Modular Mechatronic System "SSC2P2HV2 " USER & SOFTWARE MANUAL

modular Mechatronic System
"SSC2P2HV2 "
USER & SOFTWARE
MANUAL
Version 01.10.2014
modular Mechatronic System SSC2P2HV2 - User Manual
USER MANUAL SSC2P2HV2 V01.10.2014.doc
Page 2 of 76
Table of content
USER MANUAL ................................................................................. 6
About this manual........................................................................... 6
Tools required ................................................................................ 7
Safety issues/ Intended use and possible misuse.............................. 8
Removal of transportation safety devices .......................................... 9
First time or re-installation at final location ....................................... 10
Unpacking and checking for damages ......................................... 10
Assembling and separating the stations ....................................... 11
Cable, hose and connector marking ............................................. 12
Settings / Parameter / Password protection ..................................... 12
Maintenance .................................................................................... 13
System overview .............................................................................. 14
Touch Panels ............................................................................... 14
Emergency stop / Safety concept ................................................. 15
Resetting the EMERGENCY STOP ............................................. 16
Unit designations .......................................................................... 17
Functional Units and workpieces used............................................. 18
Workpieces................................................................................... 18
Service Unit (= pneumatic air inlet)............................................... 18
Magazine Units............................................................................. 18
Belt Conveyor ............................................................................... 18
Sorting Unit................................................................................... 19
Handling Unit ................................................................................ 19
Pneumatic Press .......................................................................... 20
ASRS ........................................................................................... 20
Manual transfer device ................................................................. 21
The control of the mechatronic system ............................................ 22
Technical Data ................................................................................. 23
Electrical connections overview: ...................................................... 24
Primary power connections (mains cable of power supplies) ....... 24
Connections between Functional Units and controls (PLCs) ........ 24
Connecting an Ethernet (ProfiNet) switch: ................................... 25
System operation ............................................................................. 26
Page 3 of 76

Pre-operation checklist ................................................................. 26
Powering ON ................................................................................ 26
Powering OFF .............................................................................. 26
Quick Start - basic operation of system/stations .............................. 27
System setup and functional grouping ............................................. 35
Section 1: Magazine and Testing ................................................. 35
Section 2: Handling ...................................................................... 35
Section 3: Press ........................................................................... 36
Section 4: ASRS (Automatic Storage and Retrieval System) ....... 36
Operating modes & step sequences ................................................ 37
Operating Mode No operation .................................................... 37
Operating Mode Manual ............................................................ 38
Operating Mode Automatic stop................................................. 38
Operating Mode Automatic running ........................................... 38
PLC program steps Magazine and Testing (PLC 1) ..................... 39
PLC program steps Handling Unit (PLC 2): .................................. 39
PLC program steps Press (PLC 2): .............................................. 40
PLC program steps ASRS (PLC 2): ............................................. 40
Alarms and messages ..................................................................... 41
List of alarms (PLC 1)................................................................... 42
List of alarms (PLC 2): .................................................................. 43
System Touch Panel Station 1 ...................................................... 45
Start screen .................................................................................. 45
Main screen (Menu) ..................................................................... 45
Alarm list + history ........................................................................ 47
Unit screens (for all sections) ....................................................... 48
Statistics screen: .......................................................................... 49
Parameter screens ....................................................................... 49
Main parameter screen ................................................................ 49
Parameter screen for magazine and testing ................................. 50
System screens ............................................................................ 51
System screen for TP177 settings................................................ 51
System screen for user management........................................... 51
System Touch Panel Station 2 ...................................................... 53
Start screen .................................................................................. 53
Page 4 of 76

Main screen (Menu) ..................................................................... 53
Alarm list + history ........................................................................ 55
Main unit screen ........................................................................... 56
Unit screens for all sections of station 2: ...................................... 56
Unit screen for shelf display and management:............................ 58
Statistics screen ........................................................................... 58
Parameter screens ....................................................................... 59
Main parameter screen ................................................................ 59
Parameter screen for Handling Unit ............................................. 60
Parameter screen for ASRS ......................................................... 60
System screens ............................................................................ 61
System screen for TP177 settings................................................ 61
SOFTWARE MANUAL ..................................................................... 63
Purpose ........................................................................................ 64
Programming language ................................................................ 64
Using the STEP 7 Manager .......................................................... 64
Layout and line compartments ..................................................... 66
Software structure ........................................................................ 66
Operating block OB1 .................................................................... 67
Operating block OB100 ................................................................ 67
Data block DB1 ............................................................................ 67
Data block DB4 ............................................................................ 67
Data block DB8 ............................................................................ 68
Data block DB47 .......................................................................... 68
Basic group Program organization FC01H................................ 68
Basic group Inputs FC10H ........................................................ 68
Basic group Alarms FC20H....................................................... 69
Basic group Common functions FC30H .................................... 70
Basic group Manual mode FC40H ............................................ 70
Basic group Automatic mode FC50H ........................................ 71
Basic group Device control FC60H ........................................... 73
Basic group Communication FC70H ......................................... 73
Basic group Human machine interface FC80H ......................... 74
Basic group Outputs FC90H ..................................................... 74
Page 5 of 76

USER MANUAL
About this manual
In order to operate the mechatronic system properly and troubleshoot
it if necessary, it is essentially to read this user manual thoroughly.
We strongly recommend also reading the accompanying standard
technical documentation of the individual functional modules. Some
of these functional modules are modified within this specific
application. In this case the changes are explained in this manual.
These technical modifications are also represented in the customized
diagrams (i.e. electrical diagrams) provided with the system. Please
refer to these for complete information.
Without having read the manuals it will be very difficult to understand
the system fully and grasp why it behaves a specific way in a
situation. Therefore it is cordial to have a good understanding of the
processes behind the system, meaning to know how the system
behaves when it is functioning properly. Without this basic knowledge
it will be very difficult, if not impossible to distinguish between proper
functions and faults and therefore unable to carry out
troubleshooting.
In the manual you will find some symbols besides the text. These
symbols highlight especially important text passages.
Very important notice / safety related information
Important / useful information for working with the

equipment
[Manual]
Button on touch panel or computer screen
Page 6 of 76

Tools required
Some or all of following tools may be required to install the
mechatronic system and to carry out adjustments. They are not
provided with the mechatronic system but can be obtained
additionally.
Set of Allen keys
Set of spanners
Digital Multimeter
Set of screwdrivers
Hose cutter
Page 7 of 76
Safety issues/
Intended use and possible misuse
The provided equipment is intended for training purposes in

mechatronics and PLC programming only.
It is designed to be altered within certain limits by the trainer or

trainees if wished.
Changes must only be carried out by skilled personnel or by

trainees under the supervision of trainers.
During training a trainer familiar with the system must be

present.
The equipment is only to be used indoors within the

temperature limits of +10 to +40C and humidity limits of 20 to
70% relative humidity.
The system is rated for a primary power supply of 100H240 V

AC, 50/60 Hz. The secondary voltage level is 24 V DC. Do not
exceed these voltage ranges.
Static electricity may cause damage to the product.

Adequately protect against static electricity during installation
and operation.
While exercising on the system make sure you do not have

any lose cables that may get in contact with each other or
parts of the system. They may cause shortcuts resulting on
equipment damage.
The system must not be used for industrial purposes, such as

production of any goods.
Always turn off the power before performing any wiring, even if
it is "only" on the 24 V DC side of the control. Ignoring that
advice may result in electrical shock or damage to the
equipment.
Always use proper functioning measuring devices when

working on the system.
Air hoses must be of proper size and suitable for the working
pressure.
Never use frayed, damaged or deteriorated hoses. Use only

proper type and size of hose end fittings and connections.
Avoid free hose ends - they will whip and may cause injury.
Make sure that hoses are fully depressurized before

disconnecting them.
Page 8 of 76
Never play with compressed air. Do not apply it to your skin or

direct an air stream at people. Never use it to clean dirt from
your clothes. When using it to clean equipment, do so with
extreme caution and use eye protection.
Never turn the arm of the Handling Unit manually without

removing the motor relays first. Ignoring this precaution may
result in damage of the connected on-board control
electronics.
Never move the axes of the ASRS manually without removing

the motor relays first. Ignoring this precaution may result in
damage of any connected control electronics or PLC.
Removal of transportation safety devices

The axes of Handling Unit and ASRS are secured for transportation
to prevent any damage. Remove these transportation safety devices
before operating the system.
Handling Unit:
Remove cable tie. Do not
remove any further items.
ASRS:
Remove the 3 screws marked in
the image left. Then remove the
AL-profile portal (marked with
red tape) which is mounted to
stabilize the axes of the ASRS.
Page 9 of 76
First time or re-installation at final location

The mechatronic system is shipped in whole by Christiani ex-works
directly to the customer. This reduces on-site installation to a
minimum. After having received the system from Christiani proceed
with the following steps:
Unpacking and checking for damages
Check packaging for any damages.
In case the packaging is damaged take photos for later

evidence.
Unpack/unwrap the goods carefully

packaging material completely.
Remove any boxes with accessories from the system.
Check the system again visually for any damages.
In case of any damages take photos for later evidence.
Remove the clearly marked transportation safety locks which

are used at ASRS and Handling Unit.
Check pneumatic hoses and electrical cables for any

damages; in case there are any get skilled personnel to
determine level of damage and take suitable action.
Check, if you have received all goods within the scope of

delivery.
Make sure no small parts are hidden between packaging

material.
Plug in all connecting cables between PLC and functional

units.
Unpack the workpieces (cube halves) from the accessories

boxes and fill them into the magazine units. Take care to place
them into the proper magazine, since the workpieces and
magazines are different.
and
remove
any
Page 10 of 76

Assembling and separating the stations
The mechatronic system consists of two individual stations:
Station 1 consists of:
1 base plate, 1 Pneumatic Service Unit, 2 Magazine Units, 1 Belt
Conveyor, 1 Sorting Unit, 1 PLC, 1 HMI Operator Panel (with touch
panel, EM-stop and Quit button)
Station 2 consists of:
2 base plates permanently connected, 1 Pneumatic Service Unit, 1
Pneumatic Press, 1 Handling Unit, 1 ASRS, 1 PLC, 1 HMI Operator
Panel (with touch panel, EM-stop and Quit button)
Both stations can be mounted on trolleys (optional). They can be
physically separated and either be operated together or individually.
In order to operate the complete mechatronic system it is required to
have both stations properly mechanically and electrically connected.
Mechanical connection between base plates of Station 1 and
Station 2:
Stations disconnected
Stations connected
Assembling the slides of the Sorting Unit:

The slides of the
Sorting Unit have
been removed for
transportation of the
system.
Before
using the system,
please mount them.
They are fixed to two
poles of the Belt
Conveyor by means
of two screws and
hammer nuts.
Page 11 of 76

Cable, hose and connector marking
Some cables may have been removed for transportation to

avoid damage during shipping.
All cables, hoses and connectors are marked in a way which

allows to easily identify the destination of the cable or hose.
For further information please refer to the electrical diagrams.
As a general rule a cable labeled -W1 always leads to a

connector -X1, a cable labeled W2 always leads to a
connector X2.
Make sure, that the unit designations (i.e. +PPN) do agree
Settings / Parameter / Password protection

The program and parameters of the system are protected. They are
accessible via the touch panel of the system.
LOGIN: Admin
PASSWORD: 58030
Page 12 of 76
Maintenance
The mechatronic system respectively its functional units do not need
much maintenance. However, when working with the system you
may need to fine-adjust one or the other unit for proper positioning or
aligning of workpieces. The same applies with adjustments regarding
piston movement of the cylinders and tension of toothed belts. These
topics should be covered by the teacher during training lessons.
Check from time to time, if the spring pins are still firmly inserted into
the lower cube halves. For more information see chapter "Overview workpieces".
No maintenance at all is needed with regards to the PLC.
Nevertheless you should observe the cables for damages, especially
the primary power cables, since they carry a dangerous voltage level.
If for any reason cables get damaged contact an electrically
competent person to carry out the required work or replace the cable
immediately with an equivalent new one. Make sure to disconnect
the affected device from any power source before starting with
repairs.
The only spots where maintenance work may be required are
metallic surfaces such as:
cylinder rods (i.e. Handling Unit, Pin Unit)
axles (i.e. ASRS)
gears and spindles (i.e. Handling Unit, ASRS)
guide rods and guide rails (i.e. Handling Unit, ASRS)
Keep surfaces clear from rust and dirt. Clean them on a regular
basis and cover the surfaces after cleaning with a common rust
preventive lubricant.
Page 13 of 76
System overview
The Mechatronic System "SSC2P2HV2" consists of two individual

stations. A station always consists of T-slotted base plate(s) which
can be optionally mounted on trolleys with wheels. On the base
plate(s) different individual functional modules, such as Service
Units, Belt Conveyors, etc. are mounted.
Touch Panels
The mechatronic system includes two touch panels. When following
instruction or looking at control elements make sure you are looking
at the proper touch panel.
1) System touch panel (located at station 1)
2) System touch panel (located at station 2)
Page 14 of 76

Emergency stop / Safety concept
Since the system consists of two stations which can be operated
independently it also features two independent safety circuits.
Thus the system has two emergency stop buttons (one at each
operator panel). Each emergency stop only affects its own station,
even if the stations are connected and the system is operated as
one.
That means:
pressing the EM-stop at station 1 will only shut off station 1,
pressing the EM-stop at station 2 will only shut off station 2.
If an EM-stop is activated on one station and there is an ongoing
process on the other station, it will continue until completion.
EM-Stop
EM-QUIT
(blue)
The status of the safety circuit can be seen on the safety relay:
EM-stop pressed
EM-stop released
EM-QUIT pressed =
Safety circuit OK
Page 15 of 76
Resetting the EMERGENCY STOP

After an EMERGENCY STOP occurrence the system needs to be
reset.
Do the following steps:
Make sure the reason for the emergency stop has been
removed and the system is in proper condition.
Release the EM-Stop button
Press the blue EM-QUIT button on the system operator panel
If there is no other fault present, the system is now ready to be

started again.
EM-Stop
EM-QUIT
(blue)
Page 16 of 76

Unit designations
All functional units within the system have a unique designation that
allows to identify them, mainly in the context of the electrical
diagrams, but also in the context of the PLC program. These
designations are labeled at each unit. They are also labeled at
cables, so it is very easy to identify the target a cable leads to.
The list below shows the designations.
+MAG1
Magazine Unit 1
+MAG2
Magazine Unit 2
+BC
Belt Conveyor on station 1
+SU
Sorting Unit (Testing and Sorting)
+HU
Handling Unit (Manipulator)
+PPN
Pneumatic Press Unit
+ASRS_HA
Automatic Storage Retrieval System,

Horizontal Axis
+ASRS_VA
Automatic Storage Retrieval System,

Vertical Axis
+ OP
Operator Panel
+CTRL
Control / PLC board
+PS
Power Supply
The complete part designation consists of:

=system+location-function:connection
i.e. =mMS+CTRL1-F1:A1
labels the terminal A1 of the safety relay K1 on control 1 of the
complete mechatronic system mMS.
Page 17 of 76
Functional Units and workpieces used

Workpieces
The system uses two types of cube halves as workpieces.
The lower cube halves have already pins inserted and are stored in
MAG1. Check from time to time that, if the spring pins are still firmly
inserted into the lower cube halves. The upper cube halves have no
pins inserted and stored in MAG2.
Service Unit (= pneumatic air inlet)

The Service Unit comprises of a pressure regulator valve with 3/2way valve, pressure gauge, adjusting knob (twistable/lockable) and
water separator. It is completely fixed upon one mounting plate,
which enables its easy and flexible mounting on an aluminium profile
plate both stand-alone and together with additional functional units.
The inlet for pneumatic air is located at the Service Units of station 1
and 2. Connect the pneumatic compressor's outlet via a suitable
hose with the 6 mm quick coupling connector of the Service Unit.
The provided air pressure at the inlet may not exceed 10 bar.
Magazine Units
Up to 10 stacked workpieces can be accommodated in the Magazine
Units (MAG1 and MAG2). Always the lowest workpiece is pushed out
of the stack through a pneumatic cylinder, which is controlled by a
5/2 directional control valve. A limit switch controls the filling level of
the magazine.
Belt Conveyor
The functional assembly Belt Conveyor (BC) on station 1 consists of
a 680 mm long and 50 mm wide belt line. At the end of the belt line a
fiber optic sensor with amplifier is mounted to detect arriving
workpieces and stop the belt motor. By means of a reversing
contactor circuit the Belt Conveyor can be moved in two directions
(forward/reverse).
Page 18 of 76

Sorting Unit
The functional assembly Sorting Unit (SU) allows to test workpieces,
determine their material properties and orientation and sort them
onto three slides if required. To serve this purpose it consists of six
sensors and three pneumatic cylinders. These sensors are:
ultrasonic (analog), optical and inductive.
The ultrasonic sensor detects when a workpiece on the belt conveyor
reaches the inspection section. It triggers a signal to stop the belt
shortly after workpiece detection. The ultrasonic sensor needs to be
properly programmed and its measuring range set. See technical
datasheet of sensor or technical documentation of Sorting Unit for
more information.
The optical sensor detects whether the material is light or dark (light
= white/aluminium, dark = black). The inductive sensor establishes
whether the workpiece is metallic or non-metallic. The optical sensor
of the Testing Unit needs to be programmed for proper operation.
Refer to the Functional Unit's technical documentation and the
datasheet of the sensor for more information.
The Sorting Unit is designed to be mounted sideways at the belt
conveyor (+BC1). It can be fitted both to the left or right side of the
belt conveyor (viewed in direction of travel). However it is essentially
that it is mounted in such a way that, in direction of travel, the
workpiece arrives first at the ultrasonic sensor. The height of the
Sorting Unit can be adjusted to fit the height of the Belt Conveyor (i.e.
100 mm or 115 mm).
Afterwards testing the belt is started again. Depending on the recipe
for the complete cubes, unwanted cube halves are sorted onto three
slides. Workpiece detection at the slides is done via three optical
sensors.
Handling Unit
The Handling Unit (HU) on station 2, allows to carry out pick-andplace tasks. Workpieces are picked up from one place and
deposited at another place. The available three-axis manipulator
covers a work area of 270. In this work area any number of positions
can be struck. The actuator of the X-axis takes place over a direct
current motor with integrated speed/position sensor, which can be
controlled with the appropriate evaluation electronics and a PLC. The
left and right-hand motions of the actuator are achieved with a
reversing contactor circuit. The twist-proof double acting pneumatic
cylinder with a range of 60 mm moves the Y-axis to and fro. The Zaxis is moved with a twist-secure double acting pneumatic cylinder
with a range of 100mm. For pick-up of the workpieces the
manipulator is furnished with a vacuum sucker and a Venturi nozzle.
Page 19 of 76

Note: The Handling Unit requires a PLC with two fast counter inputs
in order to be able to evaluate the speed sensor signals.
Caution!
Never move the arm of the manipulator by hand without releasing the
relays before. Inducted voltage may destroy the motors electronics
and the speed sensor electronics.
Pneumatic Press
Two workpieces (cube halves) can be processed in the Pneumatic
Press (PPN). This unit is designed to press two cube halves together
to produce one complete cube. Workpieces are placed subsequently
by an upstream functional unit in the drawer of the Press Unit. The
drawer pulls the pieces to be processed into the press room. The
safety door closes and the press cylinder begins to extend. The two
cube halves are pressed together with a force of around 220 N (at 4
bar). At last the safety door opens and the workpieces are pushed
out of the press room and are ready to be picked up.
The press has a workplace that is closed completely on three sides
and by a safety door on the fourth side. Safety screens made of
Plexiglas enable the observation of the press operation. To achieve
the required safety level in stand-alone mode, the Press Unit is
equipped with two buttons allowing two-hand operation. In automatic
mode, respectively in an integrated environment (station/system)
these buttons have usually no functionality.
If the Pneumatic Press is embedded within a bigger system the twohand operation buttons may not be wired and therefore be
redundant.
ASRS
The functional assembly ASRS (+ASRS_VA and +ASRS_HA)
consists of a vertical axis (VA), horizontal axis (HA) and a storage
rack, which are altogether mounted on two profile plates. The
combination of vertical and horizontal axle enables filling the rack in
two dimensions. Takeover of workpieces takes place at a predefined
transfer position. It can be marked by a twin bore in the positioning
bracket of the horizontal axle. In case of any other transfer position
the twin holes need to be masked.
From the transfer position the workpiece is moved to an empty
compartment of the rack. The carriage of the horizontal axle moves
the vertical axle. On the carriage of the vertical axle a double-acting
pneumatic cylinder with a fork for taking up workpieces is mounted.
Page 20 of 76

The positioning of both axles is made via holes in the brackets of
both axles. These are recognized by fork light barriers. Micro
switches detect the end position of the carriages. One of each micro
switch serves for hard stop (hard-wired) the other one delivers a
signal to the PLC to stop motion. The axles consist each of a linear
guide on which a bearing carriage is moved. The drive for the vertical
axle takes place through a spindle, for the horizontal axle through a
belt. The direct current geared motors used are operated by a
reversing contactor circuit.
There are seven storage spaces on four levels each - makes it
overall 28 storage spaces available. The workpieces must have a
square base of 50x50 mm and can have a height of up to 50 mm.
In addition to the standard equipment, the ASRS may optionally be
fitted with an optical transducer located at the rack feeder's fork. It is
used for monitoring whether a workpiece is present on the rack
feeder. If present, this sensor has a PNP logic.
Caution!
Never move the axes of the ASRS by hand without releasing the
relays before. Inducted voltage may destroy any connected
electronic device.
Manual transfer device

The system is fitted with a manual transfer device which is located at
the intersection between station1 and station 2. In single station
mode (stations not connected) place workpieces here
manually. The Handling Unit
of station 2 will pick up the
workpiece from here.
(Image: main screen of touch panel #2)
On system touch panel 2 a

flashing button will indicate
which workpiece is required
next. This can be either a
lower cube half (Lower CH)
or, if a lower cube half is
already present in the press
unit, an upper cube half
(Upper CH). Place the
required workpiece in the transfer device and press the flashing
button afterwards.
Page 21 of 76
The control of the mechatronic system

On both stations of the mechatronic system PLCs and safety devices
are present.
The controls (CTRL1 and CTRL2) consist of a PLC DIN rail on which
besides the PLC itself different components are mounted, such as
terminal blocks, fuse and safety relay. All wires and cables are
placed in cable ducts.
For further information on wiring please refer to the electrical

diagrams.
The PLC hardware consists of a SIMATIC S7 PLC with the following
modules:
1 Compact CPU 314C-2PN/DP with integrated digital and

analog inputs/outputs, ProfiNet and Profibus DP interface.
Page 22 of 76

The operating voltage of the controls is 24 V DC. The primary power
supply is rated @ 90H264 V AC, 50/60 Hz (automatic selection).
The primary mains cable is directly led to the insulated power supply
thus practically eliminating the risk of unintentional contact with a
dangerous voltage level.
Technical Data
Electrical power consumption:
Station 1 in operating condition:
Station 2 in operating condition:
approx. 34 VA
approx. 38 VA
The control part is equipped with a 5 x 20 mm fuse rated @ 1 A T.

Spare fuses are provided with the system.
Pneumatic air consumption:
Complete system in operating condition:
approx. 9 l/min.
General data:
Dimensions:
2000 x 550 x 650 mm

(length x width x height)
Weight Station 1 (without trolley):
34 kg
Weight Station 2 (without trolley):
48 kg
Page 23 of 76
Electrical connections overview:

The following electrical connections can be found within the system:
Primary power connections (mains cable of power supplies)
Power and signal distribution (safety interlocks)
Connections between Functional Units and PLC
Ethernet connection between PCLs and Touch Panels and

between Station 1 and Station 2.
Primary power connections (mains cable of power supplies)

The system comes with three independent power supplies:
2 x for the PLC
1 x for the Ethernet switch
Plug them into 230 V AC power sockets.
Connections between Functional Units and controls (PLCs)

Each functional unit has between one and four cable(s) for electrical
connection. These cables run directly from the modules to the PLC.
This way of wiring allows maximum flexibility when using the
functional units. Each module can be easily detached from the
system and used stand-alone, by simply disconnecting the cable(s)
and the pneumatic connection.
The cables are labeled with their designation according to the
electrical drawings. Please refer to the electrical drawings for more
information.
Page 24 of 76

Connecting an Ethernet (ProfiNet) switch:
The systems PLCs are connected to each other via Ethernet/
ProfiNet. The connection can be separated at the Ethernet switch
located on station 2. If you need to separate the stations please
remove the cable leading to station 1 (marked with a red circle in the
image below) and all cables leading to external programming devices
(computers).
Image: Location of Ethernet switch
Image: Available ports for external programming devices or external

Ethernet/ProfiNet components.
Note: the Ethernet switch has its own power supply, thus
requires an own power socket. The power supply of the switch
is rated at 100 - 240 V AC.
Page 25 of 76
System operation
Pre-operation checklist
Before you start the system go through the following checklist:
Stations are mechanically properly connected
Stations and units are mechanically aligned to each other
The power cables are plugged into the main power supplies
Pneumatic air is connected to the system and turned on
Main switch at the power supplies are ON
Touch Panel has booted up properly showing Start Screen
Powering ON
In order to operate the system it is necessary to provide all
subsystems with electrical and pneumatic power. After having
established and checked all required electrical and pneumatic
connections:
switch ON mains power at the power supplies
press one or both blue EM-QUIT button (on the operator

panels)
switch ON mains power at the air compressor
turn ON pneumatic air supply at the Service Units located on

both stations
Powering OFF
After using the mechatronic system:
STOP the system/station by pressing the STOP button on the

touch panel(s)
turn OFF pneumatic air supply at the Service Unit located on

both stations
switch OFF mains power at the air compressor
switch OFF mains power at the power supplies
Page 26 of 76
Quick Start - basic operation of system/stations

Note: Extract (print) pages 27 34 from the complete manual as
quick reference sheets.
Behind each touch panel there is a power supply with a mains

switch.
Turn ON the main switch to provide the system with electrical power.
The PLCs and touch panels should now be powered, the touch panel
should boot an after a while show the company logo of Christiani.
Also at the back side of the system there are two pneumatic service
units, one at each end. They are pneumatic air inlets and main
switches to turn air pressure on/off and set the system air pressure
(~ 4 bar).
Switch ON air pressure her by turning the knob at the top of the
service unit. Check, if system pressure is on and properly set by
means of the pressure gauge fitted to the pneumatic service unit.
Page 27 of 76

Once the control of the mechatronic system has powered up, the
screen of the touch panel(s) will show the system start screen.
Menu
Press the button [Menu] to display the main menu.
Usually, now the [Quit] button will flash in red, indicating that there is
a fault (the safety circuit is not closed).
Page 28 of 76

Reset the safety circuit:
Check, if
the system is in proper condition and safe to operate
one or both emergency stop buttons are pressed, if so release
them by gently turning and pulling
press the blue EM-QUIT button
EM-Stop
EM-QUIT
(blue)
The status of the safety circuit can be seen on the safety relay:
EM-stop pressed
EM-stop released
EM-QUIT pressed =
Safety circuit OK
After having reset (quit) the system, all 3 LEDs at the safety relay
should be illuminated green. The [Quit] buttons on the touch panels
should no longer flash in red.
If system air pressure is on the vertical axis of the Handling Unit
should extend (move upwards).
Page 29 of 76

Line Type / Operation Mode selection
Operation mode selection consists of
Line Type setting (single = stations are run individually /
connected = both stations run together)
Automatic / Manual selection
To set the line type press [Parameters] at the bottom screen of the
main menu:
Then select the desired setting:

.
It is important to set the line type properly; otherwise the system will
not work but generate error messages.
It is possible to select single, even if the network connection is
present. However, if the network connection is disconnected it is
necessary to select Single
Page 30 of 76

Once the line type is set it is possible to select the operation mode.
Note: Selected buttons are generally highlighted in green showing
the current configuration setting or operation mode.
Select the desired operation mode by either pressing the button
[Manual] or [Automatic] in the top left corner of the menu.
.
Manual mode:
In Manual mode it is possible to operate each actuator individually to
check its proper function by using the [Extend] / [Retract] or
[Forward] / [Backward] buttons. Next to the buttons for the actuators
the PLCs out- and inputs are displayed to assist troubleshooting in
case an actuator or sensor is not responding.
This applies for both stations in the same way.
.
Note: Pressing the [Start] button in manual mode has no effect.
Page 31 of 76

Automatic mode with Line Type connected:
In Automatic mode the [Storage] button must be highlighted (green),
otherwise the system will not start, since no task is selected.
Therefore press [Storage] and afterwards press [Start].
.
The system will now produce cubes and store them in the ASRS.
Unwanted cube halves will be sorted out onto the slides.
Note: if the system is in connected mode both station will always
have the same mode of operation. It is not possible to select
Automatic at one station and Manual at the other.
Automatic mode with Line Type Single Station 1:

The process on station 1 is identical independently of the line type
setting. By pressing [Start] the system expels cube halves from the
Magazines onto the Belt Conveyor, test/sorts them and moves them
finally to the end of the Belt Conveyor. If connected the Handling
Unit picks the cube halves up at the end of the Belt Conveyor. In
Single mode the workpiece stays at the end of the Belt Conveyor
until manual removal by the operator.
As soon as the workpiece is removed the Magazine will expel the
next cube half.
Page 32 of 76

Automatic mode with Line Type Single Station 2:
In Connected mode the Handling Unit of station 2 automatically
picks up a workpiece at the end of the Belt Conveyor as soon as it
arrives there.
In Single mode the Handling Unit will pick up workpieces from the
transfer device instead of the Belt Conveyor, since station 1 may not
be present (physically detached) and therefore neither the Belt
Conveyor will be present.
However, since no sensors are available at the transfer device the
Handling Unit has no way of knowing, whether a workpiece is there
or not. Therefore the processes in Single mode and Connected
mode slightly differ.
In Single mode the user needs to place the proper workpiece at the
transfer device. The required workpiece is indicated at the touch
panel of station 2.
Depending what workpiece is required next, either the [Upper CH] or

the [Lower CH] button is flashing in green.
Place the required workpiece in the transfer device and afterwards
press the button which is flashing. The Handling Unit will move to the
transfer device and pick up the workpiece. The process on station 2
will alternately require a lower and an upper cube half. Once both
cube halves are placed in the press the process will continue
identically to the way it runs in Connected mode.
Process description:
Press [Automatic] then press [Start]
[Lower CH] is flashing
Place lower cube half in transfer device, then press [Lower CH]
Handling Unit picks up and moves lower cube half to Press Unit
[Upper CH] is flashing
Place upper cube half in transfer device, then press [Upper CH]
Handling Unit picks up and moves upper cube half to Press Unit
Cube halves are pressed together in the Press Unit, afterwards
picked up by the Handling Unit, moved to the ASRS and stored
there.
Page 33 of 76

Own notes:
Page 34 of 76
System setup and functional grouping

As explained in the chapters before the mechatronic system consists
of the following functional units:
2 Magazine Units
1 Sorting Unit
1 Belt Conveyor
1 Handling Unit
1 Pneumatic Press
1 ASRS
These functional units of the assembly line are program-wise

grouped into the following 4 functional sections:
Section 1: Magazine + Testing (Sorting)
Section 2: Handling
Section 3: Press
Section 4: ASRS
Section 1: Magazine and Testing

Aluminium and black/white plastic cube halves (= workpieces) are
expelled from two magazines to the Belt Conveyor. At the end of the
Belt Conveyor an optical sensor signals the arrival of the cube
halves.
While being transported forward on the Belt Conveyor, the Sorting
Unit checks the workpieces for their material properties and
orientation. Workpieces with wrong orientation (according to the
parameter setting), wrong material or wrong color are expelled from
the line onto three slides.
Section 2: Handling
The Handling Unit is the central device for workpiece distribution
between different sections.
Handling Unit jobs:
Transport lower cube halves from Belt Conveyor to Press
Transport upper cube halves from Belt Conveyor to Press
Transport finished cubes from Press to ASRS (Storage)
Page 35 of 76

Section 3: Press
Handling Unit 1 places one of each cube halves in the Pneumatic
Press. After the press punching operation is finished the completed
cube is picked up by Handling Unit and dropped off at the rack feeder
of the ASRS for storing.
Section 4: ASRS (Automatic Storage and Retrieval System)
The ASRS can have 2 operating modes:
STORAGE and RETRIEVAL
In this application only STORAGE mode can be activated.
Storage:
The rack feeder gets the finished cubes from the Handling Unit and
places them in one of the 28 available spaces in the rack shelf. The
touch panel provides a specific screen for shelf display and shelf
management. This diagnosis screen shows all finished cubes in the
rack and allows the operator to manipulate rack occupancy.
Retrieval (not used in this application):
The rack feeder takes finished cubes from the shelf rack and moves
them to a transfer position, where the Handling Unit picks them up
and places them somewhere else. This mode is not available in this
application
Page 36 of 76
Operating modes & step sequences

The system has 4 operating modes, depending on actual safety
conditions and operator selection. The operating modes are activated
or selected with the following priority:
No operation
Manual
Automatic stop
Automatic running
The operating mode can be selected from the main screen of the
operator panel.
Operating Mode No operation
The operating mode No operation blocks all movements in case of
an emergency stop condition. This mode is automatically activated
by hardware interlocks and the PLC if one of the following conditions
is true:
Emergency stop button pressed
Safety interlock circuit not closed
Safety relay not activated
In this operating mode, the PLC will set all outputs for valves and
drives to LOW signal. Power supply for all valves and drives will be
disconnected by hardware interlocks using a specific safety relay.
To reset this condition, it is necessary to close the safety interlock
circuit:
Remove the reason for the incident and make sure the system
is in proper condition again. I.e. check all connections.
Release the EM-Stop button
Press the blue EM-QUIT button on the system operator panel
If there is no other fault present, the system is now ready to be

started again.
Page 37 of 76

Operating Mode Manual
Manual mode is especially designed for diagnosis and maintenance
purposes. All devices can be operated manually from the system
touch panel.
Manual mode can by activated by pressing the button [Manual] at the
main screen of the system touch panel.
In manual mode safety interlocks are still operational. All common
interlocks for automatic operation are not active.
Operating Mode Automatic stop

The PLC switches the operating mode automatically to Automatic
stop if the following conditions are all true:
No emergency stop condition
Safety interlock circuit closed and safety relay activated
Buttons [Manual]/[Automatic] are set to [Automatic]
Automatic running not active
Operating Mode Automatic running

Automatic mode is designed for a fully automated process. Automatic
operation can be started and stopped by the operator at any time.
From operating mode Automatic stop, the operator can switch to
Automatic running by pressing the push button [Start] at the system
touch panels.
Pressing the push button [Stop] at the system touch panels will stop
the automatic mode immediately. Alarms category 1 will also stop
automatic execution.
In automatic mode all safety interlocks are operational. All common
interlocks for automatic operation are active, too.
In operating mode Automatic running all devices on this station are
controlled by the following step sequences:
Page 38 of 76

PLC program steps Magazine and Testing (PLC 1)
Step
0
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Not active
Homerun (move all units to home position)
Check for moving workpieces in section
(in case of workpiece moving in this section the controller
jumps to the related step)
Wait for enable start (Storage must be activated)
Extend magazine cylinder
Retract magazine cylinder
Move workpiece to checking position
Check workpiece for orientation, material and colour
Move workpiece to push out position
Extend separation cylinder
Retract separation cylinder
Move workpiece to transfer position
Wait for workpiece transfer (transfer position empty)
Remove workpiece if the workpiece orientation does not fit
with the request from Module 2
PLC program steps Handling Unit (PLC 2):

Step
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Description
Not active
Wait for new Job
Move to belt conveyor
Retract vertical cylinder
Generate vacuum
Extend vertical cylinder
Move to press
Release vacuum
Move to press
Generate vacuum
Move to ASRS
Release vacuum
Page 39 of 76

20
21
22
23
24
25
26
27
28
Move to parking position

Move to ASRS (retrieval, not used)
Retract vertical cylinder (retrieval, not used)
Generate vacuum (retrieval, not used)
Extend vertical cylinder (retrieval, not used)
Move to belt conveyor extern (retrieval, not used)
Retract vertical cylinder (retrieval, not used)
Release vacuum (retrieval, not used)
Extend vertical cylinder (retrieval, not used)
PLC program steps Press (PLC 2):

Step
0
1
2
3
4
5
6
7
8
9
10
11
Description
Not active
Wait for lower cube halve
Wait for upper cube halve
Retract pusher
Close safety door
Extend punch
Retract punch
Open safety door
Extend pusher
Wait for workpiece transfer (press empty)
PLC program steps ASRS (PLC 2):

Step
0
1
2
3
4
5
6
7
8
9
10
11
Description
Not active
Wait for new job
Move rack feeder to transfer position
Wait for cube on fork
Move rack feeder to shelf rack
Extend fork cylinder
Move rack feeder down (set down cube on rack)
Retract fork cylinder
Move rack feeder to shelf rack
Extend fork cylinder
Page 40 of 76

12
13
14
15
Move rack feeder up (pick up cube from rack)

Retract fork cylinder
Move rack feeder to transfer position
Wait for workpiece transfer (fork empty)
Pushing the button [Manual] at the system touch panels will reset the
actual step number to zero. The next time Automatic running is
used, the step sequence will start with step 1 (automatic homerun)
and continue operation depending on existing moving workpieces in
the section (decision is made in step 2).
It is possible to delete moving workpieces on the related unit screens
of the system touch panels (only if automatic is not running).
Alarms and messages

The control system generates alarm messages automatically, to help
the operator in case of malfunction of equipment and other problems.
All movements of devices and workpieces are monitored. If a certain
time limit is exceeded, an alarm is generated and a specific text
message is displayed at the message screen of the system touch
panels.
For training purposes the text message function at the system touch
panels can be turned off.
All alarms are allocated to two categories:
Alarms of category 1 will stop automatic execution

Alarms of category 2 are only displayed indications with some
effects on related devices
Most alarms are stored and must be reset by pressing the push
button [Quit] at system touch panels.
In case of category 1 or 2 alarms there is a flashing red signal on the
system touch panels.
Flashing means a new alarm of category 1 or 2 has

occurred
Always on means an alarm of category 1 or 2 is still
active, but already acknowledged by pressing the push
button [Quit].
Page 41 of 76

List of alarms (PLC 1)
No.
1
2
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
33
34
37
Text
Common
Safety interlock circuit not closed (Emergency
stop)
Common
Communication fault with module 2 (ProfiNet)
Magazine + Separation
Time limit magazine cylinder 1 extend
Time limit magazine cylinder 1 retract
Time limit magazine cylinder 2 extend
Time limit magazine cylinder 2 retract
Time limit separation cylinder 1 extend
Time limit separation cylinder 1 retract
Time limit workpiece moving from magazine to
checking position
Time limit workpiece moving from checking
position to separation cylinder 1
position to transfer position
Magazine 1 empty
Magazine 2 empty
Workpiece height off range
Category
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Page 42 of 76

List of alarms (PLC 2):
No.
1
2
33
34
35
36
37
38
48
49
50
51
52
53
54
65
66
67
68
69
70
71
72
Text
Common
Safety interlock circuit not closed (Emergency
stop)
Common
Communication fault with module 1 (ProfiNet)
Handling Unit
Time limit rotation right
Handling Unit
Time limit rotation left
Handling Unit
Time limit vertical cylinder extend
Handling Unit
Time limit vertical cylinder retract
Handling Unit
Time limit horizontal cylinder extend
Handling Unit
Time limit horizontal cylinder retract
Handling Unit
Rotation axis blocked (no impulses from encoder)
Press
Time limit safety door open
Press
Time limit safety door close
Press
Time limit pusher extend
Press
Time limit pusher retract
Press
Time limit punch extend
Press
Time limit punch retract
ASRS
Time limit horizontal axis forward
ASRS
Time limit horizontal axis backward
ASRS
Time limit vertical axis up
ASRS
Time limit vertical axis down
ASRS
Time limit fork cylinder extend
ASRS
Time limit fork cylinder retract
ASRS
Workpiece not on fork
ASRS
Category
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Page 43 of 76
73
74
75
76
77
78
79
Workpiece still on fork

ASRS
Workpiece on fork unknown
ASRS
Limit switch horizontal axis forward
ASRS
Limit switch horizontal axis backward
ASRS
Limit switch vertical axis up
ASRS
Limit switch vertical axis down
ASRS
Horizontal axis has wrong position
ASRS
Vertical axis has wrong position
2
2
2
2
2
2
2
Page 44 of 76
System Touch Panel Station 1

The system touch panels are the main means for diagnosis and
parameter setup as well as a device for alarm message display. The
panels provide information about current conditions for all sections of
the system and are used to edit parameters like positions for encoder
controlled positioning devices.
Start screen
Menu
Main screen (Menu)

The main screen provides the operator with basic information about
all sections in the process line.
Shows current
recipe for
cube production
Page 45 of 76
Push buttons on top:
Automatic (Switches to automatic mode)

Manual (Switches to manual mode)
Start (Start Automatic running)
Stop (Stop Automatic running)
Storage (On/Off for storage line from magazine to ASRS)
L-Test (Lamp test, only working, if light pole present)
Quit (Reset alarms)
Alarm Indicators on top:
Alarm category 1
Alarm category 2
Mode (operating mode):
No operation
Manual
Automatic stop
Automatic running
WP Ident:
shows the result of the last workpiece examination at

testing position
The following results are possible:

o
o
o
o
o
o
Lower cube halve aluminium

Lower cube halve plastic black
Lower cube halve plastic white
Upper cube halve aluminium
Upper cube halve plastic black
Upper cube halve plastic white
Cube picture on right side shows the current program selection

(recipe) for the storage line:
Program for upper cube halves (Aluminium, plastic black,

plastic white)
Program for lower cube halves (Aluminium, plastic black,
plastic white)
Page 46 of 76
Section overview:
WP = Workpiece moving in section

AL = Section has alarm category 1 or 2
Screen navigation buttons at the bottom:
Messages (screens with alarm list and alarm history)

Units (diagnosis and manual screens for all sections)
Parameter (parameter setup screens)
System (system screen for touch panel)
Alarm list + history

(press [Messages] on main screen)
The alarm list contains all current alarm messages with alarm
numbers.
The alarm history provides an alarm message buffer with all previous
alarm messages. It contains the message text with time for alarm
coming and alarm going off. The size of the alarm buffer is 500
messages. After the buffer is full, the oldest entry will be automatically deleted.
Alarm list:
History
Alarm history:
Menu
Messages
Menu
Page 47 of 76

Unit screens (for all sections)
(press [Units] or press direct unit buttons on main screen)
For station 1 there are 2 unit screens available. Switch between
screens by using the [NEXT] / [PREVIOUS] buttons.
Screen 1: Magazine Units and Belt Conveyor
Screen 2: Sorting Unit
.
The unit screens provide the following information and controls:
Actual step number with variable text description

Alarm category 1 or 2 active
Moving workpieces
Clear button (button works only if automatic is not running)
Manual controls (Push buttons for manual mode and
indicator lights for diagnosis, O=Output, I=Input)
Actual workpiece height in mm
Page 48 of 76

Statistics screen:
(press [Statistics] on main screen)
The statistic screen allows data analysis by showing the number of

stored and removed cubes during a specific time frame. All data are
sorted by workpiece materials. To start a new monitoring period all
counters can be deleted by pushing the button [Clear All].
Parameter screens
(press [Parameter] on main screen)
Main parameter screen
.
Common settings
Show alarm text messages on/off (for training purposes, it

is possible to turn alarm text messages off)
Page 49 of 76
Line Type (Selection between Single mode = each

station works separately and Connected mode = The 2
stations are connected and work together)
The main parameter screen allows the selection of the actual

program as follows:
Upper cube halves (Aluminium plastic black plastic

white)
Lower cube halves (Aluminium plastic black plastic
white)
Program selection is interlocked with moving workpieces on the

storage line. To change the actual program settings, it is necessary
to empty the storage line between magazine and ASRS or delete all
moving workpieces on this line.
Specific parameter screens for other sections can be selected from
the main parameter screen.
Parameter screen for magazine and testing
The parameter screen for magazine and testing allows the following
settings:
Time delay for workpieces moving between sensor and

testing cylinder in seconds
Page 50 of 76

System screens
(press [System] on main screen)
System screen for TP177 settings
System screen 1 displays actual date and time from the PLC and
allows the change of date and time settings.
The push button [Control panel] opens a windows setup screen for all
basic touch panel settings (see documentation for TP177B).
System screen for user management

(user level Administrator required)
User screen
System
Menu
System screen 2 provides a list of all users with admission to one or

several of the following protected levels (groups).
Level 1 - Operator
Level 2 - Advanced operator
Level 3 - Teacher
Level 9 - Administrator
Page 51 of 76

Upper levels include permission for lower levels.
These levels can be used to protect single input fields, controlling
buttons or screen navigation buttons. The setup must be done with
WinCC flexible software using the screen editor (see operator
manual for WinCC flexible for further information).
Login for user level Administrator:
User name: Admin
Password: 58030
Page 52 of 76
System Touch Panel Station 2

Start screen
Menu
Main screen (Menu)

The main screen provides the operator with basic information about
all sections in the process line.
.
Push buttons on top:
Automatic (Switches to automatic mode)

Manual (Switches to manual mode)
Start (Start Automatic running)
Page 53 of 76
Stop (Stop Automatic running)

Storage (On/Off for storage line from magazine to ASRS)
L-Test (Lamp test, only working, if light pole present)
Quit (Reset alarms)
Alarm Indicators on top

Alarm category 1
Alarm category 2
Mode (operating mode)
No operation
Manual
Automatic stop
Automatic running
WP Ident:
shows the result of the last workpiece examination at
testing position
The following results are possible:
Lower cube halve aluminium
Lower cube halve plastic black
Lower cube halve plastic white
Upper cube halve aluminium
Upper cube halve plastic black
Upper cube halve plastic white
Cube on right side shows the actual program selection for the
storage line:
Program for upper cube halves (Aluminium, plastic black,
plastic white)
Program for lower cube halves (Aluminium, plastic black,
plastic white)
Section overview
WP = Workpiece moving in section
AL = Section has alarm category 1 or 2
Screen navigation buttons at the bottom:
Messages (screens with alarm list and alarm history)
Units (diagnosis and manual screens for all sections)
Parameter (parameter setup screens)
System (system screen for touch panel)
Page 54 of 76

Alarm list + history
(press [Messages] on main screen)
The alarm list contains all actual alarm messages with alarm
numbers.
The alarm history provides an alarm message buffer with all previous
alarm messages. It contains the message text with time for alarm
coming and alarm going off. The size of the alarm buffer is 500
messages. After the buffer is full, the oldest entry will be
automatically deleted.
Alarm list:
History
Alarm history:
Menu
Messages
Menu
Page 55 of 76

Unit screens
(press [Units] or press direct unit buttons on main screen)
Main unit screen
.
Specific unit screens for all sections and the shelf display can be
selected from the main unit screen.
Unit screens for all sections of station 2:

.
Page 56 of 76

.
The unit screens provide the following information and controls:

Actual step number with variable text description
Alarm category 1 or 2 active
Moving workpieces with Clear button (button works only if
automatic is not running)
Manual controls (Push buttons for manual mode and
indicator lights for diagnosis, O=Output, I=Input)
Actual position for rotation axis (Handling unit)
Page 57 of 76

Unit screen for shelf display and management:
An additional unit screen shows all finished cubes on the shelf and
allows the operator to manipulate shelf occupancy.
Using the push buttons at the shelf and the bottom, the operator can
set cubes to and clear cubes from single shelf racks as well as
setting/clearing all shelf racks at one time.
This screen also shows the number of cubes on the shelf.
Statistics screen
The statistic screen allows data analysis by showing the number of

stored and removed cubes during a specific time frame. All data are
sorted by workpiece materials. To start a new monitoring period all
counters can be deleted by pushing the button Clear All.
Page 58 of 76

Parameter screens
(press [Parameter] on main screen)
Main parameter screen
.
Common settings:
Show alarm text messages on/off (for training purposes, it

is possible to turn alarm text messages off)
Line Type (Selection between Single mode = Each
station works separately and Connected mode = The 2
stations are connected and work together)
The main parameter screen allows the selection of the actual

program as follows:
Upper cube halves

(Aluminium plastic black plastic white)
Lower cube halves
(Aluminium plastic black plastic white)
Program selection is interlocked with moving workpieces on the

storage line. To change the actual program settings, it is necessary
to empty the storage line between magazine and ASRS or delete all
moving workpieces on this line.
Specific parameter screens for other sections can be selected from
the main parameter screen.
Page 59 of 76

Parameter screen for Handling Unit
(press [Handling Unit] on parameter screen)
The parameter screen for handling unit 1 allows the following

settings:
4 positions for rotation axis in degree
Parameter screen for ASRS
(press [ASRS] on parameter screen)
The parameter screen for ASRS allows the following settings:

Maximum number of cubes in shelf (Limit for storage)
Page 60 of 76

System screens
(press [System] on main screen)
System screen for TP177 settings
System screen 1 displays actual date and time from the PLC and
allows the change of date and time settings.
The push button Control panel opens a windows setup screen for
all basic touch panel settings (see documentation for TP177B).
Page 61 of 76

System screen for user management
(user level Administrator required)
User screen
System
Menu
System screen 2 provides a list of all users with admission to one or

several of the following protected levels (groups).
Level 1 - Operator
Level 2 - Advanced operator
Level 3 - Teacher
Level 9 - Administrator
Upper levels include permission for lower levels.
These levels can be used to protect single input fields, controlling
buttons or screen navigation buttons. The setup must be done with
WinCC flexible software using the screen editor (see operator
manual for WinCC flexible for further information).
Login for user level Administrator:
User name: Admin
Password: 58030
Page 62 of 76
modular Mechatronic System

"SSC2P2HV2 "
SOFTWARE MANUAL
Version 01.12.2012
Page 63 of 76
Purpose
The software manual provides general information about the PLC
software application and the interface between PLC and HMI. It does
not explain all interlocks and functional correlations in detail.
It is intended for students in the field of S7 programming,
maintenance- and service personnel. In order to understand this
manual, general knowledge of automation technology and S7
programming is required. To use this manual effectively, you should
already be familiar with the theory behind S7 programs which is
documented in the online help for STEP 7.
Programming language
The programming language is STL (STatement List). STL
corresponds to the "Instruction List" language defined in the
International Electrotechnical Commission's standard IEC 1131-3.
STL is the best and most professional of all available languages for
PLC programming, because it corresponds directly with the PLC
processor commands and allows the programmer to use all available
methods and PLC capabilities.
The knowledge of statement list instructions and procedures is
needed to fully understand the subjects of this manual and
comprehend the actual program code.
Using the STEP 7 Manager

It is recommended to open and display the project in the STEP 7
project window as reference during study of this software manual.
The project window is split into two halves. The left half shows the
tree structure of the project. The right half shows the objects that are
contained in the object open in the left half in the selected view (large
symbols, small symbols, list, or details).
At the top of the object hierarchy is the object "ESL01" as the icon for
the whole project. It can be used to display the project properties and
serves as a folder for networks (for configuring networks), stations
(for configuring the hardware), and for S7 programs (for creating
software). The objects in the project are displayed in the right half of
the project window when you select the project icon.
Page 64 of 76

Click in the left half of the window on the boxes containing a plus sign
to display the full tree structure of the project and mark the
Bausteine folder of PLC_1 or PLC_2. You will get a general
overview of the software structure and see all blocks used in this
project.
Page 65 of 76

Layout and line compartments
For software organization the assembly line is divided into 4 sections:
Magazine and Sorting Units (Symbol = MT)

Handling Unit 1 (Symbol = H1)
Press Unit (Symbol = PR)
Storage and Retrieval ASRS (Symbol = SR)
These sections are used as neat and useful arrangement in many

parts of the data structure and program administration.
The sequence of these sections follows the flow of workpieces
moving through the assembly line.
Software structure
The software is structured for both PLCs in 10 basic groups:
Program organization
Inputs
Alarms
Common functions
Manual mode
Automatic mode
Device control
Communication
Human machine interface
Outputs
FC01H
FC10H
FC20H
FC30H
FC40H
FC50H
FC60H
FC70H
FC80H
FC90H
It is referring to the assembly line sections by 4 step sequences:

PLC 1:
Magazine and testing
FC101H
PLC 2:
Handling unit
Press
ASRS
FC131H
FC161H
FC191H
Beyond that, the programme contains operating blocks with basic

PLC functionality and several data blocks.
Page 66 of 76

Operating block OB1
The operating block OB1 represents the main sweep cycle of the
PLC programme. All other function blocks must be called directly or
indirectly from the OB1 main program.
In this application the first block for each basic group is called in
OB1. All other function blocks are called afterwards.
Operating block OB100

The operating block OB100 is used as PLC start up procedure and
processed only during the first cycle every time the PLC is started. It
contains all necessary operations to clear certain memory bits and
set data block values to start up conditions.
Data block DB1

DB 1 contains all actual values used in the programme like:
Current operating mode

Current step numbers for step sequences
Actual positions and current position setpoints
Actual PLC cycle counter
Actual support values for alarm processing
Actual values for ASRS handling
Data block DB4

DB4 contains adjustable machine parameters like:
Machine status bits

Delay times
Positions for handling unit
Parameter for ASRS
These parameters can be edited at the HMI parameter screen.
Page 67 of 76

Data block DB8
Data block DB8 is used as interface between the PLC program and
the human machine interface TP177B. It contains all necessary
common signals and values for communication between PLC and
HMI like:
Actual HMI screen number

Alarm bits
Bits for HMI push buttons
Adjustable process values
Status bits and values for visualization
Date and time settings
Data block DB47

DB47 is used as instance DB for reading encoder inputs. This is a
system function of the PLC and will be no further explained in this
manual. (For more information see CPU manual)
Basic group Program organization FC01G

The function blocks FC1 and FC2 are used to implement common
functionality, which can be utilized in other parts of the PLC program
as supportive features such as
Impulse flags (Memory bits which are TRUE for only one
PLC cycle per time unit)
PLC cycle counter
Common timer
Basic group Inputs FC10G

This group of function blocks is used to read different types of inputs
and to transfer these signals and values to memory bits and data
words.
Common digital inputs (transfer to memory bits M150.0M164.4)

Analog inputs (transfer to data words in DB1)
Encoder inputs (transfer to data words in DB1)
Inputs from ASRS rack feeder positions (analyse and
transfer to data words in DB1)
Page 68 of 76

For several practical reasons like flexibility and reutilization of
function blocks for other applications, it is recommended to use
memory bits instead of digital inputs for common functions.
Basic group Alarms FC20G

The basic group Alarms contains all functions connected with
generating of alarms and alarm processing. In the PLC program
alarms are defined as memory bits MW130-MW142.
Each memory word contains 16 bits = 16 Alarms and correlates with
one of the assembly line sections.
All alarms are allocated to 2 categories:
Alarms category 1 will stop automatic execution (MW130)

Alarms category 2 are only displayed indications with some
specific effects on related devices (MW132-MW142)
The group starts with FC21 Alarm administration. This function

block contains functionality for:
Generating of alarm status bits (M128.0-M128.1)

Monitoring the occurrence of new alarms (M129.0)
Resetting alarms
The alarms are generated in function blocks FC22-FC26 which are

also corresponding with the assembly line sections and used as
interlock conditions in all following program groups.
Usually, alarm bits are set in one of the function blocks FC22-FC28
and must be reset by the operator. The operator uses a push button
PB Quit on the main HMI screen which is connected with
DB8.DBX60.4. In FC21-NW5 this bit is used to reset all alarm
memory bits. In case the alarm condition still exists, the alarm will be
set again in FC22-FC28 and therefore active in all following
interlocks.
A list of all alarm texts can be found in the WinCC application for HMI
TP177B. In FC82 HMI Messages, all alarm memory words are
transferred to the HMI interface DB8. This is necessary, to switch the
sequence of the first and second byte in each word.
Page 69 of 76

Basic group Common functions FC30G
The Common function blocks contain basic process functionality
such as
FC31 Operating Modes

FC32 Program selection
FC33 Workpiece management
FC34 Common status bits
The assembly line is controlled by use of 4 operating modes:

1.) No operation
2.) Manual operation
3.) Automatic stop
4.) Automatic running
All conditions and interlocks for operating modes are contained in
FC31-NW3. Conditions for operating modes are safety inputs, alarms
and operator actions. Several Bits in DB8 (HMI interface) connected
with push buttons on the main HMI screen are used for operator
input.
In FC32 (Program selection) memory bits are set for all available
assembly-program versions of the assembly line. Program selections
come from the main parameter screen of the HMI using DB8.DBW80
and DB8.DBW82.
The workpiece management in FC33 sets and resets memory bits
M90.0 H M95.4 for every workpiece moving in one of the 6 sections
of the assembly line. This memory bits are used in other parts of the
program for device control and workpiece monitoring.
In FC34 common status bits are defined for different processing
purposes. All status bits are described by memory bit- and network
comments. They are used as interlocking conditions in automatic
mode, device control and other parts of the program. To understand
the purpose and functionality of each status bit, it is recommended to
use the reference table for cross references provided by the
SIMATIC STEP 7 manager.
Basic group Manual mode FC40G

FC40 = Manual operation calls function blocks FC41-FC44 which
contain the manual operations for each assembly line section. The
function blocks are only active in manual mode.
Page 70 of 76

In order to control devices from different parts of the program in
varying operating modes, each device has a specific Device status
bit (M70.0-M80.0). In manual mode, these status bits are set in the
manual function blocks FC41-FC46 by connecting the bits with HMI
interface bits from push buttons displayed on the manual HMI
screens.
Basic group Automatic mode FC50G

Automatic mode can be divided into operating mode Automatic stop
and operating mode Automatic running. In Automatic stop all
devices and units of the assembly line are stopped and ready for the
operator to push the Start button (DB8.DBX60.2) at the main HMI
screen. In Automatic running all devices of the assembly line are
controlled automatically by step sequences and position controllers.
In FC50 = Automatic operation, all basic administrative issues for
automatic mode are handled:
Resetting step sequence numbers in manual mode

Calling of step controllers in automatic mode
Calling of position controllers
Calling of device function blocks
FC51 manages all step controllers. Each section of the assembly line
has a specific step sequence. Step controllers work with a step
number (DB1.DBW10-20) and step function blocks (FC101-FC258).
Each step of a sequence has a separate function block. This system
has the advantage of easy programming and diagnosis.
The actual step numbers have always a uniquely defined decimal
value and can be changed easily by overwriting the actual step
numbers with a new value in DB1.DBW10-20.
In each step, only one specific function block of the sequence is
active. The step function block contains the enabling conditions for
the next step as well as other process functions and calculations.
Function blocks for step sequences are called by using a calling
command with indirect addressing. A typical programming code for
calling step blocks looks like this:
L "DB_ACT".STEP_NO_MT
L 100
+I
T #ADR_FC
UC FC [#ADR_FC]
Description for commands and values:
Page 71 of 76
L DB_ACT".STEP_NO_MT = Load actual step number

L 100 = Load 100 (Offset for function block Step 1-11 =
FC101-FC111)
+I = S7 Command for addition
T #ADR_FC = Transfer to calculated address for function
block
UC FC [#ADR_FC] = Calling of function block
FC52 contains the position controller for the rotation drive in handling
unit 1. The position controller handles and corresponds with the
following values and memory bits:
DB1.DBW44 Actual rotation position (from encoder)
DB1.DBW48 Setpoint for rotation position (from step function
blocks)
M108.0 Position ok (actual value equals setpoint)
M108.1 Rotation axis direction left (request for drive control)
M108.2 Rotation axis direction right (request for drive control)
FC53 contains the position controller for the ASRS rack feeder. The
following values and bits are handled in this function block:
DB1.DBW150 Actual row number
DB1.DBW152 Actual slot number
DB1.DBW154 Actual rack number
DB1.DBW160 Setpoint for row number
DB1.DBW162 Setpoint for slot number
DB1.DBW164 Setpoint for rack number
M112.0 Horizontal axis position ok (actual value equals setpoint)
M112.1 Horizontal axis direction forward (request for drive control)
M112.2 Horizontal axis direction backward (request for drive
control)
M112.3 Vertical axis position ok (actual value equals setpoint)
M112.4 Vertical axis direction up (request for drive control)
M112.5 Vertical axis direction down (request for drive control)
M112.6 Rack feeder in transfer position (enable signal for interface
with handling unit)
In FC54-FC59 the Device status bits (M70.0-M80.0) are set for
automatic mode depending on the actual step bits, the request bits
from the position controllers, status bits from workpiece management
and other common status bits.
Page 72 of 76

Basic group Device control FC60G
FC60 calls all device function blocks FC61-FC64. In these blocks,
the Device status bits which are set in manual and automatic mode
are interlocked with other basic conditions like operating mode,
safety interlocks etc. to set and resets memory bits (M170.0-M183.7)
which are directly connected to the device outputs of one of the 6
assembly line sections. Therefore the final device control is located in
this section.
Basic group Communication FC70G

The 2 Stations of the assembly line are connected by a SIMATIC
ProfiNet connection. This connection uses standard Ethernet
hardware components and specific SIMATIC software blocks.
SIMATIC STEP 7 software comes with a special application called
NetPro to handle all Networking issues in a project. To open
NetPro, you have to mark one of the PLC CPUs in the STEP 7
manager and click on Verbindungen.
You will see the following screen:
You can see all PLCs and HMI Panels connected to Ethernet (1).
In the lower part of the screen, you see the S7-Connection between
PLC1 (CPU) and PLC2 (CPU).
The S7 Connection works with 2 standard function blocks
FB14=Get and FB15=Put which are called from FB71 of PLC1.
For more information regarding S7/ProfiNet Communications please
use the specific Siemens documentations.
Page 73 of 76
Basic group Human machine interface FC80G

Function blocks FC80-FC84 are used to handle the signal exchange
between PLC and HMI TP177B. FC80 calls the function blocks
FC81-FC84. All function blocks work in combination with the HMI
interface DB8.
FC81 contains common functions, especially writing the actual date
and time from PLC to TP177B and set the PLC clock with values
edited on the HMI system screen. This is necessary, because the
TP177B clock is not buffered by battery. Therefore the PLC clock is
used for reliable date and time information.
In FC82 all memory bits for alarm display are transferred to the HMI
interface data block DB8. As part of this transfer the sequence of the
first and second byte in each word is switched, because the TP177B
works with a different order of low byte and high byte than the PLC
memory bit area.
FC83 handles specific bits and values to support visualization on
HMI screens in correlation with WinCC flexible specifications.
FC84 contains counter for statistical purposes like:
Number of workpieces finished separate for each line

program
Number of workpieces pushed out
Basic group Outputs FC90G

Similar to PLC inputs, memory bits are used in the program instead
of activating direct PLC outputs. Therefore digital and analog PLC
outputs appear only within the group of these function blocks. It has
many advantages like easy cross reference and diagnosis as well as
easy re-utilization of function blocks in other projects.
This group of function blocks is used to transfer these memory bits
(M170.0-M183.7) to the PLC outputs. Analog outputs are not used in
this application therefore FC92 contains no program code.
Page 74 of 76
Page 75 of 76
Copyright:
Dr.-Ing. Paul Christiani GmbH & Co. KG

Technisches Institut fr Aus- und Weiterbildung
Hermann-Hesse-Weg 2
D-78464 Konstanz
info@christiani.de
Page 76 of 76

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USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

Very important notice / safety related information

Important / useful information for working with the

Button on touch panel or computer screen

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

Set of Allen keys

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

The provided equipment is intended for training purposes in

It is designed to be altered within certain limits by the trainer or

Changes must only be carried out by skilled personnel or by

During training a trainer familiar with the system must be

The equipment is only to be used indoors within the

The system is rated for a primary power supply of 100H240 V

Static electricity may cause damage to the product.

While exercising on the system make sure you do not have

The system must not be used for industrial purposes, such as

Always use proper functioning measuring devices when

Never use frayed, damaged or deteriorated hoses. Use only

Make sure that hoses are fully depressurized before

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

Never play with compressed air. Do not apply it to your skin or

Never turn the arm of the Handling Unit manually without

Never move the axes of the ASRS manually without removing

Removal of transportation safety devices

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

First time or re-installation at final location

Check packaging for any damages.

In case the packaging is damaged take photos for later

Unpack/unwrap the goods carefully

Remove any boxes with accessories from the system.

Check the system again visually for any damages.

In case of any damages take photos for later evidence.

Remove the clearly marked transportation safety locks which

Check pneumatic hoses and electrical cables for any

Check, if you have received all goods within the scope of

Make sure no small parts are hidden between packaging

Plug in all connecting cables between PLC and functional

Unpack the workpieces (cube halves) from the accessories

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

Assembling the slides of the Sorting Unit:

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual

Some cables may have been removed for transportation to

All cables, hoses and connectors are marked in a way which

As a general rule a cable labeled -W1 always leads to a

Make sure, that the unit designations (i.e. +PPN) do agree

Settings / Parameter / Password protection

USER MANUAL SSC2P2HV2 V01.10.2014.doc

modular Mechatronic System SSC2P2HV2 - User Manual