MPS500 Siemens Manual Level2 Mill105 RV2AJ A001

MPS 500
Manual
This document consists of 4 parts, divided up into:
• Part A contains the manual of the system or station.

• Part B, in as far as present, contains a collection of exercises together with the
relevant solutions or additional information.
• Part C contains the circuit diagram of the system or station.
• Part D contains the data sheets of the system or station.
Order no.:
Name: Manual MPS500
Designation: MPS500_Siemens_Manual_Level2_Mill105_RV2AJ_A001.doc
Date: July 08
Author: Schober / Espenberger
Graphics: Schober / Espenberger
Layout: Schober
© Festo Didactic GmbH & CoKG., D-73770 Denkendorf, 2008
Internet: www.festo.com/didactic
e-mail: did@festo.com
This manual, all text and illustrations contained included, is protected by copyright. Any utilisation
outside the limits of the copyright law and other than training purposes are not permissible without
our definite approval. This applies in particular to reproductions, operations, translations, micro
filming and the storing and processing into electronic systems. Parts of this manual may be copied by
the authorised user, exclusively for teaching purposes. Distribution of this documentation, as well as
reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences
are liable to compensation. All rights reserved, especially the right to execute registrations concerning
patents, designs for use and patterns.
2 © Festo Didactic GmbH & CoKG. • MPS 500

Contents
1. Introduction ______________________________________________________ 7
1.1. General information MPS500 ____________________________________ 7
1.2. Transport system station _______________________________________ 8
1.3. Short cuts ___________________________________________________ 8
2. General safety instructions __________________________________________ 9
2.1. Use according to regulations ____________________________________ 9
2.2. Handling the system ___________________________________________ 9
2.2.1. Dangers in handling the machine _____________________________ 9
2.2.2. Safety precautions in standard operation ______________________ 9
2.2.3. Dangers due to electric current _____________________________ 10
2.2.4. Dangers due to pneumatic energy ___________________________ 10
2.2.5. Maintenance – Servicing – Malfunction removal ________________ 11
2.2.6. Organisational measures __________________________________ 11
2.3. Personnel ___________________________________________________ 11
2.3.1. Notes on personnel _______________________________________ 11
2.3.2. Training operations _______________________________________ 11
2.3.3. Outside training operations ________________________________ 11
2.3.4. Safety symbols __________________________________________ 12
3. Start-up ________________________________________________________ 13
3.1. Transport ___________________________________________________ 13
3.2. Set-up _____________________________________________________ 14
© Festo Didactic GmbH & CoKG. • MPS 500 3

Contents
3.2.1. General information ______________________________________ 14
3.3. Commissioning ______________________________________________ 17
3.3.1. Pneumatic commissioning _________________________________ 17
3.3.2. Electric commissioning ____________________________________ 17
3.3.3. Establishing communication connections with I/O-coupling ______ 18
3.3.4. EMERGENCY-STOP system _________________________________ 29
3.4. Start-up process _____________________________________________ 31
4. Operation _______________________________________________________ 33
4.1. General notes on operation ____________________________________ 33
4.1.1. Handling regulations ______________________________________ 33
4.1.2. Operating regulations _____________________________________ 33
4.2. Transport system station ______________________________________ 34
4.3. Adjustment _________________________________________________ 36
4.3.1. Requirements ___________________________________________ 36
4.3.2. Adjustment process of MPS-stations _________________________ 36
4.3.3. Adjustment process commissioning and AS/RS station __________ 36
4.3.4. Adjustment process of CNC-machine _________________________ 37
4.4. Automatic __________________________________________________ 37
4.4.1. Conditions and automatic start-up ___________________________ 37
4.5. Error and error acknowledgement _______________________________ 37
4.5.1. Error indication of the MPS-stations _________________________ 38
4.6. Process description ___________________________________________ 39

Contents
4.7. Material flow ________________________________________________ 40
4.7.1. Condition 1 – material flow from product input to product output _ 41
4.7.2. Condition 2 – material flow from product input to stock _________ 42
4.7.3. Condition 3 – material flow from stock to product output ________ 43
4.7.4. Condition 4 – material flow mixed operation __________________ 44
5. WinCC __________________________________________________________ 45
5.1. System information for MPS 500 Level 2 __________________________ 45
5.1.1. Start-up MPS 500 Level 2 __________________________________ 45
5.1.2. Profibus network settings __________________________________ 46
5.2. Commissioning MPS 500 Level 2 ________________________________ 47
5.2.1. Step 1 – PLC Download ____________________________________ 47
5.2.2. Step 2 – Setup WinCC _____________________________________ 47
5.2.3. Step 3 – Search for computer name __________________________ 54
5.2.4. Step 4 – Check Connection Parameter ________________________ 57
5.2.5. Step 4 – Activate WinCC ___________________________________ 59
5.3. Use MPS 500 Level2 Runtime Application _________________________ 60
6. Technology _____________________________________________________ 75
6.1. Operating position 1 __________________________________________ 77
© Festo Didactic GmbH & CoKG. • MPS500 5

Contents
7. Pneumatics _____________________________________________________ 79
7.1. The valve ___________________________________________________ 79
7.2. The valve interface ___________________________________________ 80
7.2.1. Configuration the additional power supply (load voltage) ________ 81
7.3. Pneumatic connection _________________________________________ 82
8. Electrical system _________________________________________________ 83
8.1. Supply voltage _______________________________________________ 83
8.2. Control cabinet ______________________________________________ 84
8.3. EMERGENCY-STOP system _____________________________________ 85
8.3.1. External EMERGENCY-STOP device __________________________ 85
8.3.2. EMERGENCY-STOP at the PLC-board _________________________ 85
8.3.3. Remote Control Connector _________________________________ 87
8.3.4. Interface Drive unit Inputs _________________________________ 89
8.3.5. Interface Drive unit Outputs ________________________________ 91
9. Control system___________________________________________________ 93
9.1. Control set-up _______________________________________________ 93
9.2. Wiring ______________________________________________________ 94
9.2.1. I/O-components _________________________________________ 94
9.2.2. ASi-participant ___________________________________________ 97
9.3. Programming _______________________________________________ 104
10. Fault finding __________________________________________________ 105

1. Introduction
1.1. General information This manual describes the handling of a MPS500 system with Emco Mill 105. It
MPS500 contains explanations and descriptions of all the processes required for operation.
Description of facts ensues partly by means of graphics or images, which are to
serve an easier understanding.
The MPS500 system is a successively expandable system consisting of individual

stations. However, the central unit is always the transport system. For this reason,
this manual is not only a general manual, but also a station manual for the transport
system. Each one of the other stations possesses its own manual.
Operation is not dependant on the operating position the material flow is being
started from. Still, the sequential order of the stations require adherence, as it is
pre-defined in the PLC-program.
The MPS500 system is designed in such a way, that the amount and kind of MPS-
stations attached is of no importance. A complete processing cycle of the work-piece
is always warranted. For this, the transport system is required under any
circumstances.
In complete set-up, the work-piece is isolated from the distribution station to be

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

Introduction
Testing of the work-pieces for their condition, according to type, is required in the
stations, as the work-piece carriers are distinguishable by their drillings on the
underside, but they do not carry any work-piece information. Only this warrants
correct processing.
1.2. Transport system The transport system station is responsible for the transport of the work-pieces
station within the system, which consists of various stations. A transport system comes into
action for faultless long distance transferral of a work-piece between stations.
The transport system requires several components for the work-pieces to be

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

2. General safety instructions
2.1. Use according to This installation has been developed and produced exclusively for training purposes
regulations in the fields of automation and communication. The training company, as well as the
instructors are to ensure, that the trainees pay strict attention to the safety
precautions, as described in the accompanying manuals.
Festo Didactic accepts no liability charges for possible damages to any trainee of the
training company and/or further third parties, which might occur during
use/operation of the installation, if it is not part of a true training situation; except
Festo Didactic caused such damages deliberately or by negligence.
Due to the product liability law and various EC-directives, the following directions
are required from and are to be strictly observed by the operator.
2.2. Handling the system 2.2.1. Dangers in handling the machine
The installation has been constructed technologically up to date and in conformance

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

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

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

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

specified intervals.
Secure the compressed air and electricity supplies to prevent unintentional start-up.
During all of the inspections, maintenance and repair work, the machine must be de-
energised and de-pressurised and secured against accidental restart.
All screw connections released during maintenance, inspection or repair work must
be checked to ensure correct re-tightening.
2.2.6. Organisational measures
All existing safety devices must be checked at regular intervals.
2.3. Personnel 2.3.1. Notes on personnel
Basically two situations have to be considered, concerning matters on personnel.
• Activities during training operations

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

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

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

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

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

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

3. Start-up
3.1. Transport For the delivery of the stations, care is to be taken that the transport of the stations
is to be executed by a suitable transport vehicle only. The weight amounts up to 500
kg, depending on the station.
The route of transport is to be cleared in advance, to be accessible to the transport

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

Start-up
3.2. Set-up 3.2.1. General information
The installation is to be set up in a frost-free room with maximum relative air

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

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

interference such as welding plants, large motors and contactors are to be checked
for electromagnetic compatibility in advance and screened where necessary.
To ensure faultless operation a load-bearing floor is required to avoid settling.
Allow sufficient distance between the installation and the wall of the room.
Any dust originating from construction work has to be kept off the installation (by
covering).
The transport system station is the central element in this system. All of the other
stations are in connection with this station. For this reason, it is necessary to
examine the condition of the premises in detail before set-up.
Once the set-up position has been decided upon, the system can be installed in this
position. At first, the room has to be measured, if not done so previously. The
measures of all of the stations have to be marked roughly onto the floor space (i.e.
with adhesive tape), to avoid shifting at a later stage.
Now, the conveyor belt can be adjusted to an even level, by means of a spirit-level.
The belt should be adjusted to the height of 896 mm, the height of the transport belt
itself.
The transport system is to be screwed firmly to the ground by means of mounting

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

Start-up
The following shows a complete set-up situation adapted to a more basic area
design. The stations are to be adjusted as shown, to warrant faultless work-piece
transfer.
Set-up situation MPS500 example

Start-up
Dimensional drawing of set-up MPS500 example

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

connection before start-up. This process is described in the following chapters. All
the other station’s descriptions can be found in the relative station manual.
3.3.1. Pneumatic commissioning
The mechanic set-up requires to be completed. In the beginning, the station is to be

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

The control cabinet for controlling the station is supplied with 230V/400V voltage.
The cable contained in the delivery possesses a standard plug with protective
covering, which is to be plugged into a sufficiently secured plug. Distribution boards
are included in the delivery, for the connection of the other stations as well. In case
an extension is required for the cable of the distribution board, it is to be executed
by a trained expert only. For the operators, the socket is to be secured.
For avoidance of problems during the operational process, individual protection

(16A) of the installation is recommended.
Attention has to be paid to the correct polarity of the power supply plug, as only one
phase of the main switch is to be de-activated in the transport system station.

Start-up
3.3.3. Establishing communication connections with I/O-coupling
The internal communication lines of the transport system station are hard-wired and
do not require connection or plugging in.
The communication connections to the other stations are to be set up according to

the following examples. The examples are kept on general terms, and as such are
valid for all of the stations. Deviations from standard are especially referred to.
Example I/O-connectors example
For the system to “know” that stations are present and processing can occur in the
stations, they are to be connected to the system by means of I/O-connectors. Each
time, the connectors are established by means of the control panel – not in case of
the robot and the vision station, as these are directly connected to the respective
control devices (see the following drawings).

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

2. Connection by I/O – one side cable 4 mm plug / one side SYS-link plug
between transport system and MPS–stations
3. Connection by I/O – one side 37 pin Sub D-plug / one side SYS–link plug
between transport system and vision station
4. Connection by I/O – one side Phönix-plug / one side SYS–link plug
between AS/RS station and transport system
5. Connection by I/O – one side SYS–link plug / one side SYS–link plug
between robot station (RIA-BOX) and transport system
6. Connection by I/O – one side hard wired / one side SYS–link plug
between robot station (RIA-BOX) and milling machine
The connections are shown as graphics on the following pages.

Start-up
Robot with
assembly
Transfersystem - Station 4
OUT0 IN4
OUT1 IN5 Bit1 Bit0 Order
OUT2 Order Bit0

IN6 0 0 x
Order Bit1
0 1 Assemble
OUT3 IN7 1 0 Sorting out
IN0 ERR CODE #0
OUT4 1 1 At bus:
ERR CODE #1
Take part on
IN1 OUT5 palette
Order aktiv (busy)
IN2 OUT6
Station ready
IN3 OUT7
AS/RS
HRL20
Pending order
OUT0 IN4 Pending

OUT1 IN5 order Bit1 Bit0 Order
Order Bit0 0 X
OUT2 IN6 X No processing
Order Bit1 1 0 0 Reserved
OUT3 IN7 1 0 1 Storing
AS/RS filled up
IN0 OUT4 1 1 0 Evacuating, oldest part
AS/RS free
IN1 OUT5
Order aktiv (busy)
IN2 OUT6
Station ready
IN3 OUT7
Sorting/
Pick-Alfa Kommissioning
Part available (PartAV)
OUT0 IN4 OUT6 IN4

OUT1 IN5 OUT7 IN5
OUT2 IN6
OUT3 IN7
Next station ready
IN0 OUT4 IN6 OUT4
Station ready
IN1 OUT5 IN7 OUT5
IN2 OUT6
Stations ready
IN3 OUT7

Start-up
Distribution Station Testing Station Transportsystem
PART AV PART AV PART ON

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

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

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

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

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

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

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

Start-up
Connection Vision station –Transport system

Start-up
Station HRL20 Transportsystem
PART ON
Pending PALLET
order Bit1 Bit0 Order
0 X X No processing
TRANSPORT
1 0 0 Reserved
AS-i
Control panel new 1 0 1 Storage
1 1 0 Retrieval, oldest part
IN ........
1 1 1 Retrieval, jungest part
SYSLINK (AS-i)
0V 0V
OUT 6 Pending order
IN 4 OUT 0 AS-I Addr:
OUT 7 OUT 1 AS-I Addr:
Order Bit0
OUT 2 AS-I Addr:
OUT 4 IN 6 Order Bit1 OUT 3 AS-I Addr:
OUT 5 IN 7
Stock is full
AS-I Addr:
Stock is empty IN 1 AS-I Addr:
Order aktiv (busy) IN 2 AS-I Addr:
Station ready IN 3 AS-I Addr:
IN 0
IN 1
Cabel
IN 2 SYSLINK - plug
IN 3
OUT 0 SYSLINK
OUT 1
OUT 2
OUT 3
0V
Connection AS/RS station - Transport system

Start-up
Connection Robot station - Transport system

Start-up
Connection Robot station – PC Mill 105

Start-up
Profibus adresses and wiring

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

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

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

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

Start-up
3.4. Start-up process For the MPS500-installation the first start-up has been executed in the factory
already.
For the installation to be ready for operation execute the following directions:
1. Mains supply 230 V/400V AC for power supply unit, connect control cabinet of
transport system, milling machine and commissioning station.
2. Power supply unit 24V DC with connections +24V/0V/earth are connected
correctly to the stations and activated (except for robot: only after adjustment of
the transport system).
3. Each station is supplied with ca. 6 bar compressed air.
4. I/O-communication connectors (laboratory plugs) are connected according to
communication plan.
5. All of the PLC-programs are loaded into the respective controls. The controls are
switched to RUN and the red error indicators of the controls are not on.
6. All of the EMERGENCY-STOP signal generators (push-buttons, door contact, light
barriers, a.s.o.) are not to be switched on, i.e. activated.
7. Activate the main switch of the transport system station.
8. Acknowledge the EMERGENCY-STOP of the control cabinet of the transport
system.
9. Remove all of the work-pieces from the installation, i.e. stations:
- Remove work-pieces from the palettes on the transport system
- Clear the storage shelves of the AS/RS station (HRL20)
- Clear the slides of the sorting/commissioning station
10. The magazines of all of the stations are to be stocked up:
- Magazines (piston, spring and cover) of the robot station with assembly
- Fill magazine of the distribution station with basic bodies
11. Now adjust the stations and the transport system (see chapter – Operation).

Start-up

4. Operation
The chapter Operation describes the control units required for the operation, as well
as start-up and close-down of the system.
4.1. General notes on The stations demand strict adherence to certain rules of operation. Negligence in
operation observing these rules may cause errors in the stations’ processes. Also, damage to
bodily health may not be excluded.
Strict observance of the following rules is demanded.
4.1.1. Handling regulations
• Manual interference during the stations’ operation is prohibited.

• In case of larger audiences, a mechanical barrier of the station is required.
• It is prohibited to pull off any cables while under voltage supply.
• Any kind of liquid is to be kept from the installation, at all times.
4.1.2. Operating regulations
• The stations are to be operated from trained personnel only.

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

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

below.
4.2. Transport system The control elements of the control cabinet of the transport system station are
station required for the start-up of the transport system and, as such, the complete system.
Main switch Transport system station
The main switch is located on the side of the control cabinet of the transport system
station, supplying the control cabinet of the transport system station with voltage.
The conveyor belts and the system can only be started, once the control cabinet
receives voltage supply.

Operation
Control elements Transport system station
Name Element Function
Error H8 Flashes Indicator Acknowledge error
Flashes Indicator Start-up request

H5
Automatic on Light on Indicator Installation in operation
S5 Start up installation
H6 Light on Indicator Controller off

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

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

Operation
4.3. Adjustment 4.3.1. Requirements
The MPS-stations of distribution, testing, processing, PIC-alfa and sorting can be

started with the adjustment process, as following.
At first, adjustment of the distribution station is absolutely required, if the swivel

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

activation) is independent from the switch position of the key actuator AUTO/MANU.
4.3.2. Adjustment process of MPS-stations
1. RESET- Lamp is lit up → Request for adjustment.

2. RESET- Activate push-button.
3. Station moves to basic position.
4. The START-lamp indicates arrival in basic position.
5. AUTO/MAN - turn key actuator to 'AUTO' position (continuous cycle).
6. Activate START push-button → Station is in operation (no indication)
4.3.3. Adjustment process commissioning and AS/RS station
Due to station-specific reasons, the commissioning and AS/RS stations require a

different adjustment process from that of the MPS-stations:
1. The EMERGENCY-STOP system is activated (no signal generator is active;

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

Operation
4.3.4. Adjustment process of CNC-machine
1. Switch on main switch CNC milling machine (Key switch)

2. Switch on PC / Mill
3. Application WIN NC 32 is started automatically
4. Switch key switch at CNC- milling machine to FMS- mode
5. The reset mode is started at the operation panel at the robot station.
6. It is not possible to choose/change program from CNC machine from the robot
station/controller
4.4. Automatic 4.4.1. Conditions and automatic start-up
1. MPS-stations are ready for automatic mode after the adjustment process.
2. Unlock EMERGENCY-STOP of the transport system station and acknowledge.
3. 'AUTOMATIC ON' - Lamp flashes fast → Request for start-up of the transport
system.
4. 'AUTOMATIC ON' - Activate push-button → Transfer system starts up.
5. Operational condition is indicated by the 'AUTOMATIC ON'-lamp.
6. Only at this point activate the robot controller. The procedure of commissioning
of the robot assembly is described separately.
4.5. Error and In case an error occurs in the transfer system, it is shown by a slowly flashing
error 'AUTOMATIC ON'-lamp. As soon as the error has been eliminated, it can be
acknowledgement acknowledged with the 'AUTOMATIC ON'-push-button.
Possible errors: e.g. a palette with work-piece arrives at the stopping station for
distribution/testing.
All further errors are described in the chapter “Fault finding”.

Operation
4.5.1. Error indication of the MPS-stations
Station Indicator light H1 Indicator light H2
Distribution Magazine empty
Testing Work-piece red / silver Work-piece black / silver
PIC-alfa Wait until processing of

(Processing) work-piece is concluded
Processing Processing in operation
Sorting Slide(s) full

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

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

Operation
4.7. Material flow The MPS500 installation reacts flexible to the changes during the production
process and controls the material flow according to circumstances. For this, various
starting conditions are described.
Warenausgabe
Product output Lager
Stock Montage
Assembly
Small parts stock
Pre-sorting
Wareneingang
Product input Processing
Bearbeitung Quality assurance
Qualitätssicherung
Layout of material flow of the MPS500 System
The following icons are used for the representation of the material flow.
Legend

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

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

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

Operation
4.7.3. Condition 3 – material flow from stock to product output
The installation is in operation. The magazine of the distribution station is empty,

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

Operation
4.7.4. Condition 4 – material flow mixed operation
The installation is in operation. The distribution station can isolate work-pieces

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

5. WinCC
5.1. System information The MPS 500 system is extended with a communication layer for using a SCADA
for MPS 500 Level 2 system (Supervision, Control And Data Acquisition) like WinCC, for MPS 500 it is
called "Level 2". For data exchange between SCADA system WinCC and the PLCs the
Profibus-DP field bus is used. All PLC stations are configured as Master, therefore
there is no data exchange programmed between PLC stations. WinCC is sending and
receiving data from/to the PLCs. PLC inputs, outputs or memory bits are used for
visualization. Reading and writing information (change value) is only possible with
memory bits or data block contents (bit, byte, word, …).
5.1.1. Start-up MPS 500 Level 2
Before activating WinCC you have to make sure all MPS 500 programs for Level 2
have been downloaded to each PLC and all system cable connections are made:
• DC24V power supply

• 6bar system pressure
• I/O communication cables according to MPS 500 handbook
Profibus cables connecting each PLC and computer
System requirements for MPS 500 project:
• Windows 2000 with SP2, English or German Version with Internet Explorer V5.5
• Step7 V5.1 SP3
• Profibus-card installed to the computer, e.g. Siemens CP5611, CP5613 or CP5511
• WinCC V5.1 with WinCC-Application "MPS 500_WinCC_Application_V3" or higher
Notice: Please make sure that all software and hardware has been installed in this order !

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

WinCC
5.2. Commissioning MPS 5.2.1. Step 1 – PLC Download

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

WinCC
Open the WinCC application for MPS 500 Level 2
→ File → Open →

WinCC
for example:
C:\siemens\wincc\WinCCProjects\MPS 500_WinCC_Application_V3\MPS
500_WinCC_Application_V3.MCP
If you start WinCC the next time, always the previous project will open automatically.
→ Open

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

WinCC
Change the computer name:

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

WinCC
→ OK
→ OK

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

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

WinCC
Open network identification
→ Advanced → Network Identification…

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

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

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

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

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

WinCC
5.3. Use MPS 500 Level2 A process visualization is developed as a hierarchical structure of windows with
Runtime Application different priority. The hierarchy of the MPS 500 Level 2 visualization is shown below.
01_Start.pdl
02_System_overview_Anlagen_Uebersicht.PDL
10_Distributing_Verteilen.PDL
03_Commissioning_Inbetriebnahme.PDL
12_Handling_Proc_Bearb.pdl
04_Profibus_Network_Netzwerk.pdl
13_Processing_Bearbeiten.pdl
05_Message_Alarm.pdl
15_RobotAssembly_RoboterMontage.pdl
16_ASRS20_Hochregallager20.pdl
17_Handling_Sorting_Sortieren.pdl
18_Sorting_Sortieren.pdl
Only below the second hierarchical level it is possible to control the MPS 500
process.

WinCC
Window: 01_Start.pdl
3 1
2
Buttons and functions:
1 Start Enter MPS 500 application

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

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

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

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

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

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

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

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

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

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

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

WinCC
2 Driver Switch Each work station can be activated/deactivated

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

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

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

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

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

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

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

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

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

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

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

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

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

WinCC

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

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

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

WinCC

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

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

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

Technology
The transport system station contains 6 operating positions. Any of the MPS-
stations can be placed in any of the 6 operating positions. The following description
relates to the standard system.
6.1. Operating position 1 The distribution and test MPS-stations are situated in operating position 1. The
work-pieces are isolated in the distribution station and transferred to the test
station. The distribution station is not connected directly to the transport system. It
is located beside the test station. The test station is connected to the transport
system, and additionally to work-piece testing it executes the work-piece transfer to
the transport system.
The material flow is started from this operating position.
6.2. Operating position 2 The PIC-alfa station is located in operating position 2. It takes care of the material
transport to the processing station, which is situated directly beside the PIC-alfa
station executes the drilling of a hole and testing afterwards.
6.3. Operating position 3 A vision system is mounted to operating position 3. The camera is mounted directly
onto the transport system and is located above the operating position, which
renders turning the work-piece superfluous. The evaluation system of the camera is
situated on a MPS-carriage or operating table.
6.4. Operating position 4 The robot assembly station is located at operating position 4, consisting of 2 MPS-
carriers, whereby the robot RV-2AJ is mounted onto the carrier, which itself is
directly situated beside the transport system. The robot executes the handling of the
work-pieces and assembly components. At this point, a model cylinder is assembled
by the robot.
6.5. Operating position 5 At operating position 5, the AS/RS station is available for material storage, where
the work-pieces can be stored and retrieved.
6.6. Operating position 6 The Sorting or commissioning station is situated in operating position 6. By means
of a PIC-alfa station, which is directly connected to the transport system, it receives
its work-pieces to sort them according to cylinder colouring.
At this operating position the material flow is concluded.

Technology

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

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

Pneumatics
LED display
ASI-LED (green) Fault-LED (red) Description
On Off Asi-Interface voltage applied, no fault
Off Off No Asi-Interface voltage on bus
Flashing On Asi-Interface address not set (equals zero)
On Flashing Short circuit / overload at inputs
Off Flashing Short circuit / overload at outputs
flashing On Failure of bus communication (Watchdog expired)
AUX PWR-LED (green) Description
On Load voltage applied
Off Load voltage applied
Status-LED (green/yellow) Description
on 1- Signal at In/Output
off 0- Signal at In/Output
7.2.1. Configuration the additional power supply (load voltage)
Setting DIP switch setting *
With load voltage ** 1,2: off
(factory setting) 3,4: on
With load voltage ***

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

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

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

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

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

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

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

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

Phönix plug -in Phönix plug-in
2pin 2pin
1 2 1 2
-XNA11 -XNA12
1 2 1 2
-XN11 -XN12
XNA13 ==> XNA18
Other external emergency-stop devices
CPU 314
CP 342-2 SM323
SIEMENS SF
BAF
Asi Master DI8/DO8 xDC24V
DC 5V SF
FRCE RUN 0
RUN APF 1
STOP CER 2
AUP 3
CM 4
-XNA1
5
-XN1
RUN-P
Phönix plug-in
30+ 6
RUN
20+ 7
10+
STOP
MRES SET
4 pin
Simatic 0 0
S7-300
1
1
1 1
2 2
5
9
3 3
4
2
2 4 4
3
5 5
2
6 6
1
3
3
7 7
X 2 X 2
X1MPI
4
4
3 4 3 4
Operatingposition 1
Emergency-stop switch device
S11 S12 S12 S21 S22 S33 S34 Y1 Y2 S52 S11 13 23 33

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

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

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

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

other stations
Line for feedback

Electrical system
8.3.3. Remote Control Connector
The FMS interface to the robot is a standardized interface. It consists of a key switch,
an emergency plug and a sys link plug. The components are mounted at the
CNC- machine.
Key switch With the key switch it is possible to change from FMS Mode to Stand Alone Mode. If
the CNC- machine is operated without a robot and the emergency system is not
active, it is necessary to switch the key switch to Stand Alone Mode.
• Key switch position 1 = FMS Mode / Emergency Stop system is active

• Key switch position 0 = Stand Alone Mode / Emergency stop system is inactive
Emergency stop plug The plug connector is a round 7pin plug. 6 of the cables are use for data transfer,
cable 7 is for a protective earth conductor. Drawn in chapter emergency stop.
Pin number Name Cable colour
1 XNA 1 White PNOZ XN1 / 1
2 XNA 2 Brown PNOZ XN1 / 2
3 XNA 3 Green PNOZ XN1 / 3
4 XNA 4 Yellow PNOZ XN1 / 4
5 XNA 5 Grey Not-Aus Board XN11 / 1
6 XNA 6 Pink Not-Aus Board XN11 / 2
7 XNA 7

Electrical system
Allocation Sys link plug Name Output / Clamp Cable colour Input Ria box
Input
Run program CNC:E0 XM1:1 White X3:1
Automatic
CNC:E1 XM1:2 Brown X3:2
mode
Reference axis CNC:E2 XM1:3 Green X3:3
AUX on CNC:E3 XM1:4 Yellow X3:4
Open door CNC:E4 XM1:5 Grey X3:5
Close door CNC:E5 XM1:6 Pink X3:6
Open clamping
CNC:E6 XM1:7 Blue X3:7
device
Close clamping
CNC:E7 XM1:8 Red X3:8
device
Door opened CNC:A0 XM1:13 Grey-pink X3:13
Door closed CNC:A1 XM1:14 Red-blue X3:14
Clamping
device CNC:A2 XM1:15 White-green X3:15
declamped
Clamping
device CNC:A3 XM1:16 Brown-green X3:16
clamped
Reference
CNC:A4 XM1:17 White-yellow X3:17
mode
CNC in
CNC:A5 XM1:18 yellow-brown X3:18
reference
CNC ready CNC:A6 XM1:19 White-grey X3:19
Not used CNC:A7 XM1:20 Grey-brown X3:20

Electrical system
8.3.4. Interface Drive unit Inputs
Name Output / Input Output Input Robot PIN Robot

Input Ria Ria Name
box box
Robot Workpiece not SB1 INPUT 1

X2:14 X0:16 16 IN 1
Station black XMB2:I1 CN100:16
assembly Orientation not SB2 INPUT 2

X2:15 X0:17 17 IN 2
okay XMB2:I2 CN100:17
Operation S1 INPUT 3
START button X3:13 X0:18 18 IN 3
panel XMG1:13 CN100:18
S2 INPUT 4
STOP button X3:14 X0:19 19 IN 4
XMG1:14 CN100:19
S4 INPUT 5
RESET button X3:16 X0:20 20 IN 5
XMG1:16 CN100:20
Robot Spring cylinder 1B1 INPUT 4

X1:13 X0:40 40 IN 8
Station retracted XMA2:I0 CN100:40
Magazine Spring cylinder 1B2 INPUT 5

X1:14 X0:41 41 IN 9
advanced XMA2:I1 CN100:41
Cover cylinder 2B1 INPUT 6

X1:15 X0:42 42 IN 10
retracted XMA2:I2 CN100:42
Cover cylinder 2B2 INPUT 7

X1:16 X0:43 43 IN 11
advanced XMA2:I3 CN100:43
Spring in pick 1S1 INPUT 6

X1:17 X0:44 44 IN 12
up position XMA2:I4 CN100:44
No cover in B1 INPUT 7
X1:18 X0:45 45 IN 13
pick up pos. XMA2:I5 CN100:45
Empty cover B2 INPUT 7

X1:19 X0:46 46 IN 14
magazine XMA2:I6 CN100:46
Downstream IP_FL INPUT 8

X1:20 X0:47 47 IN 15
station free XMA2:I7 CN100:47

Electrical system

Input Ria Ria Name
box box
CNC INPUT 32
Door opened A5.7 X1:13 X0:15 15 IN 32
milling CN100:15
machine
INPUT 33
Door closed A5.6 X1:14 X0:16 16 IN 33
CN100:16
Clamping
INPUT 34
device A5.1 X1:15 X0:17 17 IN 34
CN100:17
declamped
Clamping
INPUT 35
device A5.0 X1:16 X0:18 18 IN 35
CN100:18
clamped
Reference- INPUT 36
A4.5 X1:17 X0:19 19 IN 36
mode CN100:19
INPUT 37
Program stop A4.6 X1:18 X0:20 20 IN 37
CN100:20
INPUT 38
CNC ready A4.4 X1:19 X0:21 21 IN 38
CN100:21
Reference- INPUT 39
A4.7 X1:20 X0:22 22 IN 39
position CN100:22

Electrical system
8.3.5. Interface Drive unit Outputs

Input Ria Ria Name
box box
Operation H1 OUTPUT 0
Start lamp X3:1 X0:4 4 OUT 0
panel XMG1:1 CN100:4
Initial position H2 OUTPUT 1

X3:2 X0:5 5 OUT 1
lamp XMG1:2 CN100:5
Special
H3 OUTPUT 2
function X3:3 X0:6 6 OUT 2
XMG1:3 CN100:6
Lamp Q1
Special
H4 OUTPUT 3
function X3:4 X0:7 7 OUT 3
XMG1:4 CN100:7
Lamp Q2
Robot Retract spring 1Y1 OUTPUT 8

X1:1 X0:10 10 OUT 8
station cylinder XMA2:O0 CN100:10
Magazine Retract cover 2Y1 OUTPUT 9

X1:2 X0:11 11 OUT 9
cylinder XMA2:O1 CN100:11
CNC OUTPUT 32
Start program E7.3 X1:1 X0:4 4 OUT 32
milling CN100:4
machine
Automatic OUTPUT 33
E7.1 X1:2 X0:5 5 OUT 33
mode CN100:5
OUTPUT 34
referencing E7.2 X1:3 X0:6 6 OUT 34
CN100:6
Auxiliary drives OUTPUT 35

E7.0 X1:4 X0:7 7 OUT 35
on CN100:7
OUTPUT 36
Open door E8.3 X1:5 X0:29 29 OUT 36
CN100:29
OUTPUT 37
Close door DOOR_M X1:6 X0:30 30 OUT 37
CN100:30
Open clamping OUTPUT 38

E7.7 X1:7 X0:31 31 OUT 38
device CN100:31
Close clamping OUTPUT 39

E7.6 X1:8 X0:32 32 OUT 39
device CN100:32

Electrical system

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

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

• L2 = communication via I/O and Profibus DP for operation and observation
• L3 = communication via I/O and Ethernet for operation and observation
For this, the control for the transport system, of the Siemens S7-300 group, consists
of several modules.
9.1. Control set-up Plug-in Address Module Designation Comments

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

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

card
Control transport system example

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

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

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

Control system
OUT BIT 0 1 13 IN BIT 0

POWER 24 VDC 9 21 POWER 24 VDC
syslink pin assignment

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

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

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

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

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

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

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

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

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

05 Inputs

MF-2E1A-Z
In/outputs

07 In/Outputs

Control system

08 Inputs

MF-2E1A-Z
In/outputs

10 In/Outputs

Control system

11 Inputs

MF-2E1A-Z
In/outputs

13 In/Outputs

Control system

14 Inputs

MF-2E1A-Z
In/outputs

16 In/Outputs

Control system

17 Inputs

MF-2E1A-Z
In/outputs

19 In/Outputs

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

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

MPI-card.

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

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

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

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

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

MPS500 Siemens Manual Level2 Mill105 RV2AJ A001

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MPS 500

• Part A contains the manual of the system or station.

Name: Manual MPS500

Author: Schober / Espenberger

Graphics: Schober / Espenberger

© Festo Didactic GmbH & CoKG., D-73770 Denkendorf, 2008

2 © Festo Didactic GmbH & CoKG. • MPS 500

1. Introduction ______________________________________________________ 7

1.1. General information MPS500 ____________________________________ 7

1.2. Transport system station _______________________________________ 8

1.3. Short cuts ___________________________________________________ 8

2. General safety instructions __________________________________________ 9

2.1. Use according to regulations ____________________________________ 9

2.2. Handling the system ___________________________________________ 9

2.2.1. Dangers in handling the machine _____________________________ 9

2.2.2. Safety precautions in standard operation ______________________ 9

2.2.3. Dangers due to electric current _____________________________ 10

2.2.4. Dangers due to pneumatic energy ___________________________ 10

2.2.5. Maintenance – Servicing – Malfunction removal ________________ 11

2.2.6. Organisational measures __________________________________ 11

2.3. Personnel ___________________________________________________ 11

2.3.1. Notes on personnel _______________________________________ 11

2.3.2. Training operations _______________________________________ 11

2.3.3. Outside training operations ________________________________ 11

2.3.4. Safety symbols __________________________________________ 12

3. Start-up ________________________________________________________ 13

3.1. Transport ___________________________________________________ 13

3.2. Set-up _____________________________________________________ 14

© Festo Didactic GmbH & CoKG. • MPS 500 3

3.2.1. General information ______________________________________ 14

3.3. Commissioning ______________________________________________ 17

3.3.1. Pneumatic commissioning _________________________________ 17

3.3.2. Electric commissioning ____________________________________ 17

3.3.3. Establishing communication connections with I/O-coupling ______ 18

3.3.4. EMERGENCY-STOP system _________________________________ 29

3.4. Start-up process _____________________________________________ 31

4. Operation _______________________________________________________ 33

4.1. General notes on operation ____________________________________ 33

4.1.1. Handling regulations ______________________________________ 33

4.1.2. Operating regulations _____________________________________ 33

4.2. Transport system station ______________________________________ 34

4.3. Adjustment _________________________________________________ 36

4.3.1. Requirements ___________________________________________ 36

4.3.2. Adjustment process of MPS-stations _________________________ 36

4.3.3. Adjustment process commissioning and AS/RS station __________ 36

4.3.4. Adjustment process of CNC-machine _________________________ 37

4.4. Automatic __________________________________________________ 37

4.4.1. Conditions and automatic start-up ___________________________ 37

4.5. Error and error acknowledgement _______________________________ 37

4.5.1. Error indication of the MPS-stations _________________________ 38

4.6. Process description ___________________________________________ 39

4 © Festo Didactic GmbH & CoKG. • MPS 500

4.7. Material flow ________________________________________________ 40

4.7.4. Condition 4 – material flow mixed operation __________________ 44

5. WinCC __________________________________________________________ 45

5.1. System information for MPS 500 Level 2 __________________________ 45

5.1.1. Start-up MPS 500 Level 2 __________________________________ 45

5.1.2. Profibus network settings __________________________________ 46

5.2. Commissioning MPS 500 Level 2 ________________________________ 47

5.2.1. Step 1 – PLC Download ____________________________________ 47

5.2.2. Step 2 – Setup WinCC _____________________________________ 47

5.2.3. Step 3 – Search for computer name __________________________ 54

5.2.4. Step 4 – Check Connection Parameter ________________________ 57

5.2.5. Step 4 – Activate WinCC ___________________________________ 59