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SL-Automatisierungstechnik GmbH

Mechatronic Compact System

Station 16101 - Magazine with check unit

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SL-Automatisierungstechnik GmbH In der Bredde 37 D-58636 Iserlohn www.slhome.com 1

Training material

Content Chapter

Safety 1.0

General notes 1.0

Technical safety 1.1

Construction 1.2

Connection 1.3

Operating instructions 1.4

16101- Magazine with check unit 2.1

Control panel 3.0

Data cable 3.1

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Training material

Power supply

The modules and stations need power supply of +24 VDC. Thispower is supplied via a data interface to the station.

To the protection from dangerous tensions when being busy atthe devices and plants a current supply with power supply unitsDIN EN 60742/VDE 0551 is necessary for the realization of a pro-

tective low voltage SELV. The floating of active parts must besurely ensured.

Power Supply

Emergency exit

Together with the power supply, the user has to install a suitable

emergency circuit.The path of the current 2L+ is intended for actuators, which shallbe switched off independently on the function of the control.This current path can be switched off with the emergency stop.

If no emergency stop wiring is intended, the data interface L1

and L2 must be bridged, so that the loaded actuators by L2 aresupplied with tension.

A disconnection of compressed air is possible only when con-

necting a maintenance unit with electrical solenoid valve at the2L+ current path.

If the compressed air is not turned off by Emergency exit, the

pneumatic drives will fulfil the task or returns to the starting posi-tion.

Installation

Attention

!

Compressed Air

The compressed air connection up to 8 bars is necessary. Theworking pressure of 5 bars shall be adjusted for the stations..

Connection

A certain attention is required when starting pneumatic com-ponents because they can move when the pressure increases.

In case that there is no valve or no similar object, the com-

pressed air can be gently turned on via the hand valve.

Starting

Please take into consideration that depending on the connec-

tion - the compressed air is not necessarily turned off after usingEmergency exit in dangerous situations.

Compressed airduring emergency exit

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Training material

Control

The control is connected to the electric and pneumatic operat-

ing resources via a data interface.

Turn on the compressed air before starting the control.

Before actuating the installation, the compressed air supply has

to be established. If the compressed air supply is establishedlater on, this can result in unexpected and fast movements ofthe pneumatic drives.

A not-adjustment or a damage of the pneumatic components ispossible.

Connection

!

Coupling of installations

When coupling the installations, not only the concerned unit has

to be disconnected by the help of emergency circuit but alsoall pre- and after-connected devices, in case their operatingconstitutes a danger.

Emergency exit

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Training material

1.1 Technical security

Drives

Electric and neumatic drives cannot be moved manuall .Pneumatic drives are pre-stressed at the available compressed

air. A manual movement can cause damage or a not-adjustment of the module.

Manual activities should only be made without using com-pressed air and with absolute caution.

Disconnected electric drives are short-circuit broken. A manualmovement can cause the destruction of motor and gear.

Handling

Pneumatic

Electric

If a manual movement is necessary, the motor must be discon-nected from the relay and must be handled with care.

The change of direction of rotation of electric drives is pro-grammed with a rest period =100 ms.

Current change of direction without rest period leads to theovercharge of the motor!

Sensors

The incorrect use of the sensors can result in their destruction.In principle, the following aspects have to be observed:

Three and four-wire sensorsthese will be connec ted to the power supply power sup-

ply and at the c ircuit output, the output signal can bemeasured without charge.

Avoid short circuits! Two-wire sensors

In order to check the function a load resistor is necessary

for the limitation of the nominal current.Do not put under no circumstances directly at tension.

In order to control the function of these sensors, put theoutput on resistance of 2,4 KO on GND or connect to aPLC input (current limiting on 10 mA)

The cylinder switch should not be put into operation

without current limitation

When mounting the sensors, the instructions of the manufacturershould be observed.

Application

!

Control of function

!

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Training material

Setting indications and maintenance

The throttle valves have to be adjusted in such a way that the

movement of the piston of the cylinder is regular but not toofast. It should also be no stuttering movement of the piston.

Throttle valves

The cylinder switch (magnetic, reed switch) have to be adjustedin such a way that they are active centrically of the hysteretic(at the reed switch ca. 2 mm).

Cylinder switch

The module has to be clean and be regularly cleaned. If it is

necessary to maintain individual components, the descriptionsin the different documentations of the manufacturer are valid.(see appendix)

Maintenance

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Training material

1.2 Construktion

The modules are to be set u de endin on the confi uration

on plane surface and adjusted at the mounting plates. Subse-quently, the modules are to be specified with the splice plates.

With the standard mechanical setting of the modules, a careful

set-up of the installation is possible. A fine adjustment of the

transfer points must be set with the program flow.

The modules are to be installed from the maintenance unit with

pneumatics pipe 6 mm via the T-connectors.

Module

The o eratin ressure is to be set on 0.5 Mpa. The Hand valve is

to be opened sensitively, so that the system fills slowly with com-

pressed air and no jerky movements of the pneumatic compo-

nents occur.

Fill the system sensitively with compressed air!

Compressed air

1.3 Connection of compressed air

Installation

Connection of control

For res ectivel two modules a control is intended. At the first

control the control panel is to be connected via the 1 to 3 ca-

ble. For the other controls in the technological operational se-

quence the first module must be used with the plug "1".

Control

1 2 1 21 21 2

The bus-modules are connected to the data interface and ac -

cording to the Bus-system used, connected to the control.

BUS

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Training material

1.4 Operating instructions

The o eratin instructions a l onl on use of the STEP7-Pro rams of

the teachware. It can be used as model for the own programming.

After connectin the o eratin volta e the installation remains non-

active.

The flashing of the button STOP requests to the RESET.

Switch on the vol-

tage

The current program is stopped immediately and all functions arebroken off directly.

Pneumatically driven actuators (cylinders) lead the action be-

gun still out (conditionally by the cylinder control).

Electrically driven actuators (motors) stop the function.

STOP

All the modules are brought into a starting position. The work pieceson the modules (except RST) are to be removed before. The work

pieces on the rotary indexing table are recognized and taken by fol-lowing module.

If all functional modules have closed the RESET, the display of the startbutton flashes. The installation is ready for use. The start button re-leases following functions:

RESET

Startin the ro ram run after RESE

Activating the program flow after STOP

START

Another o eratin mode can be selected with the o eratin mode

switch.

The operating mode BA I is for the normally program flow.

The operating mode BA II has been used for the compensation proc-

esses (Functions).

Operating mode

The functions ro rammed can be activated or states can be con-

firmed with the button FUNCTION.

Function Calibrate Measure analogue

In the operating mode BA II and Installation in STOP, the mod-

ule Measure is activated with the key FUNCTION. A standard

part on the deposit indicates a value at the measuring sys-

tem. This determined value is saved as standard value to the

control. The Good evaluation is programmed with a toler-

ance of 0,5 mm.

Malfunctions or full sorting tracks are shown with a flashed LA2.

After remedying deficiencies, the program sequence contin-

ues after acknowledging with the function e FUNCTION.

FUNCTION

Calibrate

Acknowledge

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Training material

The ro ram se uence is sto ed Display STOP

Flash

The installation is in starting position and is ready to start Display START

Continuous li ht , when an acknowled e is necessar .

Acknowledge after the removal of the cause led to the malfunction

e.g. the tracks during sorting were FULL

Display

FUNCTION

Si nal lam reen O eration normal Display LA1

Si nal lam ellow Warnin , error, stora e FULL Display LA2

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Training material

2.1 Magazine with check unit

Description

Construction

The work ieces are loaded from a ma azine and de osited ona deposit.

The fill level of the magazine is checked by a through-beam

sensor and the work piece on the deposit is checked by a mi-

croswitch.

The material properties of the work piece are determined with

an optic and an inductive sensor.

A double-acting pneumatic cylinder moves each one work

piece out from the magazine.

The end positions of the cylinder piston are detected by the

contactless signal transmitter.

The control of the cylinder is done with an electric 5/2-

directional valve.

Function

Adjusting instructions

The feed c linder Z1 have to be ad usted at the front end of the

piston rod in such a way that the work piece is ushed forward

up to the micro switch S03 and activates this with a safety re-

serve of circa 1 mm. Up to the limit stop, it should still remain

approx.. 0.5 mm gap.

Feed cylinder

Magazine

(Down pi-

Checking unit

O ticsenso

Micro switch

Assembling

plateInductivesensor

Feedcylinder

Cylinderswitch

Valvecluster

Data inter-face

Lightbarrie

Erection

bolt

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Training material

Adjustmen

The feed c linder sta s out until the ri er does not suck the

work piece.

Program note

Adjusting the module

After release of the erection bolt the module is movable on themounting plate in X- and Y-direc tion. When assembling the

module, please pay attention that it is a light seat of the nuts inthe profile, so that these can rotate with tightening around 90.

If the module is adjusted for the gripper, that is more simply

to set the following module with the gripper and to adjust

the transfer position with the magazine.

Adjustment

Data

Operating voltage 24 V DC

Compressed air 0,5 Mpa, unoiledDimensions 160 x 400 x 270 mm (B x T x H)

Weight 3,2 kg

Work pieces Cylinder 30 x 20 mm (Accessories)

General

Signal transmitter 6 2 Cylinder switch1 through-beam sensor1 Micro switch

1 reflex light sensor1 induc tive sensor

Actuators 2 2 5/2-directional control valve, bistable

Communication

Ca . 0 5mmAdjustment

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Training material

Documentation

Connector pin assignment

CM Magazine withcheckin uni ASP CM-FMZ-PE

BMK operating resources Comment 1L+ M I/O X PLC

Inputs:

1B00 Cylinder switch (1Z1) FM; feed cylinder RETRACTED br bl XD.2 DE 00

1B01 Cylinder switch (1Z1) FM; feed cylinder EXTENDED br bl XD.3 DE 01

1B02 Through-beam sensorFM; Work pieces in magazine IN

STOCKbr bl sw XD.4 DE 02

1S03 Micro switch FM; Work piece ISOLATED br bl XD.5 DE 03

1B04 Sensor Optic PE; Work piece BLACK br bl/ws sw XD.6 DE 04

1B05 Sensor Inductive PE; Work piece METAL br bl sw XD.7 DE 05

XD.8 DE 06

XD.9 DE 07

XD.10 DE 10

XD.11 DE 11

XD.12 AE 00

Outputs:

1Y005/2-directional control valve

bistable (1Z1)

FM; feed cylinder EXTENDsw rt XD.15

DA 00

1Y015/2-directional control valvebistable (1Z1)

FM; feed cylinder RETRACT sw rt XD.16 DA 01

XD.17 DA 02

XD.18 DA 03

XD.19 DA 04

XD.20 DA 05

XD.21 DA 06XD.22 DA 07

XD.23

Power supply:

M XD.1

M XD.14

1L+ 24V DC XD.13

1L+ 24V DC XD.25

2L+ 24V DC XD.24

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Training material

Connection diagram

Compactmod

uleLoadingfrompartmagazinewith

checkunitattheworkpiecedeposit

=

C

M

1

3

3.4

0.1

00.3

5

MC

SCM

Gravity-feedmagazinewithtestdevice

C

M

1

p

-F

M

Z

P

E

-6

1.

dw

g

1.8.2006

Ks

2

Stromlaufplan

Optic

sensor

workpiec

eBLACK

(dark

switching

)Testdevice

4

b

l

1

b

r

1B00

1L+

2L+

M

Powersupply24VDC

1

3

2

5

2

4

1

1

4

Light

barrierwork

piecein

magazine

INSTOCK

(dark

switching)

Feed

cylinder

EXTEND

ED

Feed

cylinder

RETRAC

T

ED

2

3

1B01

bl

bl

1B02

Microswitc

hwork

piece

ISOLATE

D

5

4

6

1B03

1B04

Gravity-fe

edmagazine

br

br

sw

+

-

br

bl

1Q00

Inductive

sensor

Work

piece

METAL7

1B05

Feed

cylinde15

Feed

cylinder

RETRA

CT

1

6

1Q01

Valveterminal

M1L+

2L+

XDE

2

3

4

5

1

5

XDA

1

6

6

7

14

12

D

sw

+

-

br

bl

sw

+

bl

br

br

bl

-

SL-

Automatisierungstechnik

GmbH

Modif.

Contr.

Norm

Date

Name

Orig.

Name

Datum

Createdfor

Created

0

1

2

3

4

of

:

Sh

eet:

sheet:

5

6

7

8

9

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Training material

Pneumatic plane

Compactmod

uleLoadingfrompartmagazinewith

checkunitattheworkpiecedeposit

=

C

M

1

3

3.4

0.1

00.3

5

MC

SCM

Gravity-feedmagazinewithtestdevice

C

M

1

p

-F

M

Z

P

E

-6

1.

dw

g

1.8.2006

Ks

3

PneumaticplaneF

eedcylinder

EXTEND

RETRACT

P

1

E

A

5

E

B

3

14

1

Q

0

0

1

M

11

B

0

0

(R2)

(P)

(R1)

12

1

5

3

4(A)

2(B)

1

Q

0

1

1

B

0

1

Partsma

gazine

sw

+

bl

br

br

bl

-

SL-

Automatisierungstechnik

GmbH

Modif.

Contr.

Norm

Date

Name

Orig.

Name

Datum

Createdfor

Created

0

1

2

3

4

of

:

Sh

eet:

sheet:

5

6

7

8

9

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Training material

3.0 Control panel

Description

Construction

In a solid aluminium frame a rinted circuit board with the lo ic

elements and LED is installed. Rubber feet give a fixed hold on

the table to the control console.With the 25- ole data interface, the desk is connected to the

control and to the power supply. The desk can be used accord-

ing to the programmed functions.

Function

After removin the lateral ca s, the lower frame barrier can be

removed with light pressure on the front and back board of the

frame.

Service

4/NO

16

18

19

17

15

14

1M

6

5

4

3

2

1L +24V DC

13

25 1/COM

- S00

2/NC

- S01

1/COM

4/NO

STOP START

- S03- S02

1/COM

4/NO

2/NC

- S04

1/COM

QUIT Operating mode

I II

Control panel BP06

green

Indicator I

- P01

START

- P00

STOP

M

- P02 - P03

QUIT

- P04

Indicator II

yellow

Connection diagram

Data

Operating voltage 24 V DCDimensions 180 x 160 x 90 mm (B x T x H)Weight 0,5 kgData interface 25-pole connector D-Sub

General

Signal transmitter 5 1 Illuminated pushbutton break contact2 Illum. pushbutton normally open contact

2 toggle switchActuators 5 3 Illuminated pushbutton (LED)

2 signal lamp (LED)

Communication

Selec tor switch

Control unit

Signal lamp

Data interface

25-pole

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Training material

Documentation

Connector pin assignment

Mechatronic Compakt System ASP Control panelBP06

BMK operating resources Comment: 24V 0VCa-

ble

Desk X325 pole

St

PLC

Control panel: Control device - INPUT

-S01Illuminated pushbutton red,break contact

STOP rt ws X3.2 DE 00

-S02Illum. button green,

normally open contactSTART rt gn X3.3 DE 01

-S03Illum. button yellow,

normally open contactFUNCTION rt ge X3.4 DE 02

-S04toggle switch,

normally open contactOperating mode BA I rt gr X3.5 DE 03

-S05toggle switch,

normally open contactOperating mode BA II rt rs X3.6 DE 04

X3.7 DE 05

X3.8 DE 06

X3.9 DE 07

Control panel: Command receiver- OUTPUT

-H01 Illuminated pushbutton red STOP - PLC in Stop bl rs X3.15 DA 00

-H02 Illuminated pushbutton green START - PLC active bl vio X3.16 DA 01

-H03 Illuminated pushbutton yellowFUNCTION bl gr/rs X3.17 DA 02

-H04 Signal lamp green Display LA I bl rt/bl X3.18 DA 03

-H05 Signal lamp yellow Display LA II X3.19 DA 04

X3.20 DA 05

X3.21 DA 06

X3.22 DA 07

Power supply:

M bl XB.1

M sw XB.14

1L +24V DC (Input voltage) rt XB.25

1L +24V DC (Input voltage) br XB.13

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Training material

3.1 Data cable

Data cable 1 zu 3

Mechatronic Compact System Data cable 1-3X-Ribbon Cable X-DS I/O X PLC S7 313

Module 1

XR.34 bl XC1.1 M

XR.43 ws XC1.2 MC1 - DE 00 X2.2 IN 124.0

XR.44 br XC1.3 MC1 - DE 01 X2.3 IN 124.1

XR.45 gn XC1.4 MC1 - DE 02 X2.4 IN 124.2

XR.46 ge XC1.5 MC1 - DE 03 X2.5 IN 124.3

XR.13 gr XC1.6 MC1 - DE 04 X1.2 IN 126.0

XR.14 rs XC1.7 MC1 - DE 05 X1.3 IN 126.1

XR.9 sw XC1.12 MC1 - AE 00 X1.11 Ana.IN

XR.8 vio XC1.15 MC1 - DA 00 X2.22 OUT 124.0

XR.7 gr/rs XC1.16 MC1 - DA 01 X2.23 OUT 124.1

XR.6 rt/bl XC1.17 MC1 - DA 02 X2.24 OUT 124.2

XR.5 ws/gn XC1.18 MC1 - DA 03 X2.25 OUT 124.3

XR.41 br/gn XC1.24 2L+ 24V DC (EMERGENCY STOP)

XR.37 rt XC1.25 1L+ 24V DC

Module 2

XR.35 bl XC2.1 M

XR.47 ws XC2.2 MC2 - DE 00 X2.6 IN 124.4

XR.48 br XC2.3 MC2 - DE 01 X2.7 IN 124.5

XR.49 gn XC2.4 MC2 - DE 02 X2.8 IN 124.6

XR.50 ge XC2.5 MC2 - DE 03 X2.9 IN 124.7

XR.15 gr XC2.6 MC2 - DE 04 X1.4 IN 126.2

XR.16 rs XC2.7 MC2 - DE 05 X1.5 IN 126.3

XR.10 sw XC2.12 MC2 - AE 00 X1.11 Ana.IN

XR.4 vio XC2.15 MC2 - DA 00 X2.26 OUT 124.4

XR.3 gr/rs XC2.16 MC2 - DA 01 X2.27 OUT 124.5

XR.2 rt/bl XC2.17 MC2 - DA 02 X2.28 OUT 124.6

XR.1 ws/gn XC2.18 MC2 - DA 03 X2.29 OUT 124.7

XR.41 br/gn XC2.24 2L+ 24V DC (EMERGENCY STOP)

XR.38 rt XC2.25 1L+ 24V DC

Desk X-Desk

XR.36 bl XB.1 M

XR.25 ws XB.2 Pushbutton STOP (break contact) X2.12 IN 125.0

XR.24 br XB.3 Pushbutton START (normally open contact) X2.13 IN 125.1

XR.23 gn XB.4 Pushbutton QUIT (normally open contact) X2.14 IN 125.2

XR.22 ge XB.5 Button BA I (normally open contact) X2.15 IN 125.3

XR.21 gr XB.6 Button BA II (normally open contact) X2.16 IN 125.4

XR.26 rs XB.15 LA Pushbutton STOP (red) X2.32 OUT 125.0

XR.27 sw XB.16 LA Pushbutton START (green) X2.33 OUT 125.1

XR.28 vio XB.17 LA Pushbutton QUIT (yellow) X2.34 OUT 125.2

XR.29 gr/rs XB.18 Indicator lamp I (green) X2.35 OUT 125.3

XR.30 rt/bl XB.19 Indicator lamp II (yellow) X2.36 OUT 125.4

XR.39 rt XB.25 +24V DC

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Training material

Network 4:

A I 124.0 // 1B00 cylinder switch (1Z1) - feed cylinder retracted

A I 124.2 // 1B02 through-beam sensor - work pieces in magazine in stock= Q 125.1 // -H02 illuminated push button green - START

Network 5:

A I 124.1 // 1B01 cylinder switch (1Z1) - feed cylinder extended= Q 125.2 // -H03 illuminated push button yellow - FUNCTION

Network 6:

A I 124.1 // 1B01 cylinder switch (1Z1) - feed cylinder extendedA I 124.3 // 1S03 micro switch - work piece isolated

A I 126.0 // 1B04 sensor optic - work piece blackOA I 124.1 // 1B01 cylinder switch (1Z1) - feed cylinder extendedA I 124.3 // 1S03 micro switch - work piece isolatedA I 126.1 // 1B05 sensor inductive - work piece metal= Q 125.3 // -H04 signal lamp green - display LA I

Network 7:

A I 124.1 // 1B01 cylinder switch (1Z1) - feed cylinder extendedA I 124.3 // 1S03 micro switch - work piece isolatedAN I 126.0 // 1B04 sensor optic - work piece black

OA I 124.1 // 1B01 cylinder switch (1Z1) - feed cylinder extendedA I 124.3 // 1S03 micro switch - work piece isolatedA I 126.1 // 1B05 sensor inductive - work piece metal= Q 125.4 // -H05 signal lamp yellow - display LA II

Alternative Network 6 and 7

Network 6:

A I 124.1 // 1B01 cylinder switch (1Z1) - feed cylinder extendedA I 124.3 // 1S03 micro switch - work piece isolated

A(O I 126.0 // 1B04 sensor optic - work piece blackO I 126.1 // 1B05 sensor inductive - work piece metal)= Q 125.3 // -H04 signal lamp green - display LA I

Network 7:

A I 124.1 // 1B01 cylinder switch (1Z1) - feed cylinder extendedA I 124.3 // 1S03 micro switch - work piece isolatedA(ON I 126.0 // 1B04 sensor optic - work piece blackO I 126.1 // 1B05 sensor inductive - work piece metal)= Q 125.4 // -H05 signal lamp yellow - display LA II

_16101_u_uk

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