KG • MPS500

5.5. Automatic mode _____________________________________________ 28

5.5.1. Start automatic mode _____________________________________ 28

5.5.2. Stop automatic mode _____________________________________ 28

5.6. Commissioning – homing and Reference position of the X- and Z-axis _ 29

5.7. Teach mode _________________________________________________ 35

5.7.1. Example teach a position __________________________________ 42

5.7.2. Load positions into controller_______________________________ 42

6.1. drawings ___________________________________________________ 43

6.2. Modules in use ______________________________________________ 44

6.2.1. workpiece reception ______________________________________ 44

6.3. Technical datas ______________________________________________ 47

7. Electrical system _______________________________________________ 49

7.1. Power supply ________________________________________________ 49

7.2. Controller ___________________________________________________ 50

7.2.1. Controller design S7 ______________________________________ 50

7.3.1. I/O-Components _________________________________________ 51

© Festo Didactic GmbH & Co.KG • MPS500 7

8 © Festo Didactic GmbH & Co.KG • MPS500

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In complete set-up, the work-piece is seperated from the distribution station to be