FMS50 Manual A001 V10

FMS 50
Manual
This document consists of 4 parts, divided up into:
Part A contains the manual of the system or station.

Part B, in as far as present, contains a collection of exercises together with the
relevant solutions or additional information.
Part C contains the circuit diagram of the system or station.
Part D contains the data sheets of the system or station.
Order no.:
Name: Manual FMS 50
Designation: FMS50_Manual_A001_V10
Date: 22.12.2004
Author: Schober / Helmich
Graphics: Schober / Helmich
Layout: Schober
© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2002
Internet: www.festo.com/didactic
e-mail: [email protected]
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. • FMS 50

1. Contents
1. Contents_______________________________________________________ 3
2. Introduction ____________________________________________________ 7
2.1. General information FMS 50 _____________________________________ 7
2.2. Transport system______________________________________________ 8
2.3. Short cuts ___________________________________________________ 8
3. General safety instructions ________________________________________ 9
3.1. Use according to regulations ____________________________________ 9
3.2. Handling the system ___________________________________________ 9
3.2.1. Dangers in handling the machine _____________________________ 9
3.2.2. Safety precautions in standard operation ______________________ 9
3.2.3. Dangers due to electric current _____________________________ 10
3.2.4. Dangers due to pneumatic energy ___________________________ 10
3.2.5. Maintenance – Servicing – Malfunction removal ________________ 11
3.2.6. Organisational measures __________________________________ 11
3.3. Personnel___________________________________________________ 11
3.3.1. Notes on personnel _______________________________________ 11
3.3.2. Training operations _______________________________________ 11
3.3.3. Outside training operations ________________________________ 11
3.3.4. Safety symbols __________________________________________ 12
4. Start-up ______________________________________________________ 13
4.1. Transport ___________________________________________________ 13
4.2. Set-up _____________________________________________________ 14
© Festo Didactic GmbH & Co. • FMS 50 3

Contents
4.2.1. General information ______________________________________ 14
4.3. Commissioning ______________________________________________ 17
4.3.1. Pneumatic commissioning _________________________________ 17
4.3.2. Electric commissioning ____________________________________ 17
4.3.3. Establishing communication connections _____________________ 18
4.3.4. EMERGENCY-STOP system _________________________________ 28
4.4. Start-up process _____________________________________________ 30
5. Operation_____________________________________________________ 31
5.1. General notes on operation ____________________________________ 31
5.1.1. Handling regulations______________________________________ 31
5.1.2. Operating regulations _____________________________________ 31
5.2. Transport system_____________________________________________ 32
5.3. Adjustment _________________________________________________ 34
5.3.1. Requirements ___________________________________________ 34
5.3.2. Adjustment process of MPS-stations _________________________ 34
5.3.3. Adjustment process commissioning and AS/RS station __________ 35
5.4. Automatic __________________________________________________ 36
5.4.1. Conditions and automatic start-up___________________________ 36
5.5. Error and error acknowledgement _______________________________ 36
5.5.1. Error indication of the MPS-stations _________________________ 36
5.6. Process description___________________________________________ 37
5.7. Material flow ________________________________________________ 38

Contents
5.7.1. Situation 1 – material flow from product input to product output __ 39
5.7.2. Situation 2 – material flow from product input to stock __________ 40
5.7.3. Situation 3 – material flow from stock to product output _________ 41
5.7.4. Situation 4 – material flow mixed operation ___________________ 42
6. Profibus-DP with WinCC _________________________________________ 43
6.1. System information for FMS50 Level 2____________________________ 43
6.1.1. Start-up FMS50 Level 2 ____________________________________ 43
6.1.2. Profibus network settings __________________________________ 44
6.2. Commissioning FMS50 Level 2 __________________________________ 45
6.2.1. Step 1 – PLC Download ____________________________________ 45
6.2.2. Step 2 – Setup WinCC _____________________________________ 45
6.2.3. Step 3 – Search for computer name __________________________ 52
6.2.4. Step 4 – Check Connection Parameter ________________________ 55
6.2.5. Step 4 – Activate WinCC ___________________________________ 57
6.3. Use FMS50 Level2 Runtime Application___________________________ 58
7. Technology ___________________________________________________ 73
7.1. Operating position 1 __________________________________________ 75

Contents
8. Pneumatics ___________________________________________________ 77
8.1. The valve ___________________________________________________ 77
8.2. The valve interface ___________________________________________ 78
8.2.1. Configuration the additional power supply (load voltage) ________ 79
8.3. Pneumatic connection_________________________________________ 80
9. Electrical system _______________________________________________ 81
9.1. Supply voltage_______________________________________________ 81
9.2. Control cabinet ______________________________________________ 82
9.3. EMERGENCY-STOP system _____________________________________ 83
9.3.1. External EMERGENCY-STOP device __________________________ 83
9.3.2. EMERGENCY-STOP at the PLC-board _________________________ 83
10. Control system_________________________________________________ 85
10.1. Control set-up _____________________________________________ 85
10.2. Wiring____________________________________________________ 86
10.2.1. I/O-components _______________________________________ 86
10.2.2. ASi-participant_________________________________________ 89
10.3. Programming ______________________________________________ 96
11. Fault finding___________________________________________________ 97

2. Introduction
2.1. General information This manual describes the handling of a FMS 50 system. It contains explanations
FMS 50 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 FMS 50 system is a successively expandable system consisting of individual

stations. However, the central unit is always the transport system. For this reason,
this manual is not only a general manual, but also a station manual for the transport
system. Each one of the other stations has its own manual.
Operation is not dependant on the operating position the material flow is being
started from. Still, the sequential order of the stations requires adherence, as it is
pre-defined in the SPS-program.
The FMS 50 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
Testing of the work-pieces for their condition, according to type, is required in the
station. The work-piece carriers are distinguishable by their drillings on the
underside, but they do not carry any work-piece information. Therefor only this
assures correct processing.
2.2. Transport system The transport system is responsible for the transport of the work-pieces within the
system, which consists of various stations. A transport system comes into action to
ensure faultless carriage of work-pieces over long distances between stations.
The transport system requires several components for the work-pieces to be

positioned and transferred onto other stations. Some of them are: work-piece
carriers, palettes, stroke and index unit. A detailed description can be found in the
respective chapters.
For identification, the work-piece carriers are equipped with an I/O-ident system.
Each work-piece carrier has its individual number, as realised by a varied amount of
drillings on its underside. Thus it is possible to provide them with a specification on
their way. Up to max. 8 work-piece carriers can be used in one system.
Control of the transport system is realised by a Siemens S7, for which a control
cabinet is available, mounted onto the basic frame of the station. The station’s
internal data transmission ensues by an ASi-bus. Transmission to the other stations
is realised by an exactly defined I/O-interface.
2.3. Short cuts In this technical documentation the following abbreviations are being used:
WT = work-piece carrier
AP = operating position
Hubix = stroke and index unit
IX = stroke and index unit
ST = stopper
VS = virtual stopper!

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 recognised 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. Start-up
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.

Start-up
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).
The transport system station is the central element in this system. All of the other
stations are in connection with this station. For this reason, it is necessary to
examine the condition of the accomodation in detail before set-up.
Once the set-up position has been decided upon, the system can be installed in this
position. At first, the room has to be measured, if not done so previously. The
measures of all of the stations have to be marked roughly onto the floor space (i.e.
with adhesive tape), to avoid shifting at a later stage.
Now, the conveyor belt can be adjusted to an even level, by means of a spirit-level.
The belt should be adjusted to the height of 896 mm, the height of the transport belt
itself.
The transport system is to be screwed firmly to the ground by mounting brackets, as

soon as the transport system has been adjusted.
All of the other stations are positioned at their set-up position, to be connected with
the transport system by means of assembly aids.

Start-up
The following picture shows a complete set-up situation adapted to a more basic
area design. The stations are to be adjusted as shown, to warrant faultless work-
piece transferflow.
Set-up situation FMS 50 example

Start-up
Dimensional drawing of set-up FMS 50 example

Start-up
4.3. Commissioning Commissioning of the system can ensue only, once all of the stations are connected
to their definite position.
The transport system possesses several components, which require to be connected

before start-up. This process is described in the following chapters. Descriptions of
the other stations can be found in the corresponding station manual.
4.3.1. Pneumatic commissioning
The mechanic set-up must to be completed. In the beginning, the station is to be

connected to the pneumatic system in the room. The pneumatic maintenance unit
for the system is placed at one of the feet of the basic frame. The quick coupling
plug has a nominal size of 5 mm. In case the existing air supply system is equipped
with 7.9 mm nominal size, it is possible to exchange the quick coupling plug of the
maintenance unit with a larger one (adapter 1/8 on 1/4 required).
Once this has ensued, the station can be supplied with 6 bar and the pneumatic
commissioning is concluded.
4.3.2. Electric commissioning
At this point, the system requires to be supplied with electric voltage

The control cabinet for controlling the station is supplied with 230V voltage. The
cable included in the delivery possesses a standard plug with protective covering,
which is to be plugged into a sufficiently secured socket. Distribution boards are
included in the delivery, for the connection of the other stations as well. In case an
extension is required for the cable of the distribution board, it is to be executed by a
trained expert only. For the operators, the socket is to be secured.
To avoid problems during the operational process, individual protection (16A) of the
installation is recommended.
Attention has to be paid to the correct polarity of the power supply plug, as only one
phase of the main switch is to be de-activated in the transport system.

Start-up
4.3.3. Establishing communication connections
The internal communication lines of the transport system are hard-wired and do not
require connection or plugging in.
The communication connections to the other stations are to be set up according to

the following examples. The examples are kept on general terms, and as such are
valid for all stations. Discrepancy from standard are seperatly pointed at. Also, see
chapter “Preparation of MPS–stations for FMS 50”.
Example I/O-connectors
In order that the system “knows” that stations are present and processing can occur
stations, they have to be connected to the system by I/O-connectors. At each case,
the connections are established the control panel – not in case of the robot and the
vision station, as these are directly connected to the respective control devices (see
the following drawings).

Start-up
For more detailed information, the possible connections are listed below:
1. Connection by lab lines 4mm plug on both sides between MPS–stations

2. Connection by I/O – one side cable 4 mm plug / one side SYS-link plug
between transport system and MPS–stations
3. Connection by I/O – one side 37 pin Sub D-plug / one side SYS–link plug
between transport system and vision station
4. Connection by I/O – one side Phönix-plug / one side SYS–link plug
between AS/RS station and transport system
5. Connection by I/O – one side SYS–link plug / one side SYS–link plug
between robot station (RIA-BOX) and transport system
The connections are shown as graphics on the following pages.
For MPS-stations of the Release B the connections deviate from the connections of
Release C. For this, graphics are also available in the chapter “Preparation of MPS-
stations”.

Start-up

Start-up

Start-up
Distribution Station Testing Station Transport System
PART AV PART AV PART ON

PALLET
TRANSPORT
AS-i
IN ........
IN 0.7
IN 0.1
IN 0.1
IN 0.7
OUT 0.7
SYSLINK (AS-i)
Station 1 ready IN 2 AS-I Addr:

IN 4 OUT 6 IN 4 OUT 6 Stations ready
IN 5 OUT 7 IN 5 OUT 7 IN 3 AS-I Addr:
OUT 4 IN 6 OUT 4 IN 6 OUT 2 AS-I Addr:
Palette free OUT 3 AS-I Addr:
OUT 5 IN 7 0V OUT 5 IN 7
0V 0V
0V 0V 0V 0V
AS-I Addr:
IN 1 AS-I Addr:
OUT 0 AS-I Addr:
OUT 1 AS-I Addr:
IN 2
4mm Lab cable
IN 3
Signal SYSLINK
OUT 3
0V 0V
Connection Distribution station – Test – Transport system

Start-up
Processing Station PIC alfa Station Transport System
PART AV PART AV
Convert sensor to IN/OUTPUT-Position PART ON
dissemble el. Push-out PALLET
No application
for FMS50
TRANSPORT
AS-i
IN 0.1
IN 0.7
IN 0.1
IN 0.7
OUT 0.7
OUT 0.7
IN ........
SYSLINK (AS-i)
Processing ready for part Run release

IN 4 OUT 6 IN 4 OUT 6 IN 2 AS-I Addr:
Stations ready IN 3 AS-I Addr:
IN 5 OUT 7 Rotation release IN 5 OUT 7
OUT 4 IN 6 OUT 4 IN 6 OUT 2 AS-I Addr:
OUT 5 IN 7 OUT 5 IN 7 Pending order OUT 3 AS-I Addr:
0V 0V
0V 0V 0V 0V 0V
Part ready for AS-I Addr:

IN 1 AS-I Addr:
OUT 0 AS-I Addr:
OUT 1 AS-I Addr:
IN 2
4mm Lab cable
IN 3
Signal SYSLINK
OUT 3
0V 0V
Connection Processing station - PIC-alfa – Transport system

Start-up
Transport System PIC alfa station Sorting/Commissioning station
PARTAV PARTAV
Transport System
AS-i
IN 0.1
IN 0.7
OUT0.7
IN 0.1
IN 0.7
OUT0.7
AS-I Addr:
SYSLINK (AS-i)
OUT2 IN 4 OUT 6 IN 4 OUT 6

OUT3 FOL Stat. FREE* IN 5 OUT 7 IN 5 OUT 7
IN 2 OUT 4 IN 6 Sorting station ready OUT 4 IN 6
Stations ready
IN 3 OUT 5 IN 7 0V OUT 5 IN 7
0V 0V
0V 0V 0V 0V
OUT0
Sorting Station not ready, if:
IN 0 - it was not started (START-Button activated)
IN 1 - slides are full with workpieces
- no voltage supplied to the station
IN 2 - the station does not exist
IN 3
SYSLINK
OUT 3
0V 4mm Labor cable
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.
Connection Sorting station - PIC-alfa – Transport system

Start-up
Connection Vision station –Transport system

Start-up
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

Start-up
Connection Robot station - Transport system

Start-up
4.3.4. EMERGENCY-STOP system
The emergency-stop system is to be de-activated for transport. The connector

possibilities are listed below and are to be re-activated during start-up. The
complete emergency-stop system is described in the chapter “EMERGENCY-STOP”.
EMERGENCY-STOP connectors in control cabinet / conveyor belt
Example EMERGENCY-STOP connector on MPS- board

Start-up
All of the required EMERGENCY-STOP connectors can be established according to

this example.
i Plugs with links are to be inserted into the unoccupied operating positions, as
shown in the picture above.
Plug Type Device Example
2-pin Phönix
External
XNA11 2 Contacts for EMERGENCY-STOP
EMERGENCY- switch
STOP switch
from XNA11 to external EMERGENGY-STOP
4-pin Phönix
2 Contacts for
XNA01 EMERGENCY- e.g. Testing station
STOP,
2 Contacts for
feedback
from XNA01 at the conveyor belt to SPS-board
See also chapter EMERGENCY-STOP.

Start-up
4.4. Start-up process For the FMS50-installation the first start-up has been executed in the factory
already.
Implement the following directions that the system is ready for operation!
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
The chapter Operation describes the control units required for the operation, as well
as start-up and close-down of the system.
5.1. General notes on The stations demand strict adherence to certain rules of operation. Negligence in
operation observing these rules may cause errors in the stations’ processes. Also, damage to
physical health can not be excluded.
Strict observance of the following rules is demanded.
5.1.1. Handling regulations
Manual interference during the stations’ operation is prohibited.

In case of larger audience, a mechanical barrier of the station is required.
It is prohibited to pull off any cables while voltage supply is not deactivated.
Any kind of liquid is to be kept from the installation, at all times.
5.1.2. Operating regulations
The stations are to be operated only from trained personnel.

Operation is to ensue according to operating instructions.
Uncontrolled pressing of the various switches/push-buttons of the control units is to
be omitted/prevented.
No work-piece carriers should to be removed from the system.

Operation
Operation of the system ensues by means of several control units, as described

below.
5.2. Transport system 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 Transport system
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.

Operation
Control elements of the Transport system
Name Element Function
Indicator Acknowledge error

Error H8 Flashes
Automatic on is flashing
Flashes Indicator Start-up request

H5
Automatic on Light on Indicator system in operation
S5 Start up system
H6 Light on Indicator Automatic off

Automatic off
S6 Switch off motors of the conveyor belts
H1 Light on Indicator Controller off

Controller off Transport system is being completely de-activated
S1
(cp. EMERGENCY-STOP).
Indicator Request
H3 Light on
Controller on Acknowledge EMERGENCY-STOP
S3 Acknowledge EMERGENCY-STOP
EMERGENCY-
S2 De-activate control / EMERGENCY-STOP function
STOP
The table assists in operating the transport system station. All of the push-buttons
and lamps are described within.
Error indication/analysis is described in the chapter “Fault finding”.

Operation
5.3. Adjustment 5.3.1. Requirements
The MPS-stations of distribution, testing, processing, PIC-alfa and sorting can be

started with the adjustment process, as follows (standard-step7-program).
At first, adjustment of the distribution station is absolutely required, if the swivel

arm of the distribution station is located above the following testing station!
The adjustment process (is also to be executed after STOP- or EMERGENCY-STOP

activation) is independent from the switch position of the key actuator AUTO/MANU.
Auto – key actuator is vertical / Automatic cycle

Manuel – key actuator is horizontal / step cycle
5.3.2. Adjustment process of MPS-stations
1. RESET- Lamp light is on → Request for adjustment.

2. push RESET -button.
3. Station moves to basic position.
4. The START-lamp light is on → indicates arrival in basic position.
5. Turn AUTO/MAN - key actuator to 'AUTO' position (continuous cycle).
6. Push START -button → Station is in operation (no indication)

Operation
5.3.3. Adjustment process commissioning and AS/RS station
Due to station-specific reasons, the commissioning and AS/RS stations require a

different adjustment process:
1. The EMERGENCY-STOP system is activated (no signal generator is active;

EMERGENCY-STOP – switch unit acknowledged).
2. Turn AUTO/ MAN - key actuator to 'MAN’! (). Adjustment process can start
only, if switch is in this position.
3. Flashing RESET- Lamp → Request for adjustment.
4. Push RESET -button → Station moves to basic position:
- AS/RS station: first the axes move to their reference points and afterwards
return to their basic positions.
- Commissioning: the belt is to be activated and afterwards checked for
remaining work-pieces.
5. The RESET-lamp indicates arrival in basic position.
6. Flashing START-lamp, is a request for starting up operation of the station.
7. Turn AUTO/MAN - key actuator to 'AUTO' position.( | ).
8. Activate START push-button → Station is in operation → START-lamp is
flashing.

Operation
5.4. Automatic 5.4.1. Conditions and automatic start-up
1. Unlock EMERGENCY-STOP of the transport system and acknowledge.

2. After the adjustment process MPS-stations are ready for automatic mode.
3. 'AUTOMATIC ON' - Lamp flashes fast → Request for start-up of the transport
system. 'AUTOMATIC OFF' - Lamp lights up.
4. Push 'AUTOMATIC ON' -button → Transfer system starts up.
5. Operational condition is indicated by the 'AUTOMATIC ON'-lamp.
'AUTOMATIC OFF' - Lamp is going out.
6. Only at this point activate the robot controller. The procedure of initiation the
robot assembly is described separately.
5.5. Error and In case an error occurs in the transfer system, it is shown by a slowly flashing of the
error 'AUTOMATIC ON'-lamp and a lighten 'ERROR' lamp. As soon as the error has been
acknowledgement eliminated, it can be confirmed with the 'AUTOMATIC ON'-push-button.
Possible errors: e.g. a palette with work-piece arrives at the stopping station for
distribution/testing.
All further errors are described in the chapter “Fault finding”.
5.5.1. Error indication of the MPS-stations
Station Indicator light Q1 Indicator light Q2 Indicator light Q1 + Q2
Distribution Magazine empty
Testing Work-piece red / silver Work-piece black / silver
PIC-alfa Wait until processing of

(Processing) work-piece is concluded
Processing Processing in operation
Sorting Slide(s) full
AS/RS Stock occupied Stock empty
Assembly Spring magazine empty Cover magazine empty Piston magazine empty
Commis- Slides occupied

sioning

Operation
As a rule, the production process starts with the distribution station, where a
cylinder basic body is seperated and transfered into the system by means of the
testing station. In case no distribution station is included in the system, it is possible
to place the cylinder manually onto a work-piece carrier at any place of the transport
system. Processing of the work-piece takes place from the “place of equipment”
onwards.
5.6. Process description The following process description is limited to the transport system. The processes
of the other stations are described in the respective manuals.
1. A WT moves onto the stopper ST 1, which is extended in basic position.

2. The pallet code is read out.
3. The sensor WT at stopper ST 1 is activated.
4. The processing inside the station can take place.
5. After processing a signal is returned to the stopper.
6. Stopper ST 1 opens up and the WT is released, if the following congestion
stretch is released. The congestion stretch is controlled by a congestion sensor
and the signal is changing from 1 to 0 (negative edge) if the congestion stretch
is released.
7. After crossing the sensor WT at stopper ST1 the stopper ST1 closes up again.
8. The next WT moves onto stopper ST1.

Operation
5.7. Material flow The FMS50 installation reacts flexible to the changes during the production process
and controls the material flow according to circumstances. For this, various starting
conditions are described.
Warenausgabe
Product output Lager
Stock Montage
Assembly
Small parts stock
Pre-sorting
Wareneingang
Product input Processing
Bearbeitung Quality assurance
Qualitätssicherung
Example: Layout of material flow of the FMS 50 System
The following icons are used for the representation of the material flow.
Legend

Operation
5.7.1. Situation 1 – material flow from product input to product output
The installation has been put to operation, according to instructions.
The material input – the distribution station can distribute work-pieces (magazines
are filled) and the work-piece transfer of the test station functions faultless, ready to
start operational processing.
The robot assembly station is ready for the assembly of cylinders.
The AS/RS station is ready for operation and parts-storage (stock is empty).
The product output is ready, i.e. the PIC-alfa and sorting stations are ready for
operation and parts can be accepted.
Warenausgabe
Stock Montage
Assembly
Wareneingang
Product input
Situation 1 for material flow

Operation
5.7.2. Situation 2 – material flow from product input to stock
The installation has been put to operation, according to instructions.
The product input – the distribution station can seperate work-pieces (magazines
are filled) and the work-piece transfer of the test station functions faultless, ready to
start operational processing.
The robot assembly station is ready for the assembly of cylinders.
The AS/RS station is ready for operation and parts-storage (stock is empty).
The product output is not ready:

i.e. the PIC-alfa station is ready for operation, but the sorting station is not ready yet.
The possibility is now, that the sorting station has not been activated or
adjusted/started or already executed a sorting process (all 3 slides are occupied).
Warenausgabe
Stock Montage
Assembly
Wareneingang
Product input
In case parts are still remaining between stock and product output, they are placed
onto a buffer slide by PIC-alfa.

Operation
5.7.3. Situation 3 – material flow from stock to product output
The system is in operation. The magazine of the distribution station is empty. For
this reason it is impossible for the test station to place any work-pieces onto the
palettes. The empty palettes are allowed to pass the operating position.
The robot assembly station cannot be supplied with basic bodies, therefore
production of cylinders cannot ensue.
The AS/RS station is ready for operation and parts can be stored or removed, as the
stock contains parts and is not full up. Parts arriving on palettes are allowed to pass
through to the product output. Empty palettes are filled with parts from the stock.
The product output is ready, e.g. the PIC-alfa and sorting stations are ready for
operation and able to sort parts.
Warenausgabe
Stock Montage
Assembly
Wareneingang
Product input

Operation
5.7.4. Situation 4 – material flow mixed operation
The system is in operation. The distribution station can seperate work-pieces

(magazine stocked up) and the test station transfers work-pieces onto palettes.
The robot assembly station assembles cylinders.
The product output is ready, e.g. the PIC-alfa and sorting stations are ready for
operation, cylinder sorting.
The AS/RS station is ready for operation and is able to store or remove parts, as the
stock contains parts and is not full up. Parts arriving on palettes are allowed to pass
through to the product output. Empty palettes are filled with parts from the stock
(retrieval).
Warenausgabe
Stock Montage
Assembly
Wareneingang
Product input

6. Profibus-DP with WinCC
6.1. System information The FMS50 system is extended with a communication layer for using a SCADA
for FMS50 Level 2 system (Supervision, Control And Data Acquisition) like WinCC, for FMS50 it is called
"Level 2". For data exchange between SCADA system WinCC and the PLCs the
Profibus-DP field bus is used. All PLC stations are configured as Master, therefore
there is no data exchange programmed between PLC stations. WinCC is sending and
receiving data from/to the PLCs. PLC inputs, outputs or memory bits are used for
visualization. Reading and writing information (change value) is only possible with
memory bits or data block contents (bit, byte, word, …).
6.1.1. Start-up FMS50 Level 2
Before activating WinCC you have to make sure all FMS50 programs for Level 2 have
been downloaded to each PLC and all system cable connections are made:
DC24V power supply

6bar system pressure
I/O communication cables according to FMS50 handbook
Profibus cables connecting each PLC and computer
System requirements for FMS50 project:
Windows 2000 with SP2, English or German Version with Internet Explorer V5.5
Step7 V5.1 SP3
Profibus-card installed to the computer, e.g. Siemens CP5611, CP5613 or CP5511
WinCC V5.1 with WinCC-Application "FMS50_WinCC_Application_V3" or higher
Notice: Please make sure that all software and hardware has been installed in this order !

Profibus-DP with WinCC
6.1.2. Profibus network settings
Profibus-DP
Profibus-DP network example
Station Profibus-DP address
Distribution 2
Testing 4
Processing 6
Handling (Processing) 8
Vision System (not connected via Profibus) (reserved, 10)
Robot-interface 12
ASRS20 14
Handling (Sorting) 16
Sorting 18
Conveyor System 20

6.2. Commissioning 6.2.1. Step 1 – PLC Download

FMS50 Level 2
Reset all PLCs and download all Step7 programs for Profibus Level 2 to each PLC.
Start the PLCs again -> RUN
6.2.2. Step 2 – Setup WinCC
Double click on WinCC icon at desktop or see picture below:

Open the WinCC application for FMS50 Level 2
→ File → Open →

for example:
C:\siemens\wincc\WinCCProjects\FMS50_WinCC_Application_V3\FMS50_WinCC_Ap
plication_V3.MCP
If you start WinCC the next time, always the previous project will open automatically.
→ Open

In a WinCC project for Single-User System the computer is the operating server for
the SCADA system. Therefore you have to change the server name to your computer
name. But first you have to start the project and than change the name.
→ Start server locally
The computer name in the project should be changed to your computer name.
Otherwise the project cannot open the runtime.

Change the computer name:

→ WinCC Explorer → Computer → actual computer name in right window
→ double click → Computer properties → change name
If you don´t know the computer name please see Step 3 (example for operating
system Windows 2000)!

→ OK
→ OK

Please close WinCC and restart.
File → Exit
→ OK
Now restart WinCC (see Step 2)
next: Step 4

6.2.3. Step 3 – Search for computer name
Open Network and Dial-up Connections
→ Start → Settings → Network and Dial-up Connections

Open network identification
→ Advanced → Network Identification…

You will find the computer name, e.g. "festo1"

6.2.4. Step 4 – Check Connection Parameter
For communication between WinCC and PLCs via Profibus-DP network it is necessary
to choose system parameters for WinCC.
→ + Tag Management → + SIMATIC S7 PROTOCOLL SUITE → + PROFIBUS

PROFIBUS → on click with right mouse button → System Parameter…

Please choose your Profibus driver card. Possible Profibus cards available:
CP5511, CP5611 (e.g.), CP5613 and old CP5412
Don´t make changes if this is already your setup.
e.g. choose CP5611(PROFIBUS)
→ OK

6.2.5. Step 4 – Activate WinCC
→ File → Acticate (or click on icon at menu bar

6.3. Use FMS50 Level2 A process visualization is developed as a hierarchical structure of windows with
Runtime Application different priority. The hierarchy of the FMS50 Level 2 visualization is shown below.
01_Start.pdl
02_System_overview_Anlagen_Uebersicht.PDL
10_Distributing_Verteilen.PDL
03_Commissioning_Inbetriebnahme.PDL
12_Handling_Proc_Bearb.pdl
04_Profibus_Network_Netzwerk.pdl
13_Processing_Bearbeiten.pdl
05_Message_Alarm.pdl
15_RobotAssembly_RoboterMontage.pdl
16_ASRS20_Hochregallager20.pdl
17_Handling_Sorting_Sortieren.pdl
18_Sorting_Sortieren.pdl
Only below the second hierarchical level it is possible to control the FMS50 process.

Window: 01_Start.pdl
3 1
2
Buttons and functions:
1 Start Enter FMS50 application

2 Change Language choose language English or German
3 Exit Runtime deactivate runtime

Window: 02_System_overview_Anlagen_Uebersicht.PDL
8 9
10
5 6 1 2 3
Buttons
1 Commissioning Open picture for commissioning the system

2 Profibus Network Open picture to view Profibus connections
3 Message Alarm Open picture to view messages and alarms
4 Station buttons Click for open picture of each station.
There are additional signs displayed at:
- Distributing "Magazine empty!"
- Robot Assembly "Magazine empty!"
- ASRS20 "Storage full!"/"Storage empty!"
- Sorting "Slide(s) full!"
5 Exit Runtime Close WinCC Runtime
6 Home Return to start picture (change language)

Functions
7 Automatic ON/OFF Click for turn ON/OFF automatic function of conveyor

Reset error with click on Automatic ON (flashing)
8 Error! Sign will be displayed if there is an error occurred at
the conveyor system, see also error lamp on switch
cabinet and message at "Message and Alarm"
picture. Automatic ON button will be flashing at
switch cabinet and picture for reset the error.
9 Emergency Sign will be displayed if the Emergency System has
been activated/ not deactivated
10 Indexing Unit Pallet is displayed at indexing unit.
Pallet number is displayed from reading unit.
"Section full" is displayed.
If error is shown at the system overview please check the "Message and Alarm"
picture for detailed information.
Error location Displayed Errors Error corrective action
Distributing "Magazine empty" Fill magazine and press START-button

for restart
Distributing "Empty pallet" Pallet with part has arrived at station.

Distributing and Testing need a empty
pallet. Therefore take off part and reset
error by pressing AUTOMATIC ON-button
at conveyor or picture
Vision "Bad part" Vision system checked part as "bad

part". Take off bad part from pallet and
reset error by pressing AUTOMATIC ON-
button at conveyor or picture
Robot "Magazine empty" One of the magazines at assembly is

empty, please refill and restart robot
with START-button.
ASRS20 "Storage empty" Storage is empty
ASRS20 "Storage full!" Storage is full. Please take out parts and
reset ASRS20. Please see description for
ASRS20 at next pages!
Sorting Slide(s) full! During automatic function on of the

slides is full. Please empty and restart
station.
Also this error is displayed if one or both
stations are not started.

Window: 03_Commissioning_Inbetriebnahme.PDL
4
5
1 Driver Preset Enter the number of the driver you want to connect.
Value
Standard drivers are:
0 = not connected
1 = Distributing and Testing
2 = Handling and Processing
3 = Vision (depends on used vision system)
4 = Robot and Assembly
5 = ASRS20
6 = Handling and Sorting
The function of the driver may vary if specified
differently in the project !
Please check your Step7 program for driver
functions!

2 Driver Switch Each work station can be activated/deactivated

- green (active), the conveyor will start driver for
communication between work station
and stopper unit
- red (stopped), no communication between work
station and stopper
Activate/deactivate driver by mouse click on switch!
Warning: Each change has direct influence
to the conveyor system !!!
3 Driver Display Status of driver will be displayed
4 NOTICE A information will be displayed about driver
description
5 Back Click on to go back to system overview

Window: 04_Profibus_Network_Netzwerk.pdl
Functions:
1 Connections Each active Profibus connection from SCADA system

to PLC station will be displayed.
If the PLC station is not accessible there can be
different reasons:
- bad cable connection
- Profibus end resistor not terminated
- PLC is in "Stop" mode
- station does not exist in setup

Window: 05_Message_Alarm.pdl
Functions:
1 Messages: Error messages and system messages will be

displayed
if a certain status occurs
"Emergency"
e.g.
"Error" (at conveyor system)
"Magazine empty" (Distributing, Robot Assembly)
etc.

Window: 10_Distributing_Verteilen.PDL
4 5
1
6
7 8
1 Animated objects Position of magazine and swivel arm is shown

2 Station inputs Actual status of station inputs is shown
3 Station outputs Actual status of station outputs is shown
4 Control panel Actual status of communication is shown
(I4-I7, Q4-Q7)
With click on buttons Start, Stop or Reset it is
possible to have remote access to stations from
SCADA system
- Start-Button, activate sequence program after reset
- Stop-Button, stop sequence program
- Reset-Button, move station to normal position

5 Error!: Sign will be displayed if an error occurs at the

conveyor system, see also error lamp on switch
cabinet
6 Emergency: Sign will be displayed if the Emergency System has
8 Testing Click on to go to picture of Testing Station

Window: 11_Testing_Pruefen.pdl
3 4
1 Station inputs Actual status of station inputs is shown

2 Station outputs Actual status of station outputs is shown
(I4-I7, Q4-Q7)
possible to have remote access to stations from
SCADA system
cabinet
Following stations windows have similar functions:
12_Handling_Proc_Bearb.pdl
13_Processing_Bearbeiten.pdl
17_Handling_Sorting_Sortieren.pdl
18_Sorting_Sortieren.pdl

Window: 15_RobotAssembly_RoboterMontage.pdl
3 4
6
7 8
Warning: 1 Station inputs Actual status of station inputs is shown

For remote control of robot 2 Station outputs Actual status of station outputs is shown
please see station manual !
(I4-I7, Q4-Q7)
Control panel functions are With click on buttons Start, Stop or Reset it is
different from standard possible to have remote access to stations from
stations ! SCADA system
cabinet


Warning:
Please, don't use manual 7 Start Assembly Start assembly process manually (for
commissioning)
functions if conveyor is
running !!! 8 Take out bad part Start bad-part process manually (for commissioning)

Window: 16_ASRS20_Hochregallager20.pdl
3 4
Warning: 1 Station inputs Actual status of station inputs is shown

For remote control of 2 Station outputs Actual status of station outputs is shown
ASRS20 please see station
manual !
(I4-I7, Q4-Q7)
Control panel functions are possible to have remote access to station from
different from standard SCADA system
stations ! - Start-Button, will activate sequence program after
reset Aut/Manu-key switch has to be in Automatic
position
- Stop-Button, will stop sequence program at end of
cycle
- Reset-Button, will move station to normal position
Aut/Manu-key switch has to be in Manual position


cabinet
7 Storage cells Status of storage cells is shown (empty/full)
8 Empty Storage Button is only active if storage is full!
If storage is full please:
1. take out parts from storage
2. click on "Empty Storage" to clear storage spaces
3. click on "RESET" to restart ASRS20

7. Technology
This chapter refers to the technical interrelations of the transport system.
The technical drawings and technical data below are very helpful to facilitate set-up
of the station. The technical data of the accomodation is to be checked before set-up
of the station.
The load capacity of the ground, the sizes of doors and access are to suit to the
system’s dimensions.
Technical drawing Transport system

Technical drawing Transport system
Pos. Designation / Criterion Measurements / Feature
1 Width 500 mm
2 Max. width with stoppers 720 mm
3 Length 3000 mm
4 Max. length with stoppers 3050 mm
5 Belt height 895 mm
6 Min. belt height 905 mm
7 Max. belt height 885 mm
8 Belt width 40 mm
9 Belt speed 9 m/min.
10 Voltage of motor 230 V
11 Torque 8,7 N/cm
12 Current consumption 24 W
13 Start-up current 0,11 A
14 Speed 2600 1/min
15 Speed outlet gear 74,29 1/min
16 Transmission ratio gear 35:1
17 Weight Ca. 400 kg
18 Max. amount of work-piece carriers 8

The transport system contains 6 operating positions. Any of the MPS-stations can be
placed in any of the 6 operating positions. The following description relates to the
standard system.
7.1. Operating position 1 The distribution and testing MPS-stations are situated in operating position 1. The
work-pieces are seperated in the distribution station and transferred to the testing
station. The distribution station is not connected directly to the transport system. It
is located beside the testing station. The testing station is connected to the
transport system, and additionally to work-piece testing it performs the work-piece
transfer to the transport system.
The material flow is started from this operating position.
7.2. Operating position 2 The PIC-alfa station is located in operating position 2. It realises the material
transport to the processing station, which is situated directly beside the PIC-alfa
station executing the drilling of a hole and testing afterwards.
7.3. Operating position 3 A vision system is mounted on operating position 3. The camera is mounted directly
at the transport system and is located above the operating position. Therefore
changing position of the work-piece is not necessary . The evaluation system of the
camera is situated on a MPS-carriage or operating table.
7.4. Operating position 4 The robot assembly station is located at operating position 4, consisting of 2 MPS-
carriers, whereby the robot RV-2AJ is mounted onto the carrier, which itself is
directly situated beside the transport system. The robot executes the handling of the
work-pieces and of the assembly components. At this operating position, a model
cylinder is assembled by the robot.
7.5. Operating position 5 At operating position 5, the AS/RS station is available for material storage, where
the work-pieces can be stored and removed.
7.6. Operating position 6 The sorting or commissioning station is situated in operating position 6. By means of
a PIC-alfa station, which is directly connected to the transport system, it receives its
work-pieces to sort them according the colour ot the cylinders.
At this operating position the material flow is concluded.


8. Pneumatics
The work-piece carriers are stopped of a pneumatic cylinders. The valve required for
the control consist of one CPE10 single valve.
8.1. The valve
Example Valve CPE10
This valve terminal is especially configured for the transport system.
Pos. Designation
1 Order number 161 868
2 Order designation CPE10-M1H-5L-Mt
3 Order number cable MZB9-2E..AZ

Pneumatics
The valve is controlled via ASI, to connected the valve with the ASI-bus the valve
interface is necessary.
8.2. The valve interface
Example valve interface ASI-EVA
The valve is wired with the valve interface. Optional it is possible to connect to
inputs to the interface.
Pos. Designation
1 Order number 196 087
2 Order designation ASI-EVA-K1-2E1A-Z
3 Outputs 1
4 Inputs 2

Pneumatics
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
8.2.1. Configuration the additional power supply (load voltage)
Setting DIP switch setting *
With load voltage ** 1,2: off
(factory setting) 3,4: on
With load voltage ***

1,2: on
(seal the “24V DC” connection with
3,4: off
blanking plug type ASI-SD-FK-BL))
* Black = pressed
** The outputs/valves are provided with power via the additional supply
*** The outputs/valves are provided with power via the Asi-Interface bus

Pneumatics
8.3. Pneumatic The pressure in the supply line must not exceed 10 bar.
connection
A fine filter has to be installed, to prevent contamination by rust or similar
contamination.
A stop cock is required for the supply of the system.
The pressure regulators installed in the system should be set in between 6 and 5
bar. The filter and water separators require maintenance according to the
instructions of this documentation.
Maintenance unit

9. Electrical system
To this chapter belongs the connection of all of the supply cables and
communication cables required for the operation of the system.
To give you a better overview of the contact lines used in the installation, these are
explained in the following.
9.1. Supply voltage The transport system is delivered with the appropriate power supply plug covered
by protective contact, which is to be plugged into a socket, fixed according to
standard. The voltage amounts to 230 V.
The customer is required to ensure, that the supply net is duly earthed and does not
possess fault current monitoring.
In case several devices of the installation are to be activated simultaneously, they

can be connected to a distribution board with switch, within the scope of the
permissible total output.
The power supply (24VDC) of the transport system outside the control cabinet is
made by a 2-pin cable. The voltage supply is the 24V power supply unit in the
station. The 24V can be tapped by the clamps.
Voltage supply Transport system

Electrical system
9.2. Control cabinet The control cabinet is set up as shown in the picture below. The individual
components are designated.
Control cabinet of the Transport system
The frequency converter generates the voltage required for the motors.
The ASi-power supply unit supplies not only the ASi-voltage of 30,5 V, but also the
supply voltage of 24V for the control cabinet and the transport system.
The other components are described in detail in the respective chapters.

Electrical system
9.3. EMERGENCY-STOP The EMERGENCY-STOP system is controlled centrally by the transport system
system station. In the control cabinet of the station an EMERGENCY-STOP switch device is
located, which is connected to all of the operating positions and all external
EMERGENCY-STOP devices.
9.3.1. External EMERGENCY-STOP device
Example: external EMERGENCY-STOP Transport system
The external EMERGENCY-STOP devices are controlled by a 2-pin cable. The devices
are connected to the 2-pin Phönix plug-in contact. In case no device is plugged in,
the contact is to be established with a strapped plug.
9.3.2. EMERGENCY-STOP at the PLC-board
The PLC-boards are connected to the 4-pin plug-in contacts. In this case 2 lines are
for the feedback (station available) and 2 lines for the EMERGENCY-STOP of the PLC-
board.
An exception is made by the commissioning station, as it requires to be controlled

by 2 4-pin cables. A 4-pin cable leads to the PLC-board, as it is the case for all other
stations. However, the second cable leads to the station’s frequency converter,
which again is controlled separately.

Electrical system
External Emergency-Stop
Emergency-Stop push button Emergency-Stop push button
e.G. Testing station e.G. Transportsystem

Phönix plug -in Phönix plug-in
2pin 2pin
1 2 1 2
-XNA11 -XNA12
1 2 1 2
-XN11 -XN12
XNA13 ==> XNA18
Other external emergency-stop devices
CPU 314
CP 342-2 SM323
SIEMENS SF
BAF
Asi Master DI8/DO8 xDC24V
DC 5V SF
FRCE RUN 0
RUN APF 1
STOP CER 2
AUP 3
CM 4
-XNA1
5
RUN-P
-XN1
Phönix plug-in
30+ 6
RUN
20+ 7
10+
STOP
MRES SET
4 pin
Simatic 0 0
S7-300
1
1
1 1
2 2
5
3 3
4
2
2 4 4
3
5 5
2
6 6
1
3
3
7 7
X 2 X 2
X1MPI 3 4 3 4
4
4
Operatingposition 1
Emergency-stop switch device
S11 S12 S12 S21 S22 S33 S34 Y1 Y2 S52 S11 13 23 33

Transportsystem
A1 B1 13 23 33 43 53 63 73 81 91 A1 Y1 Y2
Power Pilz 13 23 33 43 53 63 73 81 91
If no station exists in an operating position,
-XNA2
CH. 1 IN PNOZ X9 a plug with a strap is to be inserted

-XN2
Phönix plug-in
CH. 1
CH. 2 IN for the feedback.
4 pin
START CH. 2
1
1
CH. 1 OUT
2
2
13 23 33 43
14 24 34 44 54 64 74 82 92
3
3
CH. 2 OUT
4
4
14 24 34 44
14 24 34 44 54 64 74 82 /B2 A2 43 55 A2
Y30 Y31 Y32 Y35 Y1 S37 14 24 34

Operatingposition 2
CPU 314
CP 342-2 SM323
SIEMENS SF
BAF
Asi Master DI8/DO8 xDC24V
DC 5V SF
FRCE RUN 0
RUN APF 1
STOP CER 2
AUP 3
CM 4
-XNA3
5
RUN-P
-XN3
30+ 6
RUN
Phönix plug-in
20+ 7
10+
STOP
MRES SET
4 pin
Simatic 0 0
S7-300 1 1
1
1
2 2
5
3 3
9
4 4
8
2
2
5 5
7
6 6
6
7 7
3
3
X 2 X 2
X1MPI 3 4 3 4
4
4
Operatingposition 3
Line for external Emergency-stop

Other operating positions
XNA4 ==> XNA10
Line for SPS emergency-stop

other stations
Line for feedback

10. Control system
Control of the transport system is taken on by a PLC (memory programmed control).

Function of the PLC is the control of the transport system. Additionally, it serves the
higher purpose of retaining communicating with the other stations, which occurs by
a defined I/O-interface. Consequently, the control takes on a master function in the
complete control layout.
There are 3 different versions of controlling
L1 = communication via I/O

L2 = communication via I/O and Profibus DP for operation and observation
L2 = communication via I/O and Ethernet for operation and observation
For this, the control for the transport system, of the Siemens S7-300 group, consists
of several modules.
10.1. Control set-up Plug-in Address Module Designation Comments

place
1 2 Control CPU-313C (L1/L3)
CPU-313C 2DP (L2)
3 Virtually occupied
2 4 ASi-card CP 342-2 (L1/L2/L3) For in- and external

communication
3 5 Ethernet- CP 343-1IT (L3) For operation and observation

card
Control transport system example

Control system
10.2. Wiring The station’s internal wiring and the wiring to the other stations is explained as
following.
10.2.1. I/O-components
The control elements are directly connected to the control of the Transport system.
Control elements Communication example

Control system
The I/O-interface is standardised to guarantee faultless communication. The I/O-

terminal is available at all of the operating positions.
Data I/O-terminal
Technical data
Plug type IEEE 488 24-pin
Inputs 8 (from which 4 are connected)
Outputs 8 (from which 4 are connected)
Current consumption Max. 1A each PIN
Supply voltage 24VDC

Control 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 Colour 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 Brown-
3 Output yellow 16 3 Input
green
05 White-
4 Output grey 17 4 Input
yellow
06 Yellow-
5 Output pink 18 5 Input
brown
07 6 Output blue 19 6 Input White-grey
08 7 Output red 20 7 Input Grey-brown
09 24
Voltage supply black 21 24V Voltage supply White-pink
V
10 22
11 0V Voltage supply pink-brown 23 0V Voltage supply White-blue
12 0V Voltage supply purple 24

Control system
10.2.2. ASi-participant
The ASi-participants are connected to the control by means of a yellow ASi-cable,

protected against polarity by its shape. The amount of ASi-participants is limited. Up
to max. 31 participants can be connected to an ASi-circle.
Example ASi-wiring

Control system
Asi-adresse 01 is reserved internally by the Siemens Software and is therefore not

available for any participant.
As the internal I/O-mapping of the control only starts showing singularity from ASi-
address 02 onwards, allocation of ASi-address 01 is omitted.
ASi-assignation ASi-address Module Function Designation Text

Operating position 1
Input I1 B10.1 Work-piece carrier at stopper ST1
4 I-FK
Input I2 B10.2 Congestion sensor
02 Inputs
Segment 1 Input I3 B10.3 Workpiece on workpiece carrier
Input I4 B10.4 Workpiece counter
2 I/1O-EVA- Input I1 B10.5 Stopper ST1 is released

MF-2E1A-Z
03 Input I2 Not used
In/outputs
Segment 1 Output O1 Y10.1 Release stopper ST1
Input I1 I/O-coupling Input 1

4I/O-3RG90 Input I4 I/O-coupling Input 4
04 In/Outputs
Segment 1 Output O1 I/O-coupling output 1
Output O2 I/O-coupling output 2

Control system
ASi-allocation ASi-address Module Function Designation Text

4 I-FK
05 Inputs

MF-2E1A-Z
In/outputs

07 In/Outputs

Control system

4 I-FK
08 Inputs

MF-2E1A-Z
In/outputs

10 In/Outputs

Control system

4 I-FK
11 Inputs

MF-2E1A-Z
In/outputs

13 In/Outputs

Control system

4 I-FK
14 Inputs

MF-2E1A-Z
In/outputs

16 In/Outputs

Control system

4 I-FK
17 Inputs

MF-2E1A-Z
In/outputs

19 In/Outputs

Control system
10.3. Programming In this chapter, it is not possible to refer in detail to the programming of a PLC-
control. However, the interface is shown below. The allocation list provides easy and
clear programming . The ASi-tables in this chapter are also very helpful in speeding
up allocation processes.
Example Programming interface
Two possibilities exist for the programming of the Siemens controls.
A MPI-cable is sufficient for programming, if a special Siemens-programming device

is available. However, in case programming ensues by means of a general PC, a MPI-
card is required, which has to be installed into the PC. In case a PC with this card is
available, work can start with an ordinary cable as well.
A MPI-cable with an adapter box is required, in case a PC is programmed without

MPI-card.

11. Fault finding
This error list has been drawn up to restore operation of the system as soon as
possible, after the appearance of an error.
Error Error correction
Palette with work-piece arrives in the Remove work-piece from palette and acknowledge
stopping station of distribution/testing error in transfer system.
station. Only empty palettes should reach
this point.
The commissioning station is not ready and Retrieve work-piece from palette. Clear the
the AS/RS station is full. Now, a palette with commissioning slides of the commissioning station. Re-
work-pieces arrives in the AS/RS stopping start station by activating the STARTpush-button (new).
station. Acknowledge error in the transfer system.
A work-piece is placed incorrectly on the Place work-piece manually into palette’s work-piece
empty palette in the stopping station by reception
the (air) slide of the testing station. Work- (in processing direction - right rear-end).
piece is not in fixture or is not placed in
range of the light barrier.
Palette with work-piece waits at the Palettes have to be removed from the stopping station
stopping station of PIC-alfa/sorting or only, once the work-piece has been removed from PIC-
commissioning and no action ensues. PIC- alfa.
alfa is not ready or not started up.
EMERGENCY-STOP has been activated. An EMERGENCY-STOP unit requires separate

The robot controller still keeps on acknowledgement.
bleeping after the EMERGENCY-STOP Activate the RESET key of the controller or
switch device has been acknowledged. 'ERROR/RESET' of the teachbox.

Preparation MPS-stations
Installation conditions Action
For product output, max. 18 parts can be All 3 of the slides are to be cleared.
commissioned onto 3 slides by the Activate START push-button.
commissioning station. Commissioning station is ready for operation again.
The START-lamp begins to flash, once a
commissioning process has been
concluded (slides full).
Palette with work-piece waits at stopping Work-piece is to be removed from palette by PIC-alfa.
station PIC-alfa/commissioning. Poss. start-up of PIC-alfa.
Palette with work-piece waits at stopping PIC-alfa and sorting station are not ready, e.g. not
station PIC-alfa/sorting. activated, not adjusted or one of the sorting slides is
occupied.
→ poss. retrieve work-pieces from slides
→ adjust stations and start up
→ poss. activate voltage supply or pressure
Once the cause has been debugged, activate the START

push-button.
Palette with work-piece waits at PIC-alfa Processing station is not ready.

/processing. Work-piece has been Sensor B8 „work-piece present“ is possibly not
processed and placed on palette of PIC- adjusted properly– requires re-adjustment.
alfa. No release of the palette ensues at
this point.

FMS50 Manual A001 V10

Uploaded by

Copyright:

Available Formats

FMS50 Manual A001 V10

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

FMS50 Manual A001 V10

Uploaded by

Copyright:

Available Formats

FMS 50

Part A contains the manual of the system or station.

Name: Manual FMS 50

Author: Schober / Helmich

Graphics: Schober / Helmich

© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2002

2 © Festo Didactic GmbH & Co. • FMS 50

2.1. General information FMS 50 _____________________________________ 7

2.2. Transport system______________________________________________ 8

2.3. Short cuts ___________________________________________________ 8

3. General safety instructions ________________________________________ 9

3.1. Use according to regulations ____________________________________ 9

3.2. Handling the system ___________________________________________ 9

3.2.1. Dangers in handling the machine _____________________________ 9

3.2.2. Safety precautions in standard operation ______________________ 9

3.2.3. Dangers due to electric current _____________________________ 10

3.2.4. Dangers due to pneumatic energy ___________________________ 10

3.2.5. Maintenance – Servicing – Malfunction removal ________________ 11

3.2.6. Organisational measures __________________________________ 11

3.3.1. Notes on personnel _______________________________________ 11

3.3.2. Training operations _______________________________________ 11

3.3.3. Outside training operations ________________________________ 11

3.3.4. Safety symbols __________________________________________ 12

4.1. Transport ___________________________________________________ 13

4.2. Set-up _____________________________________________________ 14

© Festo Didactic GmbH & Co. • FMS 50 3

4.2.1. General information ______________________________________ 14

4.3. Commissioning ______________________________________________ 17

4.3.1. Pneumatic commissioning _________________________________ 17

4.3.2. Electric commissioning ____________________________________ 17

4.3.3. Establishing communication connections _____________________ 18

4.3.4. EMERGENCY-STOP system _________________________________ 28

4.4. Start-up process _____________________________________________ 30

5.1. General notes on operation ____________________________________ 31

5.1.1. Handling regulations______________________________________ 31

5.1.2. Operating regulations _____________________________________ 31

5.2. Transport system_____________________________________________ 32

5.3. Adjustment _________________________________________________ 34

5.3.1. Requirements ___________________________________________ 34

5.3.2. Adjustment process of MPS-stations _________________________ 34

5.3.3. Adjustment process commissioning and AS/RS station __________ 35

5.4. Automatic __________________________________________________ 36

5.4.1. Conditions and automatic start-up___________________________ 36

5.5. Error and error acknowledgement _______________________________ 36

5.5.1. Error indication of the MPS-stations _________________________ 36

5.6. Process description___________________________________________ 37

5.7. Material flow ________________________________________________ 38

4 © Festo Didactic GmbH & Co. • FMS 50

5.7.1. Situation 1 – material flow from product input to product output __ 39

5.7.2. Situation 2 – material flow from product input to stock __________ 40

5.7.3. Situation 3 – material flow from stock to product output _________ 41

5.7.4. Situation 4 – material flow mixed operation ___________________ 42

6. Profibus-DP with WinCC _________________________________________ 43

6.1. System information for FMS50 Level 2____________________________ 43

6.1.1. Start-up FMS50 Level 2 ____________________________________ 43

6.1.2. Profibus network settings __________________________________ 44

6.2. Commissioning FMS50 Level 2 __________________________________ 45

6.2.1. Step 1 – PLC Download ____________________________________ 45

6.2.2. Step 2 – Setup WinCC _____________________________________ 45