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Trouble Shooting

170

The work-sheet for this example looks like:

Order of Maintenance

Name:

Hellmich

Order-No:

001 310800

Date:

31.08.2001

Location of Error:

Distribution Station

Sheet:

1 # 1

Error Detection

After switch-on theair pressure and the PLC, the RESET-light is flashing, which means, that the system is in normal position

starting condition OK

However, the station cannot be started by the Start-Button (RESET-light not change to off).

Error Limitation

MECHANICAL:

Is there a mechanical defect on the Start-button?

ELECTRICAL

1. Is the Start-button switching regularly? - Continuity test of switching contacts.

2. Is the signal of the button reaching the PLC? - Control by sight and voltage test.

Error Elimination

REASON

Break of wire (end sleeve) at the button at connection X.

Attach new end sleeve to the wire and connect again. Control of total sequence = error eliminated.

Planning

Please follow the description of the in instructor carefully step-by-step. Make a
detailled plan of how you want to check the error location step-by-step.

Содержание MPS 2000

Страница 1: ... Festo Didactic GmbH Co MPS 1 Handling Station MPS 2000 Instructors Edition ...

Страница 2: ...Festo Didactic GmbH Co Layout Festo Didactic GmbH Co Festo Didactic GmbH Co D 73770 Denkendorf 2002 Internet www festo com didactic e mail did festo com All rights reserved including translation rights No part of this publication may be reproduced or transmitted in any form or by any means electronic mechanical photocopying or otherwise without the prior written permission of Festo Didactic ...

Страница 3: ...f the Station expanded 23 1 7 Commissioning Download Project and Test 28 Programming 33 2 1 Programming Hardwareconfiguration 33 2 2 Programming Basics in Digital Technology AND 46 2 3 Programming Basics in Digital Technology OR 61 2 4 Programming Basics in Digital Technology RS Flip Flop 66 2 5 Programming Basics in Digital Technology AND NOT 71 2 6 Programming Basics in Digital Technology IDENTI...

Страница 4: ... 13 Programming Programming of a Auto Manu sequence 99 2 14 Programming Move to Starting Position 101 2 15 Programming Expanded movement to Starting Position 104 2 16 Project Basics of I O communication 109 2 17 Project Test the I O communication 113 2 18 Project Material flow through the FMS 119 Trouble Shooting 135 3 1 Program Trouble Shooting 135 3 2 Process Trouble Shooting 164 ...

Страница 5: ...cs could be called Automation Technology elecTRONic MECHAnic informatIC MECHATRONIC Structure of Mechatronics The structure of Mechatronical training is devided into three levels Basics single technologies Partly integrated systems Totally integrated system single technology Mechanic Electric Pneumatic PLC combination of Mechanic Electric Pneumatic PLC FMS process material and signal flow What is ...

Страница 6: ...l see some examples of the different levels for totally integrated training in the Production Automation field of MECHATRONICS Totally Integrated System a combination of single technologies to a various amount of STATIONS Partly Integrated Systems electronics pneumatics hydraulics PLC sensorics robotics CAD CNC mechanics Basic Technologies ...

Страница 7: ...on Commissioning Programming Programming single Station Communication with other Stations Trouble Shooting Programming Errors Trouble Shooting in the Process which are covered within the following projects Furtheron this Teachware is based on the idea of a Flexible Manufacturing System FMS this means this station should be and is connected to other stations called Previous and Following Station wi...

Страница 8: ...work out the respective project This time is based on experience with participants coming with no knowledge about the MPS Stations and less knowledge about programming a Simatic PLC with STEP 7 Regarding the Process Trouble Shooting there is no big difference in time between the single troubles based on experience we can say that each trouble needs around 1 5 hour including the preparation and tes...

Страница 9: ...6 1h 30min Programming Programming Basics in digital technology AND NOT programming of the basic function AND NOT 2 5 71 30min Programming Programming Basics in digital technology IDENTITY programming of the basic function IDENTITY 2 6 74 30min Programming Programming Condition Call of a Program activate a program in OB1 by a condition of the Control Panel 2 7 76 1h Programming Programming Conditi...

Страница 10: ...ect 2 6 3 1 144 45min Trouble Shooting Program Error in Project 2 7 3 1 146 30min Trouble Shooting Program Error in Project 2 8 3 1 148 45min Trouble Shooting Program Error in Project 2 9 3 1 150 45min Trouble Shooting Program Error in Project 2 10 3 1 152 30min Trouble Shooting Program Error in Project 2 11 3 1 154 45min Trouble Shooting Program Error in Project 2 12 3 1 156 30min Trouble Shootin...

Страница 11: ...nd the data sheet using the order number printed on the element itself Show the participants at the station itself which components they have to identify There are 4 different wiring diagrams for each station the station itself Station the Control Panel Panel the PLC board PLC board and the Emergency Stop if available optional Please use one of the Examples Ex 2 or Ex 3 Planning Please plan your p...

Страница 12: ... 3 Pneumatic gripper 3A1 Double acting parallel gripper actuated by 2 parallel acting cylinders inside with magent ring for end position detection gripper power 27 N open and close HGP 10 A Station outputs Station pneumatic PLC board outputs No Name Ident Description Page 1 Retro reflective sensor 3B1 Retro reflective optical sensor send out an infra red signal and measure the reflection of the li...

Страница 13: ...adress have which module and which module have which function in controlling the process Leave the cables all connected to help the participants Show them also how to use the technical manual to find out the adress of the module Please show the participants which steps and connections are necessary if the stations are coming with the Emergency Stop board and how to connect the Emergency switch but...

Страница 14: ...Commissioning 12 Festo Didactic GmbH Co MPS Execution Documentation ...

Страница 15: ...the air pressure and move them manually by hand Please be very careful move the actuators back before switching on the air pressure again Some pneumatic and the electrical actuators can not be moved in this way the pneumatic components can be activated by the manual detection button on the valve see picture Instructor show the participants how to find out an input and an output using the wiring di...

Страница 16: ... plan your activities within your team Check first which actuator could be moved by hand and which not use the technical documentation pneumatic plan Check the inputs in the wiring diagram and at the PLC The time to finish this project should be around 0 5 hour ...

Страница 17: ... barrier to the following station Q0 0 Handprev 1Y1 Solenoid of handling cyl to previous station Q0 1 Handfoll 1Y2 Solenoid of handling cyl to following station Q0 2 Lifting 2Y1 Solenoid of the lifting cylinder with gripper Q0 3 Gripper 3Y1 Solenoid of the gripper 1 open Q0 7 Previous IP_N_FO Light barrier to the previous station I O Control Panel Adress Symbol Ident Description I1 0 START S1 Star...

Страница 18: ..._Prev Input comm from Q1 6 Previous Station I1 6 CI1_Foll Input comm from Q1 4 Following Station I1 7 CI2_Foll Input comm from Q1 5 Following Station Q1 4 CQ1_Prev Output comm to I1 6 Previous Station Q1 5 CQ2_Prev Output comm to I1 7 Previous Station Q1 6 CQ1_Foll Output comm to I1 4 Following Station ...

Страница 19: ... by hand Please be very careful move the actuators back before switching on the air pressure again Some pneumatic and the electrical actuators can not be moved in this way the pneumatic components can be activated by the manual detection button on the valve see picture Instructor show the participants how to find out an input and an output using the wiring diagrams Show them why some actuators can...

Страница 20: ... plan your activities within your team Check first which actuator could be moved by hand and which not use the technical documentation pneumatic plan Check the inputs in the wiring diagram and at the PLC The time to finish this project should be around 1 5 hour ...

Страница 21: ... barrier to the following station Q0 0 Handprev 1Y1 Solenoid of handling cyl to previous station Q0 1 Handfoll 1Y2 Solenoid of handling cyl to following station Q0 2 Lifting 2Y1 Solenoid of the lifting cylinder with gripper Q0 3 Gripper 3Y1 Solenoid of the gripper 1 open Q0 7 Previous IP_N_FO Light barrier to the previous station I O Control Panel Adress Symbol Ident Description I1 0 START S1 Star...

Страница 22: ..._Prev Input comm from Q1 6 Previous Station I1 6 CI1_Foll Input comm from Q1 4 Following Station I1 7 CI2_Foll Input comm from Q1 5 Following Station Q1 4 CQ1_Prev Output comm to I1 6 Previous Station Q1 5 CQ2_Prev Output comm to I1 7 Previous Station Q1 6 CQ1_Foll Output comm to I1 4 Following Station ...

Страница 23: ... them an example how to adjust a sensor to define the back or front position of a cylinder Provide the necessary tools Deadjust the following sensors and mechanical components bold I O Station Adress Symbol Ident Description I0 0 Part_av Part_AV Workpiece is available I0 1 Han_prev 1B1 Handling at previous station I0 2 Han_foll 1B2 Handling at following station I0 3 Han_sort 1B3 Handling at sortin...

Страница 24: ...ceed I O Station Adress Symbol Ident Description Check I0 0 Part_av Part_AV Workpiece is available I0 1 Han_prev 1B1 Handling at previous station I0 2 Han_foll 1B2 Handling at following station I0 3 Han_sort 1B3 Handling at sorting position I0 4 Lift_dow 2B1 Lifting cylinder with gripper is down I0 5 Lift _up 2B2 Lifting cylinder with gripper is up I0 6 Sen_mat 3B1 Material detection signal 0 blac...

Страница 25: ...he actuators back before switching on the air pressure again Some pneumatic and the electrical actuators can not be moved in this way the pneumatic components can be activated by the manual detection button on the valve see picture Instructor show the participants how to find out an input and an output using the wiring diagrams Show them why some actuators can not be moved by hand even without air...

Страница 26: ...revious IP_N_FO Light barrier to the previous station Adress Symbol Ident Description I1 4 CI1_Prev Input comm from Q1 6 Previous Station I1 6 CI1_Foll Input comm from Q1 4 Following Station I1 7 CI2_Foll Input comm from Q1 5 Following Station Q1 4 CQ1_Prev Output comm to I1 6 Previous Station Q1 5 CQ2_Prev Output comm to I1 7 Previous Station Q1 6 CQ1_Foll Output comm to I1 4 Following Station Q0...

Страница 27: ... of sensor holders 8 check the adjustment of sensors in the holders 9 check the adjustment of sensitivity of sensor 10 tubing connections 11 connect all air pressure supplies careful turn pressure down before 12 check the adjustment of the speed of pneumatic actuators 13 connect the stations together 14 check the mechanical position of hand over to the next station 15 communication connection Plan...

Страница 28: ...n_mat 3B1 Material detection signal 0 black I0 7 Follow IP_FL Light barrier to the following station Q0 0 Handprev 1Y1 Solenoid of handling cyl to prev station Q0 1 Handfoll 1Y2 Solenoid of handling cyl to foll station Q0 2 Lifting 2Y1 Solenoid of the lifting cyl with gripper Q0 3 Gripper 3Y1 Solenoid of the gripper 1 open Q0 7 Previous IP_N_FO Light barrier to the previous station I O Communicati...

Страница 29: ... board Control Panel communication 6 connect all power supplies 7 check the adjustment of sensor holders 8 check the adjustment of sensors in the holders 9 check the adjustment of sensitivity of sensor 10 tubing connections 11 connect all air pressure supplies careful turn pressure down 12 check the adjustment of the speed of pneumatic actuators 13 connect the stations together 14 check the mechan...

Страница 30: ...plain them step by step how to download a project to the PLC Develop the process sequence on the white board first this means what is the process and how to start it Which are the Control Panel functions Tell the participants in which subdirectory they are able to find the programs à in the following screen shots the project is located in C SIEMENS STEP7 MPSVERSC Basically all screen shots and PLC...

Страница 31: ...switch 5 Station in home position and workpiece in the feeder à Reset light is on 6 Press Start button à light Start is on and process start 5 Station is not in home position à Reset light is off 6 Press Reset button à movement of actuators to home position 7 Station in home position and workpiece in the feeder à Reset light is on 8 Press Start button à light Start is on and process start The proc...

Страница 32: ...Commissioning 30 Festo Didactic GmbH Co MPS File à Open à Browse à select subdirectory here C Siemens Step7 MPSVERSC à OK left mouse button ...

Страница 33: ...tions PLC à Download à follow the instructions on the screen to download the project after download is finish switch the CPU switch to RUN and test the program 1VE_KFA Distribution Station 2PR_KFA Testing Station 3BE_KFA Processing Station 4PA_KFA Handling PickAlfa 5PU_KFA Buffer Station 6MO_KFA Assembly Station 7SO_KFA Sorting Station 8HY_KFA Hydraulic Station ...

Страница 34: ...Commissioning 32 Festo Didactic GmbH Co MPS ...

Страница 35: ...name because the configuration is the same for all stations Instructor Show how to delete the contents of a CPU using the switch of the CPU Let all the participants try it several times Explain them where to find the name of the PLC modules on the top of the module for example SM 323 and the order number 6ES7 and explain why this order number is so important for the hardwareconfiguration Explain a...

Страница 36: ...on Screen shots of the hardwareconfiguration the bold words are commands to click on the are only comments ENTER means click left mouse button once or press ENTER double click means double click the left mouse button File à New à type Name P2_01 à OK ...

Страница 37: ...Programming Festo Didactic GmbH Co MPS 35 Insert à Station à SIMATIC 300 Station ...

Страница 38: ...Programming 36 Festo Didactic GmbH Co MPS P2_01 à SIMATIC 300 1 à Hardware double click ...

Страница 39: ...Programming Festo Didactic GmbH Co MPS 37 SIMATIC 300 à RACK 300 à Rail à double click ...

Страница 40: ... à CPU 314 à 6ES7 314 1AE04 0AB0 depends on the CPU you use check the order no on the front left below corner of the CPU à V1 2 depends on the CPU you use open the flap of the CPU and you will find the right version number on the left below corner à double click ...

Страница 41: ...Programming Festo Didactic GmbH Co MPS 39 CPU 314 at the Slot 2 double click à Cycle Clock Memory à Clock Memory à 100 Memory Byte free definition ...

Страница 42: ...Programming 40 Festo Didactic GmbH Co MPS Retentive Memory à 0 Number of Memory Bytes Starting with MB0 à 0 Number of S7 Timers Starting with T0 à 0 Number of S7 Counters Starting with C0 à OK ...

Страница 43: ... Festo Didactic GmbH Co MPS 41 CPU 300 à SM 300 à DI DO 300 à SM 323 DI16 DO16x24V 0 5A depends on the input output module you use refer to the left below corner of the module to find the right number double click ...

Страница 44: ...Programming 42 Festo Didactic GmbH Co MPS SIMATIC 300 à Station à Save and Compile ...

Страница 45: ...Programming Festo Didactic GmbH Co MPS 43 PLC à Download follow the instructions on the screen to download the hardwareconfiguration ...

Страница 46: ...Programming 44 Festo Didactic GmbH Co MPS after download without an error message switch the CPU to RUN no red light SF switch the CPU to STOP again Station à Exit ...

Страница 47: ...reconfiguration and no error message while or after downloading the hardwareconfiguration have been done properly Change the switch on the CPU to RUN position if there is no read light SF the configuration was successful and then change the swithc to STOP again Documentation Please add your own comments to the screen shots ...

Страница 48: ...nditional UC Instructor Please explain the programming structure of a PLC S5 or S7 with OB1 FC FB SFB SFC Explain also the two ways to call a program Function from OB1 UC and CC Work out the Truth table Wiring diagram Logic plan and Stepping diagram together with the participants Explain that the basics on the following pages are principal functions because the output is the Start light H1 Explain...

Страница 49: ...his structure is used for education because there are mostly more than only one different exercise Programs for one station Struc02 shows a typical industrial structure because there is mostly only one Program for one station or application The first projects within this teachware are based on Struc01 later we will change it to the Struc02 to see and learn both different possibilities ...

Страница 50: ...Programming 48 Festo Didactic GmbH Co MPS ...

Страница 51: ...gered by 5 2 way valves Explain the following three graphics 5 number of connections 1 3 4 2 and 5 2 2 switching positions 2 rectangles The connections have the following functions 1 P air connection supply 2 B output B for backward stroke 3 S connection exhaust air of forward stroke 4 A output A for forward stroke 5 S connection exhaust air of backward stroke In the following drawing you can find...

Страница 52: ... connected to Y1 4 A 2 B 3 R 5 S 1 P 14 y1 4 A 2 B Activation of a single solenoid valve short power signal 24VDC connected to y2 y2 y2 y3 y3 3 R 3 R 5 S 5 S 1 P 1 P 14 14 12 12 4 A 4 A 2 B 2 B short power signal 24VDC connected to y3 Activation of a double solenoid valve ...

Страница 53: ...tputs of the Project 1 3 Work out the informations of truth table wiring diagram logic plan and stepping diagram first together with the Instructor Before programming don t forget to delete the contents of the PLC using the CPU switch The time to finish this project should be around 1 5 hour including theory File à New à type name P2_02 à OK ...

Страница 54: ...Programming 52 Festo Didactic GmbH Co MPS SIMATIC 300 1 click on station of the project P2_01 with the right mouse button à Copy ...

Страница 55: ...Programming Festo Didactic GmbH Co MPS 53 P2_02 right mouse button on the project P2_02 à Paste ...

Страница 56: ...Programming 54 Festo Didactic GmbH Co MPS X close the project P2_01 ...

Страница 57: ...Programming Festo Didactic GmbH Co MPS 55 P2_02 à Insert à Program à S7 Program ...

Страница 58: ...Programming 56 Festo Didactic GmbH Co MPS S7 Program 2 à Blocks à Insert à S7 Block à Function ...

Страница 59: ...Programming Festo Didactic GmbH Co MPS 57 FBD change programming language of FC1 to FBD Function Block Diagram à OK ...

Страница 60: ...PS Execution Documentation Edit the Organisation Block 1 first by double click on OB1 Program OB1 After editing Edit à Save à no error message Edit à Exit This procedure is always the same after editing a program à it s not mentioned anymore ...

Страница 61: ...Programming Festo Didactic GmbH Co MPS 59 Edit the the application within the Function 1 by double click on FC1 Program FC1 ...

Страница 62: ...ting the project download it to the CPU Test the function according the project description Block à PLC à Download follow the instructions on the screen This procedure to download a project is always the same after editing a program à it s not mentioned anymore ...

Страница 63: ...nd name it P2_03 Please copy the hardwareconfiguration from P2_01 or P2_02 Please use the symbol adresses shown in the list of inputs and outputs of Project 1 3 to edit the program The programming language for FC1 should be FBD for OB1 STL The FC5 shall starts unconditional The following screen shows the project structure and the symbol editor Instructor Work out the basics of an OR shown on the n...

Страница 64: ...0 1 station copy of the Hardwareconfiguration insertation of a S7 Program 2 please open the Symbol Editor P2_03 à S7 Program 2 à Symbols double click à edit the symbols the adresses and the comments and save the file Symbol Table à Save à X close the window of the Symbol Editor ...

Страница 65: ...Programming Festo Didactic GmbH Co MPS 63 ...

Страница 66: ...pping diagram first together with the Instructor Before programming don t forget to delete the contents of the PLC using the CPU switch again Insert the application function FC5 to the Blocks like described within the Project 2 2 and edit the OB1 and the FC5 After editing please download the Blocks to the CPU and test the program The time to finish this project should be around 1 0 hour including ...

Страница 67: ...f you click the right mouse button on an input or output and click on Insert Symbol you will get a list of all defined inputs and outputs within the Symbol Editor Controll Edit the project and download it Test the function according the project description ...

Страница 68: ...ame it P2_04 Please copy the hardwareconfiguration and the OB1 from the project before Please use symbol adresses How to edit the symbol editor was shown in the project P2_03 The programming language should be FBD Instructor Work out the basics shown on the next page together with the participants Explain the differences of reset and set dominant Show how to copy an OB1 into a new project Show the...

Страница 69: ...Programming Festo Didactic GmbH Co MPS 67 ...

Страница 70: ...uts of the Project 1 3 Work out the informations of truth table wiring diagram logic plan and stepping diagram first together with the Instructors Before programming don t forget to delete the contents of the PLC using the CPU switch The time to finish this project should be around 1 5 hour including theory Execution Documentation Program OB1 ...

Страница 71: ...Programming Festo Didactic GmbH Co MPS 69 Program FC1 ...

Страница 72: ...t and download it See the function of the project online on your computer see screen Test the function according the project description click on the glasses to switch to online mode after finish please switch the online mode off and close the window with Edit à Exit ...

Страница 73: ...ease use symbol adresses The programming language for FC10 should be FBD for OB1 STL The FC10 shall start unconditional Work out the Truth Table together with the instructor first Instructor Please work out the Truth table together with the participants Show how to negate an input in the program with FBD Explain that within the program they shall use the cylinder with single solenoid valve not the...

Страница 74: ...Programming 72 Festo Didactic GmbH Co MPS Execution Documentation Program OB1 ...

Страница 75: ...amming Festo Didactic GmbH Co MPS 73 Program FC10 Controll Edit the project and download it Test the function according the project description Watch FC10 with the online function description see Project 2 4 ...

Страница 76: ...project and name it P2_06 Please open the Project 2 4 P2_04 again and copy all parts you need Please use symbol adresses The programming language for FC1 and for OB1 should be STL The FC1 shall start unconditional Instructor Please tell the participants that only one logic module is needed for this project Planning Please plan your project step by step first within the group The time to finish thi...

Страница 77: ...PS 75 Execution Documentation Program FC1 OB1 is the same than in the Project 2 4 Controll Edit the project and download it Test the function according the project description Watch FC1 with the online function description see Project 2 4 ...

Страница 78: ...project you need Use FC8 to edit the program Open a new project and name it P2_07 Please use symbol adresses The programming language for FC8 is FBD for OB1 STL Instructor Explain how to rename a function right mouse button à Rename Planning Please plan your project step by step first within the team Discuss the differences to call a function FC with and without a condition The command for conditi...

Страница 79: ...Programming Festo Didactic GmbH Co MPS 77 Execution Documentation Program OB1 ...

Страница 80: ...ntroll Edit the project and download it Test the function according the project description Watch the function of the FC with the online function This controll step will be the same for all the following projects so it s not mentioned in each project anymore ...

Страница 81: ...oject with a new name Use FC1 to edit the program Please use symbol adresses The programming language for FC1 should be FBD for OB1 STL We also use another structure of the project Please see the screen shot New structure of the project and follow the structure for all following projects Also please switch the CPU to the RUN P mode Within this mode you can delete download and warmstart the CPU fro...

Страница 82: ...Programming 80 Festo Didactic GmbH Co MPS Save an open project with a new name File à Save As à P2_08 type in the new name à OK ...

Страница 83: ...Programming Festo Didactic GmbH Co MPS 81 Copy the contents of the S7 Program 2 S7 Program 2 right mouse button à Copy ...

Страница 84: ...Programming 82 Festo Didactic GmbH Co MPS CPU 314 right mouse button à Paste ...

Страница 85: ...Programming Festo Didactic GmbH Co MPS 83 Delete the S7 Program 2 S7 Program 2 right mouse button à Delete follow the instructions on the screen ...

Страница 86: ...Programming 84 Festo Didactic GmbH Co MPS Rename FC8 to FC1 CPU 314 à S7 Program 2 à Blocks à FC8 right mouse button à Rename à rename FC8 to FC1 à OK ...

Страница 87: ...Programming Festo Didactic GmbH Co MPS 85 New structure of the project ...

Страница 88: ...roject step by step first within the team Before programming don t forget to delete the contents of the PLC from the computer Edit the project programs on a sheet of paper first The time to finish this project should be around 1 0 hour Execution Documentation Program OB1 ...

Страница 89: ...Programming Festo Didactic GmbH Co MPS 87 Program FC1 ...

Страница 90: ...ctual Project as a new project named P2_09 Please use symbol adresses The programming language for FC1 should be FBD for OB1 STL Use the Hardwarecatalog Program elements to edit the program in FBD see screens Open the Hardwarecatalog and use the help function to get further informations see the screen shots Help function for an On Delay Timer Use Timer 1 for this project Instructor Discuss about t...

Страница 91: ...g Festo Didactic GmbH Co MPS 89 Open the Hardwarecatalog if the Hardwarecatalog is not open window in the right corner Program elements please open it in the FC1 View à Catalog à the window Program elements opens ...

Страница 92: ...Programming 90 Festo Didactic GmbH Co MPS Help function for an On Delay Timer Timers à S_ODT à click on the and you see a description of the function ...

Страница 93: ...ll timers with the help function and choose the right timer for your project May be it s helpful to print the help functions of the timers for further projects Edit on a sheet of paper first The time to finish this project should be around 2 0 hour including theory and print out of the different timers Execution Documentation Program OB1 ...

Страница 94: ...Programming 92 Festo Didactic GmbH Co MPS Program FC1 ...

Страница 95: ...on Use FC1 to edit the programs Please use symbol adresses The programming language for FC1 should be FBD for OB1 STL Use Timer 2 for this project Planning Please plan your project step by step first within the team Check out the function of all timers and choose the right timer for your project Edit on a sheet of paper first The time to finish this project should be around 1 0 hour 2 10 Programmi...

Страница 96: ...Programming 94 Festo Didactic GmbH Co MPS Execution Documentation Program FC1 the program OB1 is the same than for the project before ...

Страница 97: ...ld be FBD for OB1 STL Use Counter 1 for this project Instructor Explain the differences to count up or count down from the output point of view Explain the function of the edge memory Explain why it s better to use it for this project à some contacts shetter or bounce à the counting would not be correct Planning Please plan your project step by step first within the team Check out the function of ...

Страница 98: ...n Program FC1 the program OB1 is the same than for the project before The logic module P M10 0 is an edge memory this means even you hold Start button down only a short pulse will come through to the input Some contact shatter or bounce even you press them only once ...

Страница 99: ...e 8 Bits of the Memorybyte 100 100 is free defined within the Hardwareconfiguration A time period is the time the Memory is on and the time the Memory is off M100 0 0 1 sec M100 1 0 2 sec M100 2 0 4 sec M100 3 0 5 sec M100 4 0 8 sec M100 5 1 0 sec M100 6 1 6 sec M100 7 2 0 sec Instructor Show the Clock Memory and the help function within the hardwareconfiguration and explain that the adress of the...

Страница 100: ...Programming 98 Festo Didactic GmbH Co MPS Execution Documentation Program FC1 the program OB1 is the same than for the project before ...

Страница 101: ...Auto Manu switch to on Information Use FC1 to edit the program Please use symbol adresses The programming language for FC1 should be FBD for OB1 STL The first start of the cycle must be by pressing Start button not with Auto Manu switch Instructor Explain very clearly that the first cycle after the CPU is switched from STOP to RUN must be activated only by the Start button Planning Please plan you...

Страница 102: ...Programming 100 Festo Didactic GmbH Co MPS Execution Documentation Program FC1 the program OB1 is the same than for the project before ...

Страница 103: ...tion but can not be detected by a sensor take out by hand Let the participants define the action themselves according the conditions Make sure that they follow the steps like mentioned within the planning Planning Please plan your project step by step first within the team Define the input conditions of the starting position first and then define the action of the actuators The time to finish this...

Страница 104: ...Programming 102 Festo Didactic GmbH Co MPS Execution Documentation Program FC1 the program OB1 is the same than for the project before ...

Страница 105: ...Programming Festo Didactic GmbH Co MPS 103 ...

Страница 106: ...ess start at the first 1 step again The Start process can not be activated while the homing process is active and the homing process can not be activated while the Start process is active as long the Reset light flash or is on the Start button have no function as long the Start light is on the Reset button have no function Information Please edit the program FC1 in FBD which starts without any con...

Страница 107: ...Programming Festo Didactic GmbH Co MPS 105 Execution Documentation Program FC1 the program OB1 is the same than for the project before ...

Страница 108: ...Programming 106 Festo Didactic GmbH Co MPS ...

Страница 109: ...Programming Festo Didactic GmbH Co MPS 107 ...

Страница 110: ...Programming 108 Festo Didactic GmbH Co MPS ...

Страница 111: ...mmunication Planning Please plan your project step by step first within the team The time to finish this project should be around 1 0 hour Execution Documentation Please define a 1 Bit bidirectional communication network 24 VDC 0 V Input Output PNP 24 VDC Input 0 12 VDC 0 Sig 12 30 VDC 1 Sig Output 1 Sig 24 VDC PLC 24 VDC 0 V Input Output PNP 24 VDC Input 0 12 VDC 0 Sig 12 30 VDC 1 Sig Output 1 Si...

Страница 112: ...ional communication network from PLC to Robot Controller 24 VDC 0 V Input Output PNP 24 VDC Input 0 12 VDC 0 Sig 12 30 VDC 1 Sig Output 1 Sig 24 VDC PLC 12 VDC 0 V Input Output PNP 12 VDC Input 0 6 VDC 0 Sig 6 12 VDC 1 Sig max volt 30 VDC Output 1 Sig 12 VDC Robot Controller ...

Страница 113: ...it bidirectional communication network 24 VDC 0 V Input Output PNP 24 VDC Input 0 12 VDC 0 Sig 12 30 VDC 1 Sig Output 1 Sig 24 VDC PLC 12 VDC 0 V Input Output PNP 12 VDC Input 0 6 VDC 0 Sig 6 12 VDC 1 Sig max volt 30 VDC Output 1 Sig 12 VDC Robot Controller K1 k11 ...

Страница 114: ...a 1 Bit bidirectional communication network 24 VDC 0 V Input Output PNP 24 VDC Input 0 12 VDC 0 Sig 12 30 VDC 1 Sig Output 1 Sig 24 VDC PLC 12 VDC 0 V Input Output NPN 12 VDC Input 0 6 VDC 1 Sig 6 12 VDC 0 Sig Output 1 Sig 0 VDC Robot Controller K1 k11 K2 k21 ...

Страница 115: ...rial detection is on each station where it s necessary to check the material But the binary communication like input output communication is very important basic knowledge to understand the next level of communication Fieldbus Technology Instructor Please explain how to find the informations to finish the drawing Explain that only one program should be used without any changes to test all inputs a...

Страница 116: ...Programming 114 Festo Didactic GmbH Co MPS Execution Documentation ...

Страница 117: ...Programming Festo Didactic GmbH Co MPS 115 Program FC1 OB1 is the same than in the project before ...

Страница 118: ...Programming 116 Festo Didactic GmbH Co MPS ...

Страница 119: ...Programming Festo Didactic GmbH Co MPS 117 ...

Страница 120: ...Programming 118 Festo Didactic GmbH Co MPS Controll Edit the project and download it Test the function according the project description and the your planning Watch FC1 with the online function ...

Страница 121: ...t s not able to Start if Start condition is running it s not able to run the home position sequence Discuss within the whole team how to start the cycle step by step which means which station have to be started first second a s o Please do the planning together with the participants Go ahead step by step and show always the condition and the action at the station directly Explain to the participan...

Страница 122: ...Programming 120 Festo Didactic GmbH Co MPS Execution Documentation Program FC1 the OB1 is the same than at the project before ...

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Страница 136: ...Programming 134 Festo Didactic GmbH Co MPS ...

Страница 137: ...he board in a short form like for example Start button and Reset button Start light Let the participants work in the team together at the same time and take the time of each team The time to finish the trouble shooting mentioned within the documentation means the time including preparation of the error downloading error detection error location error elimination of the participants and download an...

Страница 138: ...Trouble Shooting 136 Festo Didactic GmbH Co MPS Original Project 2 2 time to finish approx 0 5 h ...

Страница 139: ...Trouble Shooting Festo Didactic GmbH Co MPS 137 Error Project 2 2 ...

Страница 140: ...Trouble Shooting 138 Festo Didactic GmbH Co MPS Original Project 2 3 time to finish approx 0 5 h ...

Страница 141: ...Trouble Shooting Festo Didactic GmbH Co MPS 139 Error Project 2 3 ...

Страница 142: ...Trouble Shooting 140 Festo Didactic GmbH Co MPS Original Project 2 4 time to finish approx 0 5 h ...

Страница 143: ...Trouble Shooting Festo Didactic GmbH Co MPS 141 Error Project 2 4 ...

Страница 144: ...Trouble Shooting 142 Festo Didactic GmbH Co MPS Original Project 2 5 time to finish approx 0 5 h ...

Страница 145: ...Trouble Shooting Festo Didactic GmbH Co MPS 143 Error Project 2 5 ...

Страница 146: ...Trouble Shooting 144 Festo Didactic GmbH Co MPS Original Project 2 6 time to finish approx 45 min ...

Страница 147: ...Trouble Shooting Festo Didactic GmbH Co MPS 145 Error Project 2 6 ...

Страница 148: ...Trouble Shooting 146 Festo Didactic GmbH Co MPS Original Project 2 7 time to finish approx 0 5 h ...

Страница 149: ...Trouble Shooting Festo Didactic GmbH Co MPS 147 Error Project 2 7 ...

Страница 150: ...Trouble Shooting 148 Festo Didactic GmbH Co MPS Original Project 2 8 time to finish approx 45 min ...

Страница 151: ...Trouble Shooting Festo Didactic GmbH Co MPS 149 Error Project 2 8 ...

Страница 152: ...Trouble Shooting 150 Festo Didactic GmbH Co MPS Original Project 2 9 time to finish approx 45 min ...

Страница 153: ...Trouble Shooting Festo Didactic GmbH Co MPS 151 Error Project 2 9 ...

Страница 154: ...Trouble Shooting 152 Festo Didactic GmbH Co MPS Original Project 2 10 time to finish approx 0 5 h ...

Страница 155: ...Trouble Shooting Festo Didactic GmbH Co MPS 153 Error Project 2 10 ...

Страница 156: ...Trouble Shooting 154 Festo Didactic GmbH Co MPS Original Project 2 11 time to finish approx 45 min ...

Страница 157: ...Trouble Shooting Festo Didactic GmbH Co MPS 155 Error Project 2 11 ...

Страница 158: ...Trouble Shooting 156 Festo Didactic GmbH Co MPS Original Project 2 12 time to finish approx 0 5 h ...

Страница 159: ...Trouble Shooting Festo Didactic GmbH Co MPS 157 Error Project 2 12 ...

Страница 160: ...Trouble Shooting 158 Festo Didactic GmbH Co MPS Original Project 2 13 time to finish approx 1 0 h ...

Страница 161: ...Trouble Shooting Festo Didactic GmbH Co MPS 159 Error Project 2 13 ...

Страница 162: ...f the programming projects The Project description is If the Auto Manu switch is off a program FC1 shall be active if the Auto Manu switch is on a program FC2 shall be active FC1 is a NOR function with the Start light H1 the FC2 is a NAND function with the Reset light H2 Use the Start and Reset button as inputs ...

Страница 163: ...Trouble Shooting Festo Didactic GmbH Co MPS 161 ...

Страница 164: ...Trouble Shooting 162 Festo Didactic GmbH Co MPS ...

Страница 165: ...Trouble Shooting Festo Didactic GmbH Co MPS 163 Error in Project ...

Страница 166: ...possible At Trouble Shooting there is one difference between so called Commissioning Errors and Maintenance Errors Both of them could be different in a way there are NO wrong wirings tubings as well as programming errors within the Maintenance Errors because the system already has been running perfectly and and an operational error had happened Such operational errors could be break of wire defect...

Страница 167: ... board page 8 Station is always in Stop mode à can not be started 6 Isolate wire at clamp XMA2 0V from Q0 on the station Station page 5 The handling cannot move to the previous station à handling is not possible to pick up a workpiece in the previous station 7 Isolate connection red of external power supply PLC board page 4 circuit no 1 No power on the whole system 8 Remove the fuse F1 on the PLC ...

Страница 168: ... a very good example how to measure an error step by step with different measuring methods 24NA 6 8 S5 3 4 S1 3 4 S3 3 4 S2 3 4 S4 3 4 S6 3 4 24V 6 8 24V 8 1 XK1 24V XK1 24NA 0V 6 8 0V 8 1 2 A2DI1 6 4 3 A2DI1 6 4 4 A2DI1 6 4 5 A2DI1 6 4 COM 5 7 XMG2 7 XG2 O6 XMG2 13 XMG2 14 XMG2 15 XMG2 16 XMG2 17 XG2 I0 XG2 I1 XG2 I2 XG2 I3 XG2 I4 XMG2 21 XG2 24VB 6 A2DI1 6 4 8 A2DI1 6 4 9 A2DI1 6 4 7 A2DI1 6 4 D...

Страница 169: ...is indicated by flashing of the RESET light The reason for malfunction must be the START button itself Measuring of the current path No 1 may be proceeded in different ways In the following two examples may be described and both of them are leading to result measuring of voltage measuring of continuity For better understanding the current path No 1 may be shown as an equivalent diagram 0V 0V 24V X...

Страница 170: ... 1 step 0V 0V 24V 0V clamp PLC board PLC input R 0V XK1 24V XMG2 21 XMG2 13 A2DI1 2 Voltage test procedure 2 step 0V 0V 24V 0V clamp PLC board PLC input R 12V XK1 24V XMG2 21 XMG2 13 A2DI1 2 Result disconnection must be located between clamp XMG2 and A2DI1 2 broken wiring ...

Страница 171: ...ttention disconnect power supply no continuity XK1 24V XMG2 21 XMG2 13 A2DI1 2 Continuity test 2 step 0V Attention disconnect power supply disconnection PLC input R 0 continuity XK1 24V XMG2 21 XMG2 13 A2DI1 2 Result disconnection must be located between clamp XMG2 and A2DI1 2 broken wiring ...

Страница 172: ... Button RESET light not change to off Error Limitation MECHANICAL 1 Is there a mechanical defect on the Start button ELECTRICAL 1 Is the Start button switching regularly Continuity test of switching contacts 2 Is the signal of the button reaching the PLC Control by sight and voltage test Error Elimination REASON Break of wire end sleeve at the button at connection X Attach new end sleeve to the wi...

Страница 173: ...gle steps and all useful informations into the work sheet Please show your result first to the instructor before removing the error Please ask your instructor for copies of this work sheets Order of Maintenance Name Order No Date Location of Error Sheet Error Detection Error Limitation MECHANICAL ELECTRICAL PNEUMATICAL Error Elimination REASON ...

Страница 174: ...Trouble Shooting 172 Festo Didactic GmbH Co MPS Controll After error elimination please check the process again step by step carefully there might be another error within the system ...

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