Station Pick&Place

Handbuch

Pick&Place station
Manual

CD-ROM included

678864 de/en
04/06 R2.2
Contents

1. Introduction __________________________________________________ 57
1.1 Training contents ______________________________________________ 58
1.2 Important notes _______________________________________________ 59
1.3 Duty of the operating authority___________________________________ 59
1.4 Duty of trainees _______________________________________________ 59
1.5 Risks involved in dealing with the Modular Production System _________ 60
1.6 Warranty and liability __________________________________________ 61
1.7 Intended use _________________________________________________ 61

2. Notes on safety _______________________________________________ 63

3. Technical data ________________________________________________ 65

3.1 Combinations _________________________________________________ 65

4. Transport/Unpacking/Scope of delivery __________________________ 67

5. Design and function ___________________________________________ 69

5.1 The Pick&Place station _________________________________________ 69
5.1.1 Set-up as individual station _____________________________________ 71
5.1.2 Set-up with downstream station __________________________________ 71
5.2 Function _____________________________________________________ 72
5.3 Sequence description __________________________________________ 72
5.4 Pick&Place module ____________________________________________ 73
5.5 Conveyor belt module __________________________________________ 74
5.6 Slide module _________________________________________________ 75

6. Commissioning _______________________________________________ 77
6.1 Workstation __________________________________________________ 77
6.2 Mechanical set up _____________________________________________ 78
6.2.1 Assembling profile plate and control console _______________________ 78
6.2.2 Assembling the station _________________________________________ 79
6.3 Adjust sensors ________________________________________________ 80
6.3.1 Proximity sensor (Pick&Place, mini slides) _________________________ 80
6.3.2 Pressure switch (Pick&Place, vacuum suction cup)___________________ 81
6.3.3 Diffuse sensor (Conveyor belt, detection of workpieces) ______________ 82
6.3.4 Through-beam sensor (Conveyor belt, detection of workpieces) ________ 83
6.4 Adjusting one-way flow control valves _____________________________ 84

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Contents

6.5 Visual check __________________________________________________ 84

6.6 Cable connections _____________________________________________ 85
6.7 Pneumatic connection __________________________________________ 86
6.7.1 Manual override _______________________________________________ 86
6.8 Voltage supply ________________________________________________ 86
6.9 Loading the PLC program _______________________________________ 87
6.9.1 Siemens controller _____________________________________________ 87
6.9.2 Festo controller _______________________________________________ 90
6.9.3 Allen Bradley controller _________________________________________ 92
6.9.4 Mitsubishi/MELSEC controller ___________________________________ 95
6.10 Starting the sequence __________________________________________ 97
6.11 Combination of stations ________________________________________ 98
6.11.1 Networking ___________________________________________________ 98
6.11.2 Hardware modifications ________________________________________ 98

7. Maintenance _________________________________________________ 99

Content of the CD-ROM ______________________________________________ 101

Assembly instructions _________________________________________ 101
Circuit diagrams ______________________________________________ 101
Programming ________________________________________________ 101
Parts lists ___________________________________________________ 101
Operating instructions _________________________________________ 102
Data sheets _________________________________________________ 102

Updates _________________________________________________________ 103

56 © Festo Didactic 678864

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 Pick&Place 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.

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1. Introduction

1.1 Training contents covering the following subjects can be taught:

Training contents
• Mechanics
– Mechanical assembly of a station
• Pneumatics
– Tubing of pneumatic components
– Vacuum technology
– Pneumatic linear and rotary drives
• Electrical
– Correct wiring of electrical components
– Connection of DC motors
• Sensors
– Use of pressure switches with integrated microprocessor
– Correct use of diffuse sensors and light barriers
– 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

• Selecting pneumatic components

– Linear drives
– Rotary drives
– Vacuum generators
• Safety during pneumatic power failure
– Vacuum reservoir
• PLC programming
– Programming of an operational mode
– Programming of a RESET sequence
– Programming of an EMERGENCY-STOP function
• Optimising cycle time

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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 contain 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.

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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!

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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.

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1. Introduction

62 © Festo Didactic 678864

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.

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2. Notes on safety

64 © Festo Didactic 678864

3. Technical data

Parameter Value

Operating pressure 6 bar (600 kPa)

Voltage supply 24 V DC, 4.5 A

Digital inputs 8

Digital outputs 6

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

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3. Technical data

66 © Festo Didactic 678864

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.

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4. Transport/Unpacking/Scope of delivery

68 © Festo Didactic 678864

5. Design and function

5.1
The Pick&Place station

The Pick&Place station is an automated insertion device.

According to DIN 8593-1 Manufacturing production processes – Joining –
Assembling – Inserting insertion is the manner of assembling, whereas a assembly
component is inserted into the shaped element of another assembly component.

The Pick&Place station inserts a workpiece insert into a workpiece housing. The
following workpiece inserts are available: a clock, a thermometer and a hygrometer.

The function of the Pick&Place station is

• to transport workpieces (housings),
• to stop workpieces (housings)
• to insert workpiece inserts
• to separate out complete workpieces (housing and insert)

Note
The workpiece inserts „Clock“, „Thermometer“ and „Hygrometer“ fits only to the
workpiece „Housing“.

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5. Design and function

The Pick&Place station consists of the following:

• Pick&Place module
• Conveyor belt module
• Slide module
• Profile plate

• Trolley
• Control console
• PLC board

Pick&Place station with trolley, control console and PLC board

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5. Design and function

5.1.1 Set-up as individual station

Set-up of the Pick&Place station as individual station or last station of a system

A stopper is fitted at the end of the conveyor belt.

5.1.2 Set-up with downstream station

Set-up of the Pick&Place station with a downstream station

The stopper at the end of the conveyor belt is removed.

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5. Design and function

5.2 The Pick&Place station is equipped with a two-axis Pick&Place module. Workpiece
Function housings placed on the conveyor are detected by the diffuse sensor. The workpiece
is transported to the pneumatic separator on the conveyor belt and detected by a
second diffuse sensor.

The Pick&Place module picks up a workpiece insert from the slide and places it on
the workpiece housing. The complete workpiece (housing and insert) is released by
the separator and transported to the end of the conveyor belt. A light barrier detects
the workpiece at the end of the conveyor belt.

The following functions can also be implemented with the station:

• Segregation of workpieces (housings or bodies) onto the slide

• Alternative feed of workpieces (housings or bodies) from the slide

5.3 Start prerequisites

Sequence description • No workpieces at the start of the conveyor belt
• Slide filled with workpiece inserts

Initial position
• Separator extended
• Belt drive switched off
• Mini slide up
• Mini slide retracted
• Vacuum off

Sequence
1. The conveyor belt motor switches on if a workpiece is detected. The workpiece is
transported to the separator.
2. The conveyor belt motor is switched off, if the workpiece is detected by the
diffuse sensor in front the separator.
3. A workpiece insert is picked up at the slide an inserted into the housing.
4. The separator is reversed and the conveyor belt motor is switched on.
5. The complete workpiece is detected at the end of the conveyor belt. The
conveyor belt motor is switched off

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5. Design and function

5.4
Pick&Place module

The Pick&Place module is a pneumatic handling device. The module is based on

precise slide units. End positions of the slides are sensed electrically via proximity
sensors.

A bellows suction cup picks up the workpiece inserts. Directly to the bellows suction
cup a vacuum filter is mounted to prevent dirt particles to reach the vacuum
generator.

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5. Design and function

5.5
Conveyor belt module

The Conveyor belt module is used to transport and buffer workpieces. Workpieces at
the start of the conveyor belt, prior to the separator and at the end of the conveyor
belt are detected by means of optical sensors with fibre-optic cables.

The conveyor belt is driven by a DC gear motor.

Outgoing workpieces can be stopped or separated out by means of a solenoid-

actuated separator. End position sensing of the separator is effected by means of
inductive sensors.

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5. Design and function

5.6
Slide module

The Slide module is used to transport or store the workpieces. This module can be
applied universally thanks to its variably adjustable inclination and height.
6 workpiece inserts can be accommodated on the slide.

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5. Design and function

76 © Festo Didactic 678864

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

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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

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6. Commissioning

6.2.2 Assembling the station

Instructions on assembling the station please find in the assembly instructions of

the Pick&Place station in the directory English\10_PickPlace\Assembly instructions
on the CD-ROM supplied.

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6. Commissioning

6.3 6.3.1 Proximity sensor (Pick&Place, mini slides)

Adjust sensors
The proximity sensors are used for end position sensing of the mini slides. The
proximity sensor is sensitive to a permanent magnet mounted to the mini slide.

Prerequisites
– Pick&Place module is assembled, proximity sensors are pre-assembled.
– Mini slides are 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 mini slide in the
position which you wish to interrogate.
2. Shift the sensor 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 mini slide).

Documents
• Data sheets
Proximity sensor SME-10 (525914) in the directory English\10_Pick&Place\Data
sheets on the CD-ROM supplied.
• Operating instructions
Proximity sensor SME-10 (659882) in the directory
English\10_Pick&Place\Operating instructions on the CD-ROM supplied.

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6. Commissioning

6.3.2 Pressure switch (Pick&Place, vacuum suction cup)

The pressure 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 pressure
switch.

Prerequisite
– Pick&Place module assembled.
– Vacuum generator, vacuum suction cup and pressure switch tubed up.
– Compressed air supply switched on.
– Pressure 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. Push the EDIT button until the LED of the pressure switch is flashing. Release the
button. The actual pressure value is stored as switching pressure.
4. Start a test run to check if the workpiece is picked up securely. Move the mini
slides from end position to end position. The workpiece should not drop down.

Documents
• Data sheets
Pressure switch SDE5-V1 (527458) in the directory English\10_Pick&Place\Data
sheets on the CD-ROM supplied.
• Operating instructions
Pressure switch SDE5-V1 (662804) in the directory
English\10_Pick&Place\Operating instructions on the CD-ROM supplied.

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6. Commissioning

6.3.3 Diffuse sensor (Conveyor belt, detection of workpieces)

The diffuse sensor is used for detection of the workpieces. A fibre optic cable is
connected to a fibre optic device. The fibre optic device emits visible red light. The
diffuse sensor detects the light reflected by the workpiece Different surfaces or
colours changes the amount of reflected light.

Prerequisites
– Fibre optic device is assembled.
– Fibre optic device is wired up.
– Power supply unit switched on.

Execution
1. Mount the fibre optic cable head to the sensor mounting bracket at the start of
the conveyor belt.
2. Connect the fibre optic cables to the fibre optic device.
3. Place a black workpiece at the start of the conveyor belt.
4. Adjust the potentiometer of the fibre optic device by means of a screwdriver until
the switching status display changes to on.

Note
Maximal 12 revolutions of the adjusting screw are permissible.

5. Place workpieces at the start of the conveyor belt.

Note
All workpieces should be detected securely.

Documents
• Data sheets
Fibre optic device SOEG_L (165327) and fibre optic cable diffuse SOEZ-RT
(165358) in the directory English\10_Pick&Place\Data sheets on the CD-ROM
supplied.
• Operating instructions
Fibre optic device (369669) and fibre optic cable diffuse (369682) in the directory
English\10_Pick&Place\Operating instructions on the CD-ROM supplied.

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6. Commissioning

6.3.4 Through-beam sensor (Conveyor belt, detection of workpieces)

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 at the end of the conveyor belt.
2. Align transmitter and receiver fibre optic cables.
3. Connect the fibre optic cables to the fibre optic device.
4. Adjust the potentiometer of the fibre optic device by means of a screwdriver until
the switching status display changes to on.

Note
Maximal 12 revolutions of the adjusting screw are permissible.

5. Place workpieces in the sensing range of the light barrier. The switching status
display changes to off.

Documents
• Data sheets
Fibre optic device (150857) and fibre optic cable through-beam (165360) in the
directory English\10_Pick&Place\Data sheets on the CD-ROM supplied.
• Operating instructions
Fibre optic device (369669) and fibre optic cable through-beam (369684) in the
directory English\10_Pick&Place\Operating instructions on the CD-ROM
supplied.

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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
– Mini slides 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 speed is reached.

Documents
• Data sheets
One-way flow control valve (175056) in the directory
English\10_Pick&Place\Data sheets on the CD-ROM supplied.
• Operating instructions
Pneumatic cylinders (391172) in the directory English\10_Pick&Place\Operating
instructions on the CD-ROM supplied.

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!

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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.

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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 valve terminal (165200) in the directory English\10_Pick&Place\Operating
instructions on the CD-ROM supplied.

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.

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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 from the directory Sources\

PLC Programs\Release C\S7 of the CD-ROM supplied

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 (CD ROM: Sources\PLC Programs\Release C\S7) 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 10PP_AS or 10PP_KFA
(AS = sequential function chart, KFA = Ladder diagram/Function block
diagram/Instruction list)

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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

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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 10PP_FEC.zip from the directory
Sources\PLC Programs\Release C\FEC of the CD-ROM supplied

Project  Restore …  Open (CD ROM: Sources\PLC Programs\Release C\FEC) 10PP_FEC.zip Open  Restore
Project, Name: 10PP_FEC OK

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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

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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)

5. 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

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6. Commissioning

– Start the PLC programming software

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

6. 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.
Open the file 10_PP_K from the directory Sources\PLC Programs\Release C\
ML 1500 of the CD-ROM supplied

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6. Commissioning

File  Open …  select a project file (CD ROM: Sources\PLC Programs\Release C\ML 1500) 10PP_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:
6. 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.
– Restore the file 10_PP_AS.pcd from the directory Sources\
PLC Programs\Release C\FX1N of the CD-ROM supplied

Extras  Project Restore …  select a project file (CD ROM: Sources\PLC Programs\Release C\FX1N)
10_PP_AS.pcd  Open  Select destination directory OK  Confirm the following note (“After saving,…”) with OK

7. Compile the project

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6. Commissioning

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 slide with a maximum of 6 workpiece inserts. 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. Put a workpiece (housing) at the start of the conveyor belt.
6. Start the sequence of the Pick&Place 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.

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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

Modification of the conveyor belt

If the Pick&Place station is operated in combination with a downstream station,

remove the mechanical stopper at the end of the conveyor belt.

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7. Maintenance

The Pick&Place 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

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Content of the CD-ROM

Note
All documents and media listed below are stored in the directory
English\10_Pick&Place on the CD-ROM (665871) supplied.

Assembly instructions Pick&Place station

Circuit diagrams Pick&Place station, electrical

Pick&Place station, electropneumatic

Programming GRAFCET Pick&Place station

I/O allocation list

Parts lists Pick&Place station

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Content of the CD-ROM

Operating instructions CPV valve terminal 165 200

Fibre-optic cable, diffuse 369 682
Fibre-optic cable, through-beam 369 684
Fibre optic device 369 669
Mini slides SLT 650 901
Pneumatic cylinders 391 172
Proximity sensor SME-10 659 882
Through-beam sensor, receiver 369 662
Through-beam sensor, transmitter 369 679
Pressure switch SDE5-V1 662 804

Data sheets 3/2-way solenoid valve, normally closed 161 416

5/2-way solenoid valve 161 414
Connector 153 329
Fibre-optic cable, diffuse 165 358
Fibre-optic cable, through-beam 165 360
Fibre-optic device 165 327
Filter ESF 191 203
Fitting 186 117
Gear motor conveyor belt 374 134
I/O terminal 034 035
Mini slides SLT-6-... 170 553
Mini slides SLT-10-... 197 894
One-way flow control valve type C 175 056
Plastic tubing PUN 4x0,75 159 662
Plastic tubing PUN 6x1 159 664
Pressure switch SDE5-V1-... 527 458
Proximity sensor SME-10 525 914
Silencer U-M5 004 645
Socket connector cable SIM-M8-4GD 158 960
Socket connector cable SIM-M8-3GD 159 420
Socket connector cable SIM-M8-3WD 159 422
Starting current limiter 150 768
Start-up valve with filter control valve 152 894
Through-beam sensor, receiver 165 323
Through-beam sensor, transmitter 165 353
Vacuum generator VN 193 552
Vacuum suction cup ESS 189 401

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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.de/Services > MPS

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Updates

104 © Festo Didactic 678864