Distributing station

Manual

648811 EN
04/06 R2.2
Intended use

This station has been developed and produced solely for vocational and further
training purposes in the field of automation and technology. The company
undertaking the training and/or the instructors is/are to ensure that trainees
observe the safety precautions described in the manuals provided.
Festo Didactic herewith excludes any liability for damage or injury caused to
trainees, the training company and/or any third party, which may occur if the system
is in use for purposes other than purely for training, unless the said damage/injury
has been caused by Festo Didactic deliberately or through gross negligence.

Order No.: 648811

Status: 04/2006
Authors: Frank Ebel, Markus Pany
Graphics: Doris Schwarzenberger, Albert Sigel
Layout: 04/2006
© Festo Didactic GmbH & Co. KG, D-73770 Denkendorf, 2006
Internet: www.festo-didactic.com
e-mail: [email protected]
The copying, distribution and utilisation of this document as well as the
communication of its contents to others without express authorisation is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Contents

1. Introduction ____________________________________________________ 5
1.1 Training contents ________________________________________________ 6
1.2 Important notes _________________________________________________ 7
1.3 Duty of the operating authority _____________________________________ 7
1.4 Duty of trainees __________________________________________________ 7
1.5 Risks involved in dealing with the Modular Production System ___________ 8
1.6 Warranty and liability _____________________________________________ 9
1.7 Intended use ____________________________________________________ 9

2. Notes on safety _________________________________________________ 11

3. Technical data _________________________________________________ 13

3.1 Combinations __________________________________________________ 13

4. Transport/Unpacking/Scope of delivery ___________________________ 15

5. Design and function _____________________________________________ 17

5.1 The Distributing station __________________________________________ 17
5.2 Function _______________________________________________________ 19
5.3 Sequence description ____________________________________________ 19
5.4 Stack magazine module __________________________________________ 20
5.5 Changer module ________________________________________________ 21

6. Commissioning _________________________________________________ 23
6.1 Workstation ____________________________________________________ 23
6.2 Mechanical set up _______________________________________________ 24
6.2.1 Assembling profile plate and control console ________________________ 24
6.2.2 Assembling the station ___________________________________________ 25
6.3 Adjust sensors __________________________________________________ 26
6.3.1 Proximity sensor (Stack magazine, ejecting cylinder) __________________ 26
6.3.2 Through-beam sensor (Stack magazine, filling level) __________________ 27
6.3.3 Micro switch (Changer, swivel drive) _______________________________ 28
6.3.4 Vacuum switch (Changer, vacuum suction cup) ______________________ 29
6.4 Adjusting one-way flow control valves ______________________________ 30
6.5 Visual check____________________________________________________ 30
6.6 Cable connections _______________________________________________ 31
6.7 Pneumatic connection ___________________________________________ 32
6.7.1 Manual override ________________________________________________ 32
6.8 Voltage supply _________________________________________________ 32

© Festo Didactic GmbH & Co. KG „ 648811 3

Contents

6.9 Loading the PLC program _________________________________________ 33

6.9.1 Siemens controller ______________________________________________ 33
6.9.2 Festo controller _________________________________________________ 36
6.9.3 Allen Bradley controller __________________________________________ 38
6.9.4 Mitsubishi/MELSEC controller _____________________________________ 41
6.10 Starting the sequence ___________________________________________ 43
6.11 Combination of stations __________________________________________ 44
6.11.1 Networking ____________________________________________________ 44
6.11.2 Hardware modifications __________________________________________ 44

7. Maintenance ___________________________________________________ 45

Appendix ____________________________________________________________ 47
Distributing station with AS-Interface _______________________________ 47

Updates ____________________________________________________________ 49

4 © Festo Didactic GmbH & Co. KG „ 648811

1. Introduction

The Festo Didactic Learning System for Automation and Technology is designed to
meet a number of different training and vocational requirements. The systems and
stations of the Modular Production System (MPS ) facilitate industry-orientated
vocational and further training and the hardware consists of didactically suitable
industrial components.

The Distributing station provides you with an appropriate system for practice-
orientated tuition of the following key qualifications

Social competence,
Technical competence and
Methodological competence

Moreover, training can be provided to instil team spirit, willingness to cooperate and
organisational skills.

Actual project phases can be taught by means of training projects, such as:

Planning,
Assembly,
Programming,
Commissioning,
Operation,
Maintenance and
Fault finding.

© Festo Didactic GmbH & Co. KG „ 648811 5

1. Introduction

1.1 Training contents covering the following subjects can be taught:

Training contents
Mechanics
‟ Mechanical construction of a station
Pneumatics
‟ Piping connections of pneumatic components
‟ Vacuum technology
‟ Pneumatic linear and rotary drives
Electrical
‟ Correct wiring of electrical components
Sensors
‟ Correct use of limit switches
PLC
‟ Programming and use of a PLC
‟ Structure of a PLC program
Commissioning
‟ Commissioning of a production system
Fault finding
‟ Systematic fault finding on a production system

Topics for project work

Replacing a relay control system with a PLC

Selecting pneumatic components
‟ Linear drives
‟ Rotary drives
‟ Vacuum cups
Safety during pneumatic power failure
‟ Vacuum reservoir
PLC programming
‟ Programming of an operational section
‟ Programming of a RESET sequence
‟ Programming of an EMERGENCY-STOP function
Optimising cycle time

6 © Festo Didactic GmbH & Co. KG „ 648811

1. Introduction

1.2 The basic requirement for safe use and trouble-free operation of the MPS is to
Important notes observe the fundamental safety recommendations and regulations.

This manual contains important notes concerning the safe operation of the MPS .

The safety recommendations in particular must be observed by anyone working on

the MPS .

Furthermore, the rules and regulations for the prevention of accidents applicable to
the place of use must be observed.

1.3 The operating authority undertakes to ensure that the MPS is used only by persons
Duty of the operating who:
authority
are familiar with the basic regulations regarding operational safety and accident
prevention and who have received instructions in the handling of the MPS ,
have read and understood the chapter on safety and the cautionary notes in this
manual.

Safety-conscious working of the persons should be regularly vetted.

1.4 Prior to commencing work, all persons assigned to working on the MPS have a duty
Duty of trainees to:

read the chapter on safety and the cautionary notes in this manual and,
observe the basic regulations regarding operational safety and the prevention of
accidents.

© Festo Didactic GmbH & Co. KG „ 648811 7

1. Introduction

1.5 The MPS is designed according to state of the art technology and in compliance
Risks involved in dealing with recognised safety regulations. However when using the system there is
with the Modular nevertheless a risk of physical or fatal injury to the user or third parties or of damage
Production System being caused to the machinery or other material assets.

The MPS is to be used only:

for its intended purpose and

in an absolutely safe conditions.

Faults impairing safety must be rectified immediately!

8 © Festo Didactic GmbH & Co. KG „ 648811

1. Introduction

1.6 In principle all our „Terms and Conditions of Sale“ apply. These are available to the
Warranty and liability operating authority upon conclusion of the contract at the latest. Warranty and
liability claims for persons or material damage are excluded if these can be traced
back to one or several of the following causes:

Use of the MPS not in accordance with its intended purpose

Incorrect assembly, commissioning, operation and maintenance of the MPS
Operation of the MPS using faulty safety equipment or incorrectly fitted or non
operational safety or protective devices
Non observance of notes in the manual regarding transport, storage, assembly,
commissioning, operation, maintenance and setting up of the MPS
Unlawful constructional modifications on the MPS
Inadequate monitoring of components subject to wear
Incorrectly carried out repairs
Catastrophies as a result of foreign bodies and vis major.

Festo Didactic herewith rules out any liability for damage or injury to trainees, the
training company and/or other third parties which may occur during the
use/operation of the system other than purely in a training situation, unless such
damage has been caused intentionally or due to gross negligence by Festo Didactic.

1.7 This system has been developed and produced exclusively for vocational and further
Intended use training in the field of automation and technology. The training authority and/or the
instructors is/are to ensure that trainees observe the safety precautions described
in the manual provided.

The use of the system for its intended purpose also includes:

following all advice in the manual and

carrying out inspection and maintenance work.

© Festo Didactic GmbH & Co. KG „ 648811 9

1. Introduction

10 © Festo Didactic GmbH & Co. KG „ 648811

2. Notes on safety

General
Trainees must only work on the station under the supervision of an instructor.
Observe the data in the data sheets for the individual components, in particular
all notes on safety!

Electrics
Electrical connections are to be wired up or disconnected only when power is
disconnected!
Use only low voltages of up to 24 V DC.

Pneumatics
Do not exceed the permissible pressure of 8 bar (800 kPa).
Do not switch on compressed until you have established and secured all tubing
connections.
Do not disconnect air lines under pressure.
Particular care is to be taken when switching on the compressed air. Cylinders
may advance or retract as soon as the compressed air is switched on.

Mechanics
Securely mount all components on the plate.
No manual intervention unless the machine is at rest.

© Festo Didactic GmbH & Co. KG „ 648811 11

2. Notes on safety

12 © Festo Didactic GmbH & Co. KG „ 648811

3. Technical data

Parameter Value

Operating pressure 6 bar (600 kPa)

Voltage supply 24 V DC, 4.5 A

Digital inputs 7

Digital outputs 7

3.1
Combinations

Possible direct MPS downstream stations

Testing Proces- Hand- Buffer Pick& Fluidic- Separat- Storing Robot Assembly* Sorting**
sing ling Place Muscle ing
MPS Press
station (PR) (BE) (HA) (PU) (PP) (FP) (TR) (LA) (R) (MO/HS) (SO)

Distributing***
(VE)

Testing
(PR)

Processing
(BE)

Handling
(HA)

Buffer
(PU)

Pick&Place
(PP)

FluidicMuscle
Press (FP)

Separating
(TR)

Storing
(LA)

Robot
(R)

Assembly*
(MO/HS)

* Assembly with Punching / ** Sorting DP / *** Distributing AS-Interface

© Festo Didactic GmbH & Co. KG „ 648811 13

3. Technical data

14 © Festo Didactic GmbH & Co. KG „ 648811

4. Transport/Unpacking/Scope of delivery

Transport
The MPS is delivered in a container with a pallet base.

The container must be transported on a suitable fork lift truck at all times and must
be secured against tipping or falling off.

The carrier and Festo Didactic are to be notified immediately of any damage caused
during transport.

Unpacking
Carefully remove the padding material in the container box when unpacking the
station. When unpacking the station, make sure that none of the station assemblies
have been damaged.

Check the station for any possible damaged once unpacked. The carrier and Festo
Didactic are to be notified immediately of any damage.

Scope of delivery
Check the scope of delivery against the delivery note and the order. Festo Didactic
must be notified immediately of any discrepancies.

© Festo Didactic GmbH & Co. KG „ 648811 15

4. Transport/Unpacking/Scope of delivery

16 © Festo Didactic GmbH & Co. KG „ 648811

5. Design and function

5.1
The Distributing station

The Distributing station is a feed device. According to VDI 3240, feed devices are
defined as units which fulfil the function of bunkering, sorting and feeding of
components. In addition, feed devices can facilitate the sorting of components
according to various sorting characteristics (shape, weight etc. of the component).

The following are feed devices:

Magazines with feed limiting,
Vibratory bowl feeder,
Inclined conveyors and
Hoppers with sorting devices.

Workpieces handled by feed devices are

Electroplated parts,
Shaped parts made of plastic,
Punched parts and
Turned components.

© Festo Didactic GmbH & Co. KG „ 648811 17

5. Design and function

The function of the Distributing station is

to separate out workpieces from a magazine and

to transfer workpieces by means of a rotary drive using a suction cup.

The Distributing station consists of the following:

Stack magazine module

Changer module
Profile plate

Trolley
Control console
PLC board

Distributing station with trolley, control console and PLC board

18 © Festo Didactic GmbH & Co. KG „ 648811

5. Design and function

5.2 The Distributing station separates workpieces from the Stack magazine module. The
Function magazine barrel of the stack magazine holds up to 8 workpieces. The filling level of
the stack magazine is monitored by means of a through-beam sensor. A double-
acting cylinder pushes out the workpieces individually.

The Changer module grips the separated out workpiece using a suction cup. A
vacuum switch checks whether a workpiece has been picked up. The arm of the
transfer unit, which is driven by a rotary drive, conveys the workpiece to the transfer
point of the downstream station.

5.3 Start prerequisites

Sequence description Magazine is filled with workpieces

Initial position
Ejecting cylinder is extended
Rotary drive is in position “magazine”

Vacuum is off

Sequence
1. The rotary drive swivels to the position “downstream station” if workpieces are
identified in the magazine and the START button is pressed.
2. The ejecting cylinder retracts and pushes a workpieces out of the magazine.
3. The rotary drive swivels to the position “magazine”.
4. The vacuum is switched on. When the workpiece is securely held, a vacuum
switch switches.
5. The ejecting cylinder advances and releases the workpiece.
6. The rotary drive swivels to the position “downstream station”.
7. The vacuum is switched off.
8. The rotary drive swivels to the position “magazine”.

© Festo Didactic GmbH & Co. KG „ 648811 19

5. Design and function

5.4
Stack magazine module

The Stack magazine module separates workpieces from a magazine. Up to

8 workpieces can be stacked in any order in the magazine barrel. The workpieces
must be inserted with the open side facing upwards.

A double-acting cylinder pushes the lowest workpiece from the gravity-feed

magazine up to the mechanical stop. This position serves as a transfer point to the
next module (e.g. Changer module).

The available workpiece in the magazine barrel is detected by means of a through-

beam sensor. The position of the ejecting cylinder is sensed electrically via inductive
sensors. The advancing and retracting speed of the ejecting cylinder is infinitely
adjustable by means of one-way flow control valves.

20 © Festo Didactic GmbH & Co. KG „ 648811

5. Design and function

5.5
Changer module

The Changer module is a pneumatic handling device. Workpieces are picked up

using a suction cup and transferred by means of a rotary drive. The swivelling range
is adjustable between 0° and 180° by means of mechanical end stops. The end
position sensing is effected by means of electrical limit switches (micro switches).

Note
The end positions of the rotary drive need to be adjusted depending on the
downstream station selected.

© Festo Didactic GmbH & Co. KG „ 648811 21

5. Design and function

22 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

The stations of the MPS are generally delivered

completely assembled
operationally adjusted as single station
commissioned
tested

Note
If stations are combined changes of the mechanical set-up and the position and
setting of sensors may be necessary.

The commissioning is normally limited to a visual check to ensure correct tubing

connections/wiring and supply of operating voltage.

All components, tubing and wiring is clearly marked so that all connections can be
easily re-established.

6.1 The following is required to commission the MPS station:

Workstation
The assembled and adjusted MPS station
A control console
A PLC board
A power supply unit 24 V DC, 4.5 A
A compressed air supply of 6 bar (600 kPa), approx. suction capacity of 50 l/min
A PC with installed PLC programming software

© Festo Didactic GmbH & Co. KG „ 648811 23

6. Commissioning

6.2 6.2.1 Assembling profile plate and control console

Mechanical set up

2 (4x)
3
4 (4x)

5 (2x)
6

1 Profile plate
2 T-head nut M6 x-32 (4x)
3 Trolley
4 Socket head screw M6x10 (4x)
5 Screw 3.5x9 (2x)
6 Control console

24 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

6.2.2 Assembling the station

Instructions on assembling the station please find in the directory

”Technical documentation\Assembly instructions”.

© Festo Didactic GmbH & Co. KG „ 648811 25

6. Commissioning

6.3 6.3.1 Proximity sensor (Stack magazine, ejecting cylinder)

Adjust sensors
The proximity sensors are used for end position sensing of the cylinder. The
proximity sensor is sensitive to a permanent magnet mounted on the piston of the
cylinder.

Prerequisites
‟ Stack magazine module is assembled, proximity sensors are pre-assembled.
‟ Cylinder is tubed up.
‟ Compressed air supply switched on.
‟ Proximity sensor is wired up.
‟ Power supply unit switched on.

Execution
1. Use the manual override of the solenoid valve to place the cylinder piston in the
position which you wish to interrogate.
2. Shift the sensor along the cylinder axis until it switches, switching status display
(LED) is on.
3. Shift the sensor a few millimetres further in the same direction until it switches
back (LED is off).
4. Place the switch half the way between the switch-on and the switch-off position.
5. Tighten the clamping screw of the sensor with a hexagon screwdriver A/F 1.3.
6. Start a test run to check if the sensor switches at the correct point
(advance/retract cylinder piston).

Documents
Data sheets
Proximity sensor SME-8 (150857)
Operating instructions
Proximity sensor SME-8 (646518)
Assembly instructions
Stack magazine module

26 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

6.3.2 Through-beam sensor (Stack magazine, filling level)

The through-beam sensor is used for monitoring the filling level of the Stack
magazine. A fibre optic cable is connected to a fibre optic device. The fibre optic
device emits visible red light. The workpiece interrupts the light barrier.

Prerequisite
‟ Fibre optic device is assembled.
‟ Fibre optic device is wired up.
‟ Power supply unit switched on.

Execution
1. Mount the fibre optic cable heads to the magazine.
2. Connect the fibre optic cables to the fibre optic device.
3. Adjust the potentiometer of the fibre optic device by means of a screwdriver until
the switching status display switches to on.

Note
Maximal 12 revolutions of the adjusting screw are permissible.

4. Insert workpieces into the magazine. The switching status display changes to off.

Documents
Data sheets
Fibre optic device (150857) and fibre optic cable through-beam (165360)
Operating instructions
Fibre optic device (369669) and fibre optic cable through-beam (369684)
Assembly instructions
Stack magazine module

© Festo Didactic GmbH & Co. KG „ 648811 27

6. Commissioning

6.3.3 Micro switch (Changer, swivel drive)

The micro switches are used for end stop sensing of the swivel drive (semi-rotary
drive). The micro switches are actuated by adjustable trip cams on the shaft of the
swivel drive.

Prerequisite
‟ Changer module assembled, micro switches pre-assembled.
‟ Rotary drive is tubed up.
‟ Compressed air supply switched on.
‟ Micro switches are wired up
‟ Power supply unit switched on.

Execution
1. Use the manual override of the solenoid valve to place the rotary drive in the
position which you wish to interrogate.
2. Shift the micro switch in the mounting bracket oblong holes until it is actuated.
3. Fix the clamping screws.
4. Start a test run to check if the micro switches are positioned correctly (move
rotary drive to the left/to the right).

Documents
Data sheets
Micro switch S-3-E (007347) and rotary drive DSR-16-180 (011910)
Operating instructions
Rotary drive (235679)
Assembly instructions
Changer module

28 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

6.3.4 Vacuum switch (Changer, vacuum suction cup)

The vacuum switch is used to detect the partial vacuum at the vacuum suction cup.
If a workpiece is securely picked up, an output signal is generated by the vacuum
switch.

Prerequisite
‟ Changer module assembled.
‟ Vacuum generator, vacuum suction cup and vacuum switch tubed up.
‟ Compressed air supply switched on.
‟ Vacuum switch is wired up.
‟ Power supply unit switched on.

Execution
1. Switch on the compressed air supply for the vacuum generator.
2. Move a workpiece close to the vacuum suction cup until it is picked up.
3. Turn the adjusting screw of the vacuum switch in an anti clockwise direction until
the yellow LED lights up.
4. Start a test run to check if the workpiece is picked up securely. Move the rotary
drive from end position to end position. The workpiece should not drop down.

Documents
Data sheets
Vacuum switch VPEV (152619)
Operating instructions
Vacuum switch (382214)
Assembly instructions
Changer module

© Festo Didactic GmbH & Co. KG „ 648811 29

6. Commissioning

6.4 One-way flow control valves are used to regulate exhaust air flow rates with double-
Adjusting one-way flow acting cylinders. In the reverse direction, air flows through the non-return valve with
control valves full cross-sectional flow.

Uncontrolled supply air and controlled exhaust hold the piston between air cushions
(improves motion, even with load changes).

Prerequisite
‟ Cylinder is tubed up
‟ Compressed air supply switched on.

Execution
1. Screw in the restrictors of the one-way flow control valves at first completely and
then loosen again one turn.
2. Start a test run.
3. Slowly open the one-way flow control valves until the desired piston speed is
reached.

Documents
Data sheets
One-way flow control valve (175056)
Operating instructions
Pneumatic cylinders (391172)

6.5 A visual check must be carried out before each commissioning!

Visual check
Prior to starting up the station, you will need to check:

The electrical connections

The correct installation and condition of the compressed air connections
The mechanical components for visual defects
(tears, loose connections etc.)

Eliminate any damage detected prior to starting up the station!

30 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

6.6
1
Cable connections

Cable connections from PLC board to control console and station

1. PLC board – station

Plug the XMA2 plug of the PLC board into the XMA2 socket of the I/O terminal of
the station.
2. PLC board – control console
Plug the XMG1 plug of the PLC board into the XMG1 socket of the control
console.
3. PLC board – power supply unit
Plug the 4 mm safety plugs into the sockets of the power supply unit.
4. PC – PLC
Connect your PC to the PLC by means of a programming cable.

© Festo Didactic GmbH & Co. KG „ 648811 31

6. Commissioning

6.7 Observe technical data!

Pneumatic connection Connect the compressed air supply to the start-up valve with filter-control valve.
Set the start-up valve with filter-control valve at 6 bar (600 kPa).

6.7.1 Manual override

The manual override is used to check the functioning and operation of the valves
and valve-drive unit combination.

Prerequisite
‟ Compressed air supply switched on.
‟ Power supply unit switched on.

Execution
1. Switch on the compressed air supply.
2. Press down the stem of the manual override with a blunt pencil or a srewdriver.
(max. width of blade:2,5mm)
3. Release the stem (the spring resets the stem of the manual override back to the
starting position), the valve moves back to the starting position.
(not with double solenoid valves!)
4. For locking manual override usage: Controll all manual overrides for being in
starting position after testing the valves.
5. Before commissioning the station make sure that all valves of the valve terminal
are in starting position.

Documents
Operating instructions
CPV_valveterminal (165100)

6.8 The stations are supplied with 24 V DC voltage (max. 5 A) via a power supply
Voltage supply unit.
The voltage supply of the complete station is effected via the PLC board.

32 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

6.9 6.9.1 Siemens controller

Loading the PLC program
Controller: Siemens S7-313C, S7-313C-2DP, S7-314 or S7-315-2DP
Programming software: Siemens STEP7 Version 5.1 or higher

1. Connect PC and PLC using the RS232 programming cable with PC adapter
2. Switch on power supply unit
3. Switch on the compressed air supply
4. Release the EMERGENCY-STOP pushbutton (if available)
5. Overall reset PLC memory:
‟ Wait until the PLC has carried out its test routines.
CPU 31xC
‟ Press the mode selector switch to MRES. Keep the mode selector switch in
this position until the STOP LED comes on for the second time and stays on
(this takes 3 sec.). You can let go of the mode selector.
‟ Within 3 sec. you must press the mode selector switch back to MRES. The
STOP LED starts to flash rapidly and the CPU carries out a memory reset. You
can let go of the mode selector.
‟ When the STOP LED comes on permanently again, the CPU has completed the
memory reset.
‟ The data on the MMC (Micro Memory Card) are not deleted. This can be done
by switching to the connected PLC via menu "PLC / Display Accessible
Nodes" and deleting all blocks in the block folder.
‟ CPU31x
‟ Turn the mode selector switch to MRES and keep the mode selector switch in
this position until the STOP LED comes on for the second time and stays on.
‟ Let go of the mode selector switch to STOP. Immediately you must turn the
mode selector switch back to MRES. The STOP LED starts to flash rapidly.
‟ You can let go of the mode selector switch.
‟ When the STOP LED comes on permanently the memory reset is completed.
‟ The PLC is ready for program download.
6. mode selector switch in STOP position
7. Start the PLC programming software

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6. Commissioning

8. Retrieve the file MPS_C.zip

Note
®
Do not unzip the following ZIP-Files using WinZip or similar software.
Please use the Siemens Software STEP7 instead.

File  Retrieve …  Select an archive MPS_C.zip Open  Select destination directory OK  Retrieving: The
retrieved data were stored in the project directory. OK  Retrieve: The following objects were retrieved. Do you
want to open these now? Yes

9. Select the hardware configuration and download it to the controller:

‟ PLC 313C
‟ PLC 313C 2DP
‟ PLC 314
‟ PLC 315 2DP
10. Select the project 01VE_AS or 01VE_KFA
(AS = sequential function chart, KFA = Ladder diagram/Function block
diagram/Instruction list, KFAFF = step chain realized with flip-flop)

34 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

11. Download the project to the controller

PLC  Download  Follow the instructions on the screen

12. Turn the mode selector switch of the CPU to RUN position

© Festo Didactic GmbH & Co. KG „ 648811 35

6. Commissioning

6.9.2 Festo controller

Controller: Festo FEC FC640, IPC CPU HC02, IPC CPU HC20
Programming software: Festo FST Version 4.02

1. Connect PC and PLC using the TTL-RS232 programming cable

2. Switch on power supply unit
3. Switch on the compressed air supply
4. Release the EMERGENCY-STOP pushbutton (if available)
5. Wait until the PLC has carried out its test routines
6. Start the PLC programming software
7. Restore the file 01VE_FEC.zip

Project  Restore …  Open 01VE_FEC.zip Open  Restore Project, Name: 01VE_FEC OK

36 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

8. Compile the project

Project  Build Project

9. Download the project to the controller

Online  Download Project  Follow the instructions on the screen

© Festo Didactic GmbH & Co. KG „ 648811 37

6. Commissioning

6.9.3 Allen Bradley controller

Controller: Micrologix (ML) 1500

Programming software: RSLogix 500/RSLINXLite

1. Connect PC and PLC using the RS232 programming cable

2. Switch on power supply unit
3. Switch on the compressed air supply
4. Release the EMERGENCY-STOP pushbutton (if available)

Note
Condition for the following operating steps is to configurate the necessary online
parameter (nodes, devices) with RSLINXLite/RSLogix 500!
After using shutdown and exit RSLogix 500 and RSLINXLite to avoid conflicts with
the serial interface!
‟
CPU ML 1500 ‟ Onlineparameter configuration
‟ Wait until the PLC has carried out its test routines.
‟ Start the RSLINXLite software.

Communications  Configure Drivers…  select the setting “RS-232 DF1 devices“ from the list
“Available Driver Types“ and click Add New…  confirm note (“Choose a name…“, default: AB_DF1-1)
with OK  Auto configure  OK  Close

‟ Start the PLC programming software

38 © Festo Didactic GmbH & Co. KG „ 648811

6. Commissioning

Comms  System Comms…  select the required controller and confirm with OK

5. Overall reset PLC memory:

‟ Wait until the PLC has carried out its test routines.
‟ CPU ML 1500
‟ Turn the mode selector switch to REM or PROG.
‟ Start the PLC programming software.
‟ Select Comms  System Comms…  select the required controller and click
Online.
‟ After connection the PLC and the PC select Comms  Clear Processor
Memory and confirm with OK.
‟ When the COMM 0.- LED stops blinking the memory reset is completed.
‟ The PLC is ready for program download.
6. Open the file 01_VE_K

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6. Commissioning

File  Open …  select a project file 01_VE_K  Open

7. Download the project to the controller

Comms.  System Comms.  select controller, click Download  Confirm the following notes
(“Revision note","…sure to proceed with Download?", "…want to go online?") with Yes or OK

8. Turn the mode selector switch of the CPU to RUN position

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6. Commissioning

6.9.4 Mitsubishi/MELSEC controller

Controller: Mitsubishi FX1N

Programming software: GX IEC Developer 6.01 or higher

1. Connect PC and PLC using the RS232/RS422 programming cable with PC adapter
2. Switch on power supply unit
3. Switch on the compressed air supply
4. Release the EMERGENCY-STOP pushbutton (if available)
5. Overall reset PLC memory:
‟ Wait until the PLC has carried out its test routines.
‟ CPU FX1N
‟ Turn the mode selector switch to STOP.
‟ Start the PLC programming software.
‟ Select Online  PLC Clear  All and confirm with Yes.
‟ The memory reset is completed.
‟ The PLC is ready for program download.
6. Restore the file 01_VE_AS.pcd or 01_VE_FUP.pcd

Extras  Project Restore …  select a project file 01_VE_AS.pcd or 01_VE_FUP.pcd  Open  Select destination
directory OK  Confirm the following note (“After saving,…”) with OK

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6. Commissioning

7. Compile the project

Project  Rebuild all

8. Download the project to the controller

Project  Transfer  Download to PLC… Confirm the following notes ("Transfer to PLC", ….) with OK

9. Turn the mode selector switch of the CPU to RUN position

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6. Commissioning

6.10 1. Fill the magazine with a maximum of 8 workpieces. The opening of the
Starting the sequence workpieces must point upwards.
2. Check the voltage supply and compressed air supply.
3. Remove workpieces at the transfer points of modules or stations prior to manual
reset.
4. Carry out the reset sequence. The reset sequence is prompted by an illuminated
RESET pushbutton and executed when the pushbutton has been pressed.
5. If a workpiece is present at the transfer point of the stacking magazine, you will
need to remove this manually.
6. Start the sequence of the Distributing station. The Start is prompted by the
illuminated START button and carried out when the pushbutton has been
actuated.

Notes
The sequence can be interrupted at any time by pressing the EMERGENCY-STOP
pushbutton or by pressing the STOP pushbutton.
With the key-operated switch AUTO/MAN, you can select either the continuous
cycle (AUTO) or individual cycle (MAN).
The following applies in the case of a combination of several stations:
The individual stations are reset against the material flow.
The warning light MAG. EMPTY is illuminated if the stacking magazine does not
contain any workpieces. Insert the workpieces and acknowledge by means of
pressing the START button.

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6. Commissioning

6.11 6.11.1 Networking

Combination of stations
In the standard version, the MPS stations are linked using optical sensors. This
type of linking is known as StationLink, which uses through-beam sensor
transmitters and receivers as sensors. The StationLink transmitter is mounted on the
incoming material side and the StationLink receiver on the outgoing material side.
By switching on or off the StationLink transmitter, the station signals the upstream
station whether it is ready to receive a workpiece or busy.

The sensors for linking several stations must be arranged face to face in alignment.
The linked stations must be securely interconnected by means of hammer head
screws.

Note
In the case of the Distributing station, only the StationLink receiver is mounted and
on the Sorting station only the StationLink transmitter.

6.11.2 Hardware modifications

Angle of rotation of the swivel drive

Depending on the downstream station following the Distributing station an

adjustment of the angle of rotation of the swivel drive may be necessary.
Instructions on procedure please find in the operating instructions of the Rotary
drive (235679).

Documents
Data sheets
Rotary drive DSR-16-180 (011910)
Operating instructions
Rotary drive (235679)
Assembly instructions
Changer module

44 © Festo Didactic GmbH & Co. KG „ 648811

7. Maintenance

The Distributing station is largely maintenance-free. The following should be cleaned

at regular intervals using a soft fluff-free cloth or brush:

The lenses of the optical sensors, the fibre-optics and reflectors

The active surface of the proximity sensor
The entire station

Do not use aggressive or abrasive cleaning agents.

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7. Maintenance

46 © Festo Didactic GmbH & Co. KG „ 648811

Appendix

Distributing station with

AS-Interface

View of the Distributing station with AS-Interface

Changes in relation to the Distributing station with I/O terminal

Stack magazine module:

‟ Single valve connector with AS-Interface
‟ Diffuse sensor with AS-Interface
Changer module:
‟ CP valve terminal with AS-Interface
Upgrade for standard PLC board:
‟ Siemens CP 343-2 AS-Interface Master
‟ AS-Interface Filter

Essential accessories

AS-Interface addressing device

(Reference: Festo Didactic catalogue)

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Appendix

1 2

1 Single valve connector with AS-Interface

2 Diffuse sensor with AS-Interface
3 CP valve terminal with AS-Interface

Details of the Distributing station with AS-Interface

Data sheets
Duo cable (018685), AS-Interface single valve connector (196083) and Diffuse
sensor AS-Interface (532929)
Operating instructions
Diffuse sensor AS-Interface (3RG730), valve terminal with AS-Interface
connection (662575), AS-Interface single valve connector (666046) and AS-
Interface extension for S7 controller (671085)
PLC program
01VE_as-i.zip

48 © Festo Didactic GmbH & Co. KG „ 648811

Updates

Up-to-date information and additional documents for the Technical documentation

of the MPS stations please find at the address:

http://www.festo-didactic.com/Services > MPS

© Festo Didactic GmbH & Co. KG „ 648811 49

50 © Festo Didactic GmbH & Co. KG „ 648811