trainingssystem mms 4.0 | r901429162/04.16 - bosch rexroth

R901429162/04.16

Operating manual

Replaces: R901429162/09.15 English

Training system mMS 4.0

This information is intended to describe the product.

If this information is to be applied, it only serves

as possible applications and suggestions.

Catalog information is not guaranteed features

of the product. The information provided does not

release the user from the obligation to conduct his

own assessments and tests. Our products

are subject to a natural process of wear and aging.

This document, as well as the data, specifications

and other information set forth in it, are the

exclusive property of Bosch Rexroth AG. We retain

all rights of use, including the rights of reproduction

and distribution.

An example configuration is shown on the

title page. The delivered product may differ from

the illustration.

Original operating instructions

Training system mMS 4.0 | R901429162/04.16 Bosch Rexroth AG 3/68

Contents

Contents

1 About this documentation ...................................................................... 5

1.1 Validity of the documentation ................................................................ 5 1.2 The following signs and symbols are used in this manual: ..................... 5 1.3 Required and supplementary documentation ....................................... 5 1.4 Layout of documentation ....................................................................... 5

1.4.1 Safety instructions ........................................................................ 5 1.4.2 Symbols ......................................................................................... 6 1.4.3 Abbreviations ................................................................................ 7

2 Safety instructions .................................................................................. 8 2.1 About this chapter .................................................................................. 8 2.2 Intended use ........................................................................................... 8 2.3 Improper use .......................................................................................... 8 2.4 Staff qualification ................................................................................... 9

2.4.1 Firms offering apprenticeships ..................................................... 9 2.4.2 Transport, set-up, installation and commissioning ..................... 10 2.4.3 Troubleshooting, maintenance and repair ................................. 10

2.5 General safety instructions ................................................................... 11 2.6 Product- and technology-dependent safety instructions ..................... 12 2.7 Personal protective equipment ............................................................ 13 2.8 Duties of the operator .......................................................................... 13 2.9 Safety installations ............................................................................... 14 2.10 Operator operating positions .......................................................... 15

3 General instructions concerning property damage and product damage 16 4 Scope of supply ..................................................................................... 17 5 About this product ................................................................................ 18

5.1 General information ............................................................................. 18 5.2 Product Description .............................................................................. 18

Control box left side - exterior .................................................................. 19 Control box right side - exterior ................................................................ 19 5.2.1 Rack, work piece detection station ............................................. 20 Control box ................................................................................................ 21 5.2.2 Processing with press station ...................................................... 22 Control box ................................................................................................ 23 Circuit diagram for hydraulic press ........................................................... 23 Hydraulic power unit description .............................................................. 24 5.2.3 High rack storage station ........................................................ 25 Control box ................................................................................................ 26 Zero point reference position ................................................................... 27 5.2.4 Conveyor R901371451 ................................................................ 28 5.2.5 Separating rack R115801073 ...................................................... 28 Filling the racks .......................................................................................... 29 5.2.6 Picking unit R115801073 ............................................................. 30 5.2.7 Sensors ........................................................................................ 30 5.2.8 Light conductor R115801073 ...................................................... 31 5.2.9 Machine control panel VAM 40 R115801080 ............................. 31 5.2.10 Maintenance unit R480318553 .............................................. 32 5.2.11 Light barrier R901396882 ....................................................... 32 5.2.12 Pinning unit R115701062 ....................................................... 33 Replenishing pins ...................................................................................... 33

4/68 Bosch Rexroth AG Training system mMS 4.0 | R901429162/04.16

Contents

5.2.13 Portal R115701064 ................................................................. 34 5.2.14 Press R115701072................................................................... 35 5.2.15 High-stack storage R115701074 ............................................. 35

6 Technical data and dimensions ............................................................. 36 6.1 Technical data ....................................................................................... 36

6.1.1 Training system mMS 4.0 ............................................................ 36 6.2 Identification of the mMS 4.0 training system ...................................... 37

7 Operating and display elements ........................................................... 38 7.1 EMERGENCY STOP button ..................................................................... 38 7.2 Operating elements on the training system ......................................... 39

7.2.1 Machine control panel VAM ........................................................ 39 7.2.2 HMI small operating panel VCP ................................................... 40

8 Transport and storage .......................................................................... 41 8.1 Delivery and unpacking ......................................................................... 41 8.2 Transport ............................................................................................... 42

8.2.1 Transport inside the building ....................................................... 42 8.2.2 Transporting between two buildings ........................................... 43

8.3 Storage .................................................................................................. 44 9 Set-up, installation and commissioning ................................................ 45

9.1 Setting up the mMS 4.0 training system ............................................... 45 9.2 Check the pneumatic supply ................................................................. 46 9.3 Check electric installation ..................................................................... 47 9.4 Installing installation and stations......................................................... 48 9.5 Commissioning the training system ...................................................... 52 9.6 Check the EMERGENCY STOP circuit ..................................................... 52

10 Description of the operating functions ................................................. 53 10.1 Select the operating mode ............................................................... 53 10.2 Manual mode operation .................................................................. 54 10.3 Operating Single Step mode ............................................................. 54 10.4 Automatic mode operation .............................................................. 55 10.5 Homing mode operation .................................................................. 56 10.6 „Check Stock“ function ..................................................................... 56 10.7 „Clear Stock“ function ...................................................................... 56 10.8 Description of the buttons ............................................................... 57

11 Fault assistance .................................................................................... 59 11.1 Faults ................................................................................................ 59 11.2 Troubleshooting ............................................................................... 60

12 Maintenance and inspection ................................................................ 61 12.1 General information ......................................................................... 61 12.2 Maintenance and inspection schedule ............................................. 62

13 Maintenance work ................................................................................ 63 13.1 General information ......................................................................... 63 13.2 Maintenance schedule ..................................................................... 64

13.2.1 Working materials, consumables, tools, measuring devices .. 64 13.2.2 Replace parts .......................................................................... 65

14 Disposal ................................................................................................ 65 15 Declaration of conformity ..................................................................... 66


About this documentation

1 About this documentation

1.1 Validity of the documentation

This documentation describes the “mMS 4.0” training system.

For reasons of simplicity, we refer to it as “mMS 4.0” in the following.

This documentation is intended for assemblers, operators, service technicians

and the system end-user.

This documentation contains important information on how to assemble,

transport, commission, operate, use, maintain and disassemble the product safely

and properly and to resolve simple faults independently.

Read the documentation in full, in particular, the “Safety information” chapter

before you start working with the product.

1.2 The following signs and symbols are used in this manual:

Activity symbol: The text next to this symbol describe activities which are

to be carried out from top to bottom in the indicated sequence.

1.3 Required and supplementary documentation

In addition to this manual on the (turnkey) mMS 4.0 training system, the following

additional documentation applies:

All user manuals for the components.

These can be viewed on the enclosed CD.

Documentation about mMS 4.0 from Bosch Rexroth.

1.4 Layout of documentation

To be able to use this documentation quickly and safely, standard safety

instructions, symbols, terms and abbreviations are used. These are explained

in the following sections to aid understanding.

1.4.1 Safety instructions

This documentation contains safety information prior to the directions whenever

there is a risk of personal injury or damage to equipment. The measures

described to avert danger must be observed.



The safety instructions are structured as follows:

Warning sign: Draws attention to the hazard

Signal word: Indicates the seriousness of the hazard

Type and source of danger: Designates the type and source of danger

Consequences: Describes the consequences of non-compliance

Precaution: Indicates how to avoid the danger

Table 1: Risk classes according to ANSI Z535.6-2006

Warning sign/signal word Meaning

DANGER Identifies a dangerous situation that will result in death

or serious injuries if not avoided/prevented.

WARNING Identifies a dangerous situation that could result in death

or serious injuries if it not avoided/prevented.

CAUTION Identifies a dangerous situation that could result in minor

to serious injuries if not avoided/prevented.

NOTE Indicates property damage: The product or the damage

can sustain damage.

1.4.2 Symbols

The following symbols denote suggestions which are not safety-relevant but

improve the comprehensibility of the documentation.

Table 2: Meaning of symbols

Symbol Meaning

If this information is not observed, the product will not

be able to be used or operated optimally.

Individual, independent action

1.

2.

3.

Numbered instruction:

The numbers indicate that the actions follow each other.

SIGNAL WORD Type and source of danger

Consequences for non-compliance

Measures on hazard avoidance



1.4.3 Abbreviations

The following abbreviations are used in this documentation:

Table 3: Abbreviations

Abbreviation Meaning

OCE Open Core Engineering

mMS 4.0 Modular Mechatronics System for Industry 4.0

Smart Device Android or iOS smart phone or tablet

HMI Human Machine Interface

Station One of three mMS 4.0 stations

Installation All three mMS 4.0 stations together

MDI Machine Data Interface, CNC manual data entry


Safety instructions

2 Safety instructions

2.1 About this chapter

The mMS 4.0 training system has been manufactured in accordance with

the general rules of technology. Nevertheless, there is the danger of personal

injury or property damage if this chapter and the safety instructions in this

documentation are not observed.

Read this documentation fully and thoroughly before you work with

the mMS 4.0 training system.

Keep the documentation in a place where there are available to all users

at any time.

Whenever passing on the Training system to third parties, include the required

documentation.

2.2 Intended use

The mMS 4.0 training system is a mechanical and electrical system with

pneumatics and/or hydraulics systems.

It may only be used to impart knowledge and expertise of advanced technical

education in the high-level programming language area and control engineering.

With respect to the set-up of whole assemblies and simulations, only the devices

and device sets are only used for the mMS 4.0 training system.

Operation is only permitted under the indicated operating conditions.

The mMS 4.0 training system is only intended for professional and not

for private use.

The mMS 4.0 training system made by Bosch Rexroth has been designed and

is intended for industrial power supply networks. Supplying the demo system

from different supply network requires additional disturbance suppression

measures (line filter, throttles, etc.).

Intended use also includes having thoroughly read and understood the safety

regulations, product information and operating instructions below, in particular,

the “Safety instructions”.

2.3 Improper use

Any other use than that described under intended use, is not intended use and

is therefore not authorized.

If unsuitable products are installed in safety-relevant applications, unintended

operating states may arise in the application which could cause personal injury

and/or property damage. Therefore, only use the product in safety-relevant

applications if such a use is specified and allowed in the product documentation.

For example in explosion-protected areas or in safety-relevant parts of a control

(functional safety).

Bosch Rexroth AG cannot assume liability for damage in the event of improper use

of the product. The user is solely responsible for the risks due to improper use.


Safety instructions

Improper use of the product is defined as in particular

Failing to the mMS 4.0 training system seriously in an appropriate manner

during the exercises and outside of lesson time,

Using the parts in a different training system,

Connecting or using other devices or device sets than that authorized

for the mMS 4.0 training system,

Combining or modifying pneumatic pressure circuits.

Supplying the system without supplementary disturbance suppression

measures (filters, throttles, etc) from non-industrial supply networks.

2.4 Staff qualification

2.4.1 Firms offering apprenticeships

Students and apprentices may only work on the mmS 4.0 training system:

Under direct supervision,

after being given appropriate instructions

by a instructor or trained member of staff.

The instructor working with the mMS 4.0 training system must be a trained

specialist familiar with the electrical pneumatic and mechanical device and

the mechatronics field.

The instructor must

give clear instructions when students or participants in the training program

are required to install control circuits in the mMS 4.0 training system,

inspect the installation and functional effects of the control circuit ensuring

safe use before switch on,

answers questions in a clear, understandable way.

Trained members of staff may also be used to supervise the mMS 4.0 training

system during the exercises.

These are qualified persons to be trained and instructed about:

the information given,

possible dangers in the event of improper use,

safeguards and safety measures.

Instructor

Trained personnel


Safety instructions

2.4.2 Transport, set-up, installation and commissioning

Work on the mMS 4.0 training system such as set-up, connection,

commissioning, and repair must only be performed by experts or persons with

sufficient qualifications and authorization who have been instructed to do so.

Persons instructed to work on the mMS 4.0 training system must be able to follow

the information in this documentation, and also, in the event of missing

information, and supplement missing information independently on account

of their professional qualifications.

2.4.3 Troubleshooting, maintenance and repair

Maintenance, repair, troubleshooting and fault removal require particular

knowledge. This work may only be performed by trained skilled workers!

Work on the electrical equipment must only be performed by a qualified

felectrician.

A qualified electrician is someone who can recognize possible hazards and

implement the appropriate safety measures due to their professional training,

knowledge, and experience, as well as their understanding of the relevant

conditions pertaining to the work to be done.

Only skilled personnel with special expertise and experience in pneumatic

components are allowed to work on the pneumatic system. Special knowledge

of pneumatics means that personnel must

– be able to read and understand pneumatic plans completely,

– in particular, fully understands the interdependencies of the installed safety

installations and

– are familiar with the function and arrangement of pneumatic components.

Only skilled personnel with special expertise in and experience of hydraulic

components are allowed to work in the hydraulics system. Specialist knowledge

of hydraulics means that the employee must

– be able to read and understand hydraulic plans completely,

– in particular, fully understands the interdependencies of the installed safety

installations and

– be familiar with the function and arrangement of hydraulic components.


Safety instructions

2.5 General safety instructions

Follow the valid regulations on accident prevention and environmental

protection.

Observe the safety regulations and provisions of the country in which

the product is used.

Only use Rexroth products when they are in a technically faultless condition.

Observe all information about the product.

Persons permitted to assemble, operate, disassemble or maintain Rexroth

products must not be under the influence of alcohol, other drugs or medication

which can impair responsiveness when doing so.

Only use accessories or spare parts approved by the manufacturer to prevent

hazards to persons owing to unsuitable spare parts.

Adhere to the technical data and environmental conditions given in the product

documentation.

If unsuitable products are installed or used in safety-relevant applications,

unintended operating states may arise in the application which could cause

personal injury and/or property damage. Therefore, only use the product in

safety-relevant applications if such a use is specified and allowed in the product

documentation.

You may only put the product into operation after it has been established that

the end product (e.g. a machine or installation) in which the Rexroth products

are fitted, meet the country-specific regulations, safety regulations and

standards for the application.

The product must not be put into operation unless this operating manual has

been read and understood.


Safety instructions

2.6 Product- and technology-dependent safety instructions

WARNING High electrical voltage

Danger to life, danger of injury due to electrical shock or severe injury!

Always de-energize the installation.

Secure the installation against being switched on accidentally.

Do not operate a device terminal box or sockets which are not connected

to the power supply (fuse boxes) of the mMS 4.0 training system. All of the

components not powered by the device's own electrical control boxes, but

using components (in use) installed in the mMS 4.0 training system are

unaffected by an EMERGENCY STOP circuit (and OFF switch). The mains

voltage continues to apply in the electrical control box.

Do not open the electrical control box. If opening is necessary, only have

the electrical control box open by a qualified electrician.

When connecting additional consumers to the mMS 4.0 training system, only

use ones approved by the manufacturer.

Only operate the mMS 4.0 training system from a supply with a functioning FI

circuit-breaker or protective earthing.

The energy cables which carry 230 V AC must not be disconnected from

the drive while the system is in operation.

Manipulated and/or non-functioning safety devices and safeguards!

Major risk of injury

Shut off the installation immediately.

Skilled personnel must remedy the fault or manipulation immediately.

Hazard caused by incorrect assembly and installation

Major risk of injury during live operation!

Assembly works and commissioning work may only be carried out

by employees at Bosch Rexroth or specialists instructed to do so.

This also applies when the product is returned to service after repair work.

Maintenance work must only be carried out by skilled workers.

WARNING Danger of crushing by the system!

Risk of injury!

Do not remove any safeguards (e.g. door switches, isolating elements)

Under no circumstances remove safety instructions or signage - make sure

they are installed.


Safety instructions

2.7 Personal protective equipment

The personal protective equipment for users of the product comprises:

Safety shoes for use during set-up/transportation of the training system

Safety gloves and eye protection for use during installation of pneumatic and

hydraulic components

All components of the personal protective equipment must be intact.

2.8 Duties of the operator

The operator must do the necessary prerequisites for the Installation and set-up

of the mMS 4.0 training system and

shall ensure that the mMS 4.0 training system is installed safely by its

personnel and/or persons instructed by him to carry out the work; he shall in

particular make sure that the underground / the surface of the table

– has sufficient load-bearing capacity

– is level and horizontal;

shall ensure compliance with accident prevention regulations (UVV), safety

regulations of the trade associations and other in-house, local requirements.

He shall instruct his employees and/or third party firm employees on possible

hazards at the place of installation.

The operator must provide adequate illumination around the area of installation

of the training system.

He must train his personnel on the following topics at regular intervals:

Observing and using the operating manual and complying with the legal

requirements;

Using the mMS 4.0 training system as intended;

Following the instructions of factory security offices and the operating

instructions from the operator;

Behavior in the event of an emergency.


Safety instructions

2.9 Safety installations

To protect personnel, the mMS 4.0 training system must be equipped with

the following safety installations:

EMERGENCY STOP buttons one for each station to complete

the EMERGENCY STOP circuit

Pneumatic and/or hydraulic pressure limitation

Mechanical safeguards

The above devices are described in greater detail as follows.

The front of the mMS 4.0 training system has an EMERGENCY STOP button

placed within easy reach.

The EMERGENCY STOP button must be pressed to prevent danger to personnel

or the mMS 4.0 training system.

A component with the EMERGENCY STOP button must be connected

to the mMS 4.0.

If a component with the EMERGENCY STOP button is not connected to the mMS

4.0, the EMERGENCY OFF button is not closed and thus will not be able

to operate.

Pressing the EMERGENCY STOP button puts the system out of operation,

i.e. the control and the drive is switched off; the mMS 4.0 training system is

stopped. The power supply unit, the PLC and the drive continue to be powered

by electricity.

The training system may only be operated at a maximum pneumatic operating

pressure of 5-6 bars. The pressure setting is made at the factory. The

compressed air is switched off when an EMERGENCY STOP is actuated.

The maximum hydraulic operating pressure for the training system is

50 bar. The pressure setting is made at the factory. The hydraulic

power unit is switched off when an EMERGENCY STOP is actuated.

To monitor circuitry in training mode, appropriate pressure gauges/pressure

limiting valves may need to be integrated in the exercise circuitry. The instructor

is responsible for doing so.

The following mechanical safeguards are available:

Contact protection for the racks, pinning unit

Contact protection on the conveyor belt

Contact protection on the press

Electrical control box for 115-230 V AC components

Casing of station 3

Additional control technology safeguards are affixed:

Light barriers on the conveyor belts

EMERGENCY STOP buttons

Pneumatic pressure limitation

Hydraulic pressure limitation

Mechanical safeguards

Control technology safeguards

WARNING Risk of injury!

Do not remove any light barriers (e.g. from the conveyor belts)

Under no circumstances remove safety instructions or signage - make sure

they are installed.


Safety instructions

2.10 Operator operating positions

The training system must be placed on a level base as upright as possible,

and the guide rollers must be locked into place. In order to teach and learn

the procedures on the mMS 4.0 training system, the following space is provided

for the mMS 4.0 training system:

Fig. 1: Space requirement (in cm), mMS 4.0 training system

Fig. 2: Space requirement (in cm), mMS 4.0 training system

The following teaching stations are provided depending on how the mMS 4.0

training system is used:

Table 4: Teaching stations for an mMS 4.0 training system

Work step Number of persons

working on the system

Number of persons

working on the system

per station

Alignment 1-4 1-3

Control points

(per station)

2 1-2

Teaching stations

80

0-80

400

234

80 80

234

240

80 80

80

0-80


General instructions concerning property damage and product damage

3 General instructions concerning property damage

and product damage

NOTE Installation pressurized and electrical voltage is present!

Damage to property!

Make sure that the system is completely depressurized.

Do not undo any lines, connections and components while the system

is under pressure.

Do not undo any plug connections while the installation remains energized.

De-energize the mMS 4.0 training system.

Incorrect adjustment of the pressure relief valves and pressure switches in

pneumatic and hydraulic components!

Damage to property!

The pneumatic and hydraulic components must only be operated at

the stipulated pressure values.

Risk to electrical equipment caused by high currents!

Damage to property!

Make sure overcurrent protection is available.

Secure the mains plug by disconnecting the mains plug.


Scope of supply

4 Scope of supply

The mMS 4.0 training system comes pre-packaged as a turnkey system.

It comprises three modules delivered on three wooden crates. The wood is heat

treated.

These stations stand on a base pallet which can be removed from four sides

by means of a pallet truck.

The upper parts of the wooden crate, comprising 4 side panels and a lid

are screwed and nailed together to bottom pallet.

Table 5: Dimensions of the wooden boxes

Designation Unit Value

Dimension Length mm 2,100

Width mm 800

Height mm 1,800

Table 6: Weight of the wooden boxes


Weight kg 100

Fig. 3: Crate with marking

The following information appears on the crate:

1 Transport instructions or warning

notices as required

2 Shipping code/barcode

3 Delivery note in a plastic pouch

4 Printed label: Gross/(where

applicable) net weight

5 Printed label: Packaging to IPPC

standard

The scope of supply of the mMS 4.0 training system includes:

3 Stations with function modules

Optional accessories (as per delivery note; 2nd sample inside)

Product documentation

1

5

4

2

3

Dimensions of the wooden boxes

Weight of the wooden boxes

Scope of supply


About this product

5 About this product

5.1 General information

The following sections of this operating manual illustrate

a variant of the mMS 4.0 training system and its components for example

purposes.

The three stations are described individually.

All operating manuals of the individual industrial components can be found

in the enclosed CD.

5.2 Product Description

The cube assembly installation comprises three stations:

Rack, workpiece detection station

Processing with pneumatic press station

High rack storage station

The three stations - rack, workpiece detection, processing with pneumatic press

and warehouse are arranged next to each other. They are connected to each other

mechanically, pneumatically and electrically. The cube assembly installation allows

the operator to set up, operate and monitor what is a fully automated process.

Fig. 4: Training system mMS 4.0

1 Rack station

2 Processing with

pneumatic/hydraulic press station

3 High rack storage station

2 3

1


About this product

2 1

3

4

2

3

1

4

5

Control box left side - exterior

Identical for all stations.

Fig. 5: Control box left side - exterior

1 Main switch of station

2 Transition plug signals

and emergency stop circuit

3 Connection cable 230 V AC

4 Ethernet feed-through

5 Maintenance unit

Control box right side - exterior

Identical for all stations.

Fig. 6: Control box right side - exterior

1 Ethernet feed-through

2 Connection socket 230 V AC

3 Transition plug signals

and emergency stop circuit

4 Compressed air feed-through


About this product

5.2.1 Rack, work piece detection station

The rack station consists of a table with lockable guide rollers and the following

function modules assembled on top of it:

2 separating racks

Conveyor belt

Sensors for materials testing

Picking unit

Machine control panel

Maintenance unit

Electrical supply with signal processing

– Main switch on left-hand side of the system

– Connector to right-hand/left-hand station

– Mains supply, fuses

– 3 emergency stop relays

– Profibus coupler

Programmable logic controller XLC L25 with supplied PLC software

Two separation racks offer space for 10 work pieces each. The placement status

is monitored by microswitches. A pneumatic cylinder pushes the bottom most

workpiece in the stack onto a conveyor that runs it past four test stations.

One optical, capacitative and inductive sensor each acquires the material

properties with a pneumatic cylinder acquiring the contour. The test result

is saved in the controller. A work piece can be removed from the conveyor belt

by means of a pneumatic cylinder. At the end of the conveyor, a sensor is used

to determine that a work piece has arrived and to stop the conveyor.

Fig. 7: Rack station

1 Separating racks

2 Conveyor belt

3 Sensors

4 Profibus coupler

(behind conveyor belt)

5 Picking unit

6 Maintenance unit

1

2

6

3 4 5


About this product

Control box

Fig. 8: Control box station rack

1 3 emergency stop relays

2 Programmable logic controller

8 inputs/outputs

3 Switching relay

4 Fuses

5 Power supply unit

3

4

2

5

1


About this product

5.2.2 Processing with press station

The processing with pneumatic/hydraulic press station comprises a table with

lockable guide rollers and the following function modules assembled on top of it:

Pinning unit

Portal with vacuum suction gripper

Pneumatic or hydraulic press

Machine control panel

Conveyor belt

Maintenance unit

Light barriers






– Field bus, Profibus

Programmable logic controller XLC L25 with supplied PLC software

The work piece is moved from the previous conveyor belt to the conveyor for this

station. It passes a light barrier and 2 pins are applied to it in the pinning unit.

Afterwards, it is moved further along by the conveyor belt until the work piece

is transferred into the press with the portal vacuum suction gripper. The second

work piece comes from the previous station and is transported to the press in the

same way. A pneumatic cylinder in the press presses the work pieces together.

The portal's vacuum sucker transfers the work piece to a conveyor for transport

onward.

Fig. 9: Processing station

1 Pinning unit

2 Conveyor belt

3 Sensors

4 Portal

5 Press

6 Maintenance unit

6

2

3 4 1 5


About this product

Control box

Fig. 10: Control box processing station



8 inputs/outputs, field line

3 Switching relay

4 Fuses

5 Power supply unit

Circuit diagram for hydraulic press

The circuit diagram for the press with hydraulically cylinder is shown as follows.

Fig. 11: Hydraulic power unit circuit diagram

3

4

2

5

1


About this product

Hydraulic power unit description

The hydraulic power unit is set to a pressure of 50 bar at the factory.

An electrically-operated 4/2 directional control valve can be used to switch off

depressurised circulation and activate the system pressure. Afterwards,

the application can be switched optionally with the manually-operated

or electrically-operated 4/3-way valve.

Fig. 12: Hydraulic power unit set-up

1 Engine with internal gear pump

2 10l oil tank

3 Pressure gage

4 Pressure relief valve

5 Electrically-operated 4/2

directional control valve

6 Manual 4/3 directional control

valve

7 Electrically-operated 4/3

directional control valve

1

2

4

3

5

6

7


About this product

5.2.3 High rack storage station

The high-stack storage station consists of a table with lockable guide rollers

and the following function modules assembled on top of it:

High-stack storage with 3x5 storage bins

Cartesian robot or two servo motor axles

Casing with safety doors

Conveyor belt

Maintenance unit

Light barriers






– Field bus, Profibus, SERCOS III

Programmable logic controller MLC L45 with supplied PLC software

The high-bay warehouse provides 15 spaces. The work pieces are transported by

a cartesian robot to their storage locations where a pneumatic boom deposits

them. The encoder of the servo drives does the positioning.

Fig. 13: Processing station

1 Cartesian robot

2 Conveyor belt

3 Sensors

4 High rack storages

5 Maintenance unit

5

3 4 1

2


About this product

Control box

Fig. 14: Control box high-stack storage station



8 inputs/outputs, field line

3 Switching relay

4 Mains contactors

5 Fuses

6 Power supply unit

7 Line filter

8 Drive controller

3

5

2

6

4

7

8

1


About this product

Zero point reference position

The zero point of the two axes of station 3 is stored by the batteries oft he

encoder cables oft he drives even in switched off mode. In case that a battery is

empty and replaced, the zero reference position is to be settled again. Both axes

must be moved to the position of the zero point. Doin this in the program in

explained in the documentation of the IndraDrive Cs. The axes must be move

mechanically to the right position. The right position is:

Horizontal axis:

Outer left edge to edge of carriage: 120mm

Vertical axis:

Lower edge of extrusion body to upper edge of flange: 189mm

Fig. 1: Reference zero point station 3

120mm

18

9m

m


About this product

5.2.4 Conveyor R901371451

Conveyor comprising Rexroth aluminum profile 60 x 60 mm, 8mm grooves, 800

mm belt length, 50 mm -width. With knife edges for lining up multiple conveyors.

Fitted with 2 light barriers at the ends of the conveyor and an additional light

barrier downstream of the picking unit. Do not remove the light barriers from

ends of conveyor. Contact protection for the deflectors.

Fig. 2: Conveyor R901371451

5.2.5 Separating rack R115801073

Separating rack to house at least 10 work pieces with dimensions

50 x 50 x 25 mm (LxWxH). Can also hold workpieces with inserted pins.

Pushed out through pneumatic cylinders. Monitoring of filling level height via

a micro switch with roller lever. Can be arranged flexibly on either side of

the conveyor R901371451.

Fig. 3: Separating rack R115801073


About this product

Filling the racks

To load the separating racks with workpieces proceed as follows:

Load aluminum cube half 50 x 50 x 25 mm into the right-hand rack from

above, while open.

Load the workpiece using two fingers and guide it as you move it down.

Load black plastic cube half 50 x 50 x 25 mm into the left-hand rack

downward, while open.

Fig. 4: Sliding in workpieces


About this product

5.2.6 Picking unit R115801073

Picking unit comprising a ramp and a cylinder to remove the workpieces.

Can be arranged flexibly on either side of the conveyor R901371451.

Fig. 5: Picking unit R115801073

5.2.7 Sensors

Sensors from left to right comprising an optical sensor R115801076, inductive

sensor R115801074, pneumatic cylinder R115801075 and capacitive sensor

R115801077 for determining the quality of work pieces. Can be mounted flexibly

on each side of the conveyor R901371451.

Fig. 6: Sensors


About this product

5.2.8 Light conductor R115801073

Light conductor with fiber-glass cables, emitter and receiver in one housing. Can

be mounted flexibly onto the conveyor R901371451.

Fig. 7: Light conductor

5.2.9 Machine control panel VAM 40 R115801080

For controlling the training system. With attachment system lockable for grooved

plates. With 30 short-stroke buttons, a authorization key switch, a feed override

dial, a spindle override dial, an On-Off button and 1 EMERGENCY STOP button.

The VAM40 must be connected to ensure the EMERGENCY STOP button

of the entire system is closed.

Fig. 8: Machine control panel VAM40


About this product

5.2.10 Maintenance unit R480318553

3/2- directional shut-off valve, manually-operated, maintenance unit with filters

and pressure control valve for lowered compressed air supply, with pressure

gauge. Pressure switch for switching off feed when air pressure is too low.

Electrically operated shut-off valve for EMERGENCY STOP situation.

Fig. 9: Maintenance unit

5.2.11 Light barrier R901396882

Light barrier with emitter and receiver in M12 round construction.

Can be mounted flexibly onto the conveyor R901371451.

Fig. 10: Light barrier


About this product

5.2.12 Pinning unit R115701062

Pinning unit for attaching connection pins. Comprising a tower with press function,

pin storage, an ejector and a slide-in cylinder. For attachment onto the conveyor

R901371451. Pins can be loaded easily from the top. Filling level is monitored

by sensors.

Fig. 11: Pinning unit

Replenishing pins

To load the pinning unit with pins, proceed as follows:

Add a sufficient quantity of pins to the plexiglas tubes on the left and right.

Make sure to continue reloading the pins and that sufficient numbers are

present.

Fig. 12: Replenishing pins


About this product

5.2.13 Portal R115701064

Portal for transporting work pieces in the pick and place application.

Slotted cylinder for transporting along the Y axis, piston rod cylinder

for conveying along the Z axis. Vacuum suction gripper with Venturi nozzle acting

as a gripper.

Fig. 13: Portal


About this product

5.2.14 Press R115701072

Press with pneumatic or hydraulic stamp for joining 2 work pieces of dimensions

50 x 50 x 25 mm (LxWxH). Cylinder with throttle check valves for pushing

the work piece in and out.

Fig. 14: Press pneumatic/hydraulic

5.2.15 High-stack storage R115701074

High-stack storage for storing/removal of work pieces. Each of the three 3 rows

can be used to store 5 work pieces. 2-axis warehouse robot with servo motors.

Pneumatic rotary module, cylinder, and gripper.

Fig. 15: High rack storages


Technical data and dimensions

6 Technical data and dimensions

6.1 Technical data

6.1.1 Training system mMS 4.0

Table 7: Technical data for mMS 4.0 training system


Total weight kg 300

Dimension Max. length mm 2400

Max. width mm 740

Max. height mm 1900

Min. operating temperature °C + 20

Max. operating temperature °C + 60

Place of installation Closed room

Ambient temperature °C + 5 to +55

Max. relative air humidity % 90 at 20 °C

Max. installation height m 1000 above sea level

Pneumatics Max. operating pressure bar 6

Min. operating pressure bar 4

Supply Connection- / operating

voltage

V 115-230 (AC)

Control voltage V 24 (DC)

Frequency Hz 50-60

Nominal power kW

Fuse A 16

Protective earthing PE (ground or

FI circuit breaker)

A-weighted continuous sound level

(at workplace of operating personnel –

during pumping)

dB (A) < 70


Technical data and dimensions

6.2 Identification of the mMS 4.0 training system

A name plate for the mMS 4.0 training system is found on the system.

The characteristics of the mMS 4.0 training system are also indicated here.

In order to identify the mMS 4.0 training system (e.g. to order spare parts),

the name plate needs the following information on it:

1 Material number

2 Material short text

3 Optional – characteristic value of output 1, e.g. max. operating pressure - 50 bar

4 Optional – characteristic value of output 2, e.g. displacement – 1.6 cm³/U

5 Production state

6 Optional – CE mark

7 Date of production, e.g.13W02 -> 2013 calendar month 02

Fig. 16: Name plate


Operating and display elements

7 Operating and display elements

7.1 EMERGENCY STOP button

An EMERGENCY STOP button must be placed on the front of the training system.

All operating modules (machine control panels) have an EMERGENCY STOP

button which can close the EMERGENCY STOP circuit.

In the event of a risk to person or machine, switch off the mMS 4.0 training

system with the button.

Actuating the EMERGENCY STOP button interrupts the power supply.

All work procedures are stopped right away and any hazardous control currents

(servo drive) and thus all movements are switched off.

There is a local EMERGENCY STOP circuit for the individual station and a global

EMERGENCY STOP circuit for the entire installation.

The circuit diagram can be viewed in the enclosed CD.

Do not use the EMERGENCY STOP button to switch off the training system

normally!



7.2 Operating elements on the training system

7.2.1 Machine control panel VAM

Fig. 17: Control elements in the training system– machine control panel VAM

1 EMERGENCY STOP button

2 Authorization key switch

3 2 x 15 short-stroke buttons

4 Feed override dial

Spindle override dial

5 On Off button

6 Connector Profibus,

EMERGENCY STOP circuit,

power supply

The purpose of the EMERGENCY STOP button is to bring the system

to a standstill in the event of a danger.

Different permissions can be allocated with the authorization key switch with

different keys.

- Position 0 is manual mode.

- Position 1 is homing mode.

- Position 2 is automatic mode.

- Position 3 is single step mode.

These are used to control the system. They comprise the start, stop and reset

buttons. These buttons can also be used in manual mode to control all actuators.

Use the “Start” with homing function button to initiate the programmed motion

sequences.

The Stop button stops it again.

Use the Reset button to start the three EMERGENCY STOP relays.

The Reset button must be pressed before each start.

The speed of the drives can be controlled with these two dials. These are only

active for station 3.

For switching the power on/off. These are only active for station 3.

Connection of VAM to stations. Profibus for closing the bus circuit. A second

connector for the power supply of the VAM and for closing the EMERGENCY

STOP circuit.

1. EMERGENCY STOP button

2. Authorization key-operated switch

3. 2 x 15 short-stroke buttons

4. Feed override dial

Spindle override dial

5. On Off button

6. Connector Profibus,

EMERGENCY STOP circuit,

power supply

1

2 3

5

6

4



7.2.2 HMI small operating panel VCP

The HMI small operating panel VCP 25 R961008358 is an optional, additional

visualization/control possibility and can be ordered separately.

Fig. 18: Control elements in the training system– small control panel VCP

1 HMI control panel

2 Snap-In attachment system

3 Contact protected 4mm lab

connector 24 V DC, 0 V,

functional earth

For control and monitoring of the workflow in a station from a

touchscreen.

Attachment system for grooved plates with 8 mm grooves, 25 mm grid.

Contact protected 4mm lab connector 24 V DC, 0 V, functional earth.

1. HMI control panel

2. Snap-In attachment system

3. Contact-protected 4mm lab socket

1

2

3


Transport and storage

8 Transport and storage

8.1 Delivery and unpacking

Screwdriver, knife, pry bar.

Transport the wooden crate n upright to the place of unpacking using a fork lift

truck or pallet truck.

Open the wire ties on the wooden crate using a knife.

Using a screwdriver, undo the front of the wooden crates and put them away.

Open up the plastic packaging using a knife.

Carefully lift each station of the mMS 4.0 training system down from the pallet

and remove from the crate.

Carefully remove the cable ties and wire ties and dispose of them

appropriately.

Dispose of the pallet and wooden box properly or store appropriately for

subsequent use.

Any transport damage and defects must be noted right away and reported

in a written damage report.

Required tool:

CAUTION Risk that the training system may fall over.

Risk of injury when lifting and transporting the machine!

When lifting and transporting the machine, always carefully do so with at least

two persons in order to prevent it from dropping.

Lift the mMS 4.0 training system by hand or with a floor conveyor.

Procedure



8.2 Transport

8.2.1 Transport inside the building

The mMS 4.0 training system can be moved and installed in a different location

any time.

Note the following during transport:

Ensure that the doors and passages are of sufficient size.

Remove attachment parts and device sets that are not needed beforehand.

Disconnect the 3 stations from all connections.

Carefully shift the individual stations.

Proceed as follows:

Disconnect the mains plug and stow away the power cable.

Remove the compressed air supplies.

Disconnect all connecting cables between the stations.

Move the training system to the new place of installation.

Move the mMS 4.0 training system on a fixed and level base.

Lock the parking brakes on the castors.

Connect up the electrical and pneumatic supplies to the system.

The mMS 4.0 training system can be put into storage or connected

to the energy supply again.

Whenever putting the system down during transportation and when using

a table with wheels, always lock the parking brakes on the wheels.

General information

Transport








8.2.2 Transporting between two buildings

Note the following during transport:

Ensure that the doors and passages are of sufficient size.


Disconnect the 3 stations from all connections.

Carefully shift the individual stations.

Proceed as follows:

Disconnect the mains plug and stow away the power cable.

Remove the compressed air supplies.

Disconnect all connecting cables between the stations.

Transport the mMS 4.0 training system as follows:

Place each station of the mMS 4.0 training system onto a pallet.

Prevent the stations of the mMS 4.0 training system from falling using belts

or plastic ties; You can use the original transport crates.

Protect each station of the mMS 4.0 training system against moisture.

Transport the pallet with the mMS 4.0 training system with a fork lift truck

or similar.

Move the mMS 4.0 training system on a fixed and level base.

At the predesignated position carefully lift each station of the mMS 4.0 training

system out of the transport box or down from the pallet.

Remove any packaging and securing ties with belts and plastic ties.

Connect the voltage supply and compressed air supply.

General information

Transport








8.3 Storage

Table 8: Storage conditions


Footprint of the mMS 4.0 training system mm approx. 4000 x 2340

Condition of the footprint level

Min. storage temperature °C +5

Max. storage temperature °C +55

Relative air humidity % 25 - 70

Max. installation height m 1000 above sea level

Requirements for storing the stations of the training system:


Remove the connecting cables.

Put the stations of the mMS 4.0 into storage as follows:

Place the stations of the training system onto a pallet

Protect the training system from dust and moisture.

The stations of the mMS 4.0 training system have now been placed into

storage.


Set-up, installation and commissioning

9 Set-up, installation and commissioning

9.1 Setting up the mMS 4.0 training system

Perfect execution of the set-up requires that:

delivery, transport or unpacking has been carried out properly as per chapter 7.2.2,

all of the required parts are in range and in a functional condition,

required auxiliary equipment, such as lifting tools, tables, are present.

Before the final set-up, please note the following points:

Make sure the required clearance for the mMS 4.0 training system and

the safety clearances to other fixed installations is present (for specifications,

see Fig. 1: Space requirement (in cm), ). Any possible attachment parts

should be taken into account.

Check the levelness of the installation surface.

Make sure that an electrical connection is present.

Make sure there is sufficient lighting at the place of installation.

The following must be taken into account during installation:

Check alignment of the mMS 4.0 training system at the place of installation.

Lock the castors of the stations.

Connect each station with each other mechanically.

Also connect the electrical and pneumatic connections.

NOTE Risk of anomalies, deviations, faults, defects during set-up or inspection

Risk of damage!

Do not put the mMS 4.0 training system in operation or place it immediately

out of service.

Find the causes of the fault and fix the defect.

Replace the damaged part.

Preparations for the set-up

Installation



9.2 Check the pneumatic supply

The mMS 4.0 training system is completely pre-assembled and tested at the

factory. During transportation, however, faults or damage may arise on the mMS

4.0 training system.

Before commissioning of the pneumatic system always check

the hose system for damage;

the proper seating of the hose couplings;

whether any of the parts can be damaged;

whether all of the attachment parts are properly connected;

Fig. 19: Pneumatic diagram profile trolley

Connect each station's maintenance unit to the air supply which is on

the extreme left.

Next, connect the stations together by making a connection between

the shutoff valve on each station with the maintenance unit of the next station.

Fig. 20: mMS 4.0 installation

Observe the shutoff valves for the air supply on each station.

The air supply is passed on from each station to the next.

The pneumatic circuit diagrams of each station can be found in the enclosed

documentation CD.

Connection



9.3 Check electric installation

To install the mMS 4.0 training system, it is required that

Each station of the training system mMS 4.0 has been set up properly

(see chapter 9.1 Setting up the mMS 4.0 training system) and is complete,

the correct connection voltage and fuse protection is available power supply

on the customer side,

Work on the electrical equipment of the training system must be performed by

a specialist electrician only,

no cables are damaged;

The connection cables are installed in a way that prevents it from being

crushed, driven over, kinked, stressed or covered.

The electrical control box cannot be opened and tampered with.

No additional consumers are connected.

Check the electrical fuse protection is correct and sufficient.

Connect the mains plug to the first and last station to the power supply

of the customer-side socket (110-230V AC).

Connect each station with each other.

All other stations are supplied via the connecting cables.

The electrical supply of the mMS 4.0 training system is established.

The electro cabinet can be viewed in the enclosed CD.

The electric circuit diagrams of each station can be found in the enclosed

documentation CD.

Prerequisites



9.4 Installing installation and stations

Pneumatic supply

The air feed should be connected to the station at the extreme left.

Connect the Ø6mm air supply hose to the maintenance unit.

Fig. 21: Compressed air feed connection

CAUTION Danger caused by lashing hoses.

Risk of injurycaused by compressed air!

Before switching on the system, make sure all compressed air hoses have

been depressurized.

Do not connect pneumatic hoses under pressure.

CAUTION Dangerous electrical voltage.

Death or serious injury!

Extracting current from the mains supply is prohibited!

Do not make any modifications to conductive parts!



The remaining compressed air supply is transmitted from station to station.

Fig. 22: Compressed air connection between two stations

Setting the pressure reducer

Notice: The pressure reducer is set to a pressure of 6 bar at the factory.

If the pressure reducer needs to be re-adjusted, proceed as follows:

Pull the cap upwards.

Set the required pressure by turning the cap.

Press the cap downwards.

Do not adjust the system pressure! The pressure switch for the emergency stop

circuit is set to this 6 bar system pressure.



Electrical power supply

Operating an individual station

The following aspects must be satisfied to operate a single station:

The connector to the transfer connectors for signals and emergency stop

circuit must be pluggable on both sides.

If not, plug the terminating plug/-socket onto the transfer module and screw

in firmly.

The emergency stop circuit of the station is not closed until the terminating

plug/socket is plugged into the transfer connector.

Fig. 23: Terminating connector plugged in

The power supply connector is next to the main switch.

It must be connected to the electricity cable with an earthing-pin plug.

Afterwards, the station can be connected to 110 – 230 V AC.

Fig. 24: Connecting the power supply



Entire installation (3 Stations)

The following aspects must be satisfied to operate the entire installation:

The transfer connectors for signals and emergency stop circuit must

be connected to both the stations on the right and left.

With the first and last station, the terminating connectors must be plugged

into the transfer connectors for signals and emergency stop circuit as for

the individual stations.

If not, plug the terminating connector/-socket into the transfer module.

The emergency stop circuit of the installation is not closed until the terminating

connector/socket are plugged into the transfer connector and the stations

are connected to each other.

Fig. 25: Connecting the transfer and terminating connectors

The power supply connectors must be connected to the left-hand station.

With the left-hand station, the connection cable must be connected to the

current cable with an earthing-pin plug and can be connected to 110-230V AC.

Fig. 26: Connecting the power supply



9.5 Commissioning the training system

Switching on the training system

The electrical / pneumatic supply and installation has been connected properly.

The functional test has been carried out.

There are no tools, cleaning cloths or other objects in the mMS 4.0 training

system.

The accessibility and the function of the EMERGENCY STOP buttons

is assured.

The training system is on a level ground and the rollers are locked.

All workpieces are removed from the installation and the high-stack storage.

The racks are filled with workpieces.

The pinning unit is filled with workpieces.

Each time the exercise is set up, examine the machine for:

– Functional reliability,

– Safety from injury.

Depending on the operating state, note the following before switching it on:

Make sure the mains plug is plugged in for the power supply of the mMS 4.0

training system.

Where necessary, unlock the EMERGENCY STOP button.

9.6 Check the EMERGENCY STOP circuit

A manual check of the EMERGENCY STOP circuit is done by pressing the

EMERGENCY STOP button after booting up each station (PLC in “RUN”).

It is now not possible to run the machine. Unlock the EMERGENCY STOP

button again and press the Reset button of each station. The system is again

ready for operation.

The power pack (115-230 V) in the control box continues to carry current even

when the EMERGENCY STOP voltage is active.

Requirements:

Switch on the machine as follows:


Description of the operating functions

10 Description of the operating functions

10.1 Select the operating mode

The operating modes are the same at each station.

The following operating modes are present in the control system:

Manual mode: Authorization key switches of the machine operating panel

to position 0.

Each actuator can be retracted and extended individually.

The buttons are located on the left-hand field of the short-

stroke buttons. The conveyor belt can be moved into both

directions with the 2 “Conveyor Belt” buttons.

Single Step mode: Authorization key switches of the machine operating panel

to position 3.

The workflow in the installation is the same as in automatic

mode. Every logical step must be passed on with the “Start”

button.

Fig. 27: Switching positions 0-3 of the authorization key switch

Automatic mode: Authorization key-switches of the machine operating panel

to position 2.

The PLC program is processed automatically. Work pieces

are conveyed from right to left in the installation. Beginning

with station 1 (work piece detection) via station 2 (work

piece processing), to station 3 (work piece storage).

Homing mode: Authorization key-switches of the machine operating panel

to position 1.

When pressing the “Start” button, all actuators are moved

to the home position.

CNC mode: Only possible for station 3. This operation mode is explained

in the operating manual of the R901430882 conversion set.

The station 3 is run as a 3-axis CNC.



10.2 Manual mode operation

To launch the existing programs at each station in manual mode, proceed

as follows:

Ensure that the EMERGENCY STOP button is unlocked.

The PLC must display “RUN” on the display.

Choose manual mode using the authorization key-switch of the machine

operating panel to position 0.

The buttons to be pressed flash.

Actuate the reset button.

Connect the “Power on” output (Station 3).

Each actuator can be actuated individually.

The conveyor belt can be moved in both directions.

Short-stroke buttons on the actuators can only be operated in manual mode.

10.3 Operating Single Step mode

To launch the existing programs at each station in single step mode, proceed

as follows:



Choose Single step mode using the authorization key-switch of the machine





Press the Start button.

Press the Start button again after each logical step.

The PLC program runs automatically with each press of the “Start” button,

the work pieces must be removed by hand from the end of the conveyor and

the ramp. After a cycle has been run through completely, the cycle can begin

from new. In the event of an interruption, press the “Start” button again.

CAUTION Risk of damage!

Before initiating a program, all work pieces are removed from the training

system and loaded into the racks. At the manual mode Station 3 either "Check

Stock" or "Clear Stock" must have been performed.

The pinning unit must be filled with pins. A friction-free processing of the system

is ensured.






is ensured.



10.4 Automatic mode operation

The mMS 4.0 training system is delivered with the following example programs:

“Station 1”: To issue, convey and test work pieces for their material

conditions and quality. Sampling incorrect parts.

Transfer to the next station.

Extended: Operation/visualization via a VCP touchpad,

control/visualization via an Open Core Engineering System.

Integrating RFID and safety technology.

“Station 2”: Transport and process work pieces. Add 3 pins, process

in a press, press together two work pieces.

Return to conveyor belt and transfer to next station.


integrating RFID and safety technology.

“Station 3”: Transport and put work pieces into storage. The work pieces

can also be removed from storage again. Transfer to the next

station is possible.


integrating RFID and safety technology.

To launch the existing programs at each station in automatic mode, proceed

as follows:



Choose automatic mode using the authorization key-switch of the machine





Press the “Start” button.

The PLC program runs automatically, the work pieces must be removed by hand

from the end of the conveyor and the ramp. After a cycle has been run through

completely, the cycle can begin from new. In the event of an interruption, press

the “Start” button again.






is ensured.



10.5 Homing mode operation

To launch the existing programs at each station in homing mode, proceed

as follows:



Choose homing mode using the authorization key-switch of the machine





Press the Start button.

All actuators move to the home position.

The PLC program runs automatically, the work pieces must be removed by hand

from the end of the conveyor and the ramp. After a cycle has been run through

completely, the cycle can begin from new. In the event of an interruption, press

the “Start” button again.

10.6 „Check Stock“ function

To check the high-bay warehouse of the station on already existing pieces,

proceed as follows:



Actuate the start button. System in home position.

Actuate start and stop button for approx. 10 sec.

High-bay warehouse checks stock for available work pieces and stores them

New work pieces will be put to free storage places

10.7 „Clear Stock“ function

To clear counter of full stock in PLC program after emptiing stock manually,

proceed as follows:



Actuate the start button. System in home position.

Actuate start, stop and home button for approx. 10 sec.

PLC counter is deleted






is ensured.



10.8 Description of the buttons

Table 9: Description of the short-stroke buttons in the machine operating panels

Short-stroke button Description Station

START starts all movements All stations

STOP Stops after each logical step

has completed

All stations

RESET Puts the EMERGENCY STOP

button into effect either for one

station or several stations

All stations

MANUAL Displays the Manual

operating mode

All stations

AUTO Displays the Automatic

operating mode

All stations

MDI Machine Data Interface, CNC

manual data entry, only used

for CNS application

All stations

Only used for station 3.

HOME Displays the Homing

operating mode

All stations

SINGLE STEP Displays the Single step

operating mode

All stations

ON OFF Connects the line to the

drives. Only used for CNC

application

All stations


CONVEYOR

BELT

In manual mode, the

conveyor belt can be moved

right and left

All stations

JOG-

JOG+

JOG RAPID

In CNC mode, the linear axes

can be moved individually

(also quickly; JOG RAPID).

Only used for CNC application

All stations


Separator rack 1

Separator rack 2

Issue per workpiece per rack Station 1,

workpiece detection

Testing Unit Extends contour test cylinder Station 1

workpiece detection

Removing Unit Extends sampling cylinder Station 1

workpiece detection

Capacitive Indicator Indicates that the capacitative

sensor was actuated

Station 1 workpiece

detection

Contour Indicator Indicates that the contour

sensor has extended

completely, workpiece open

upwards

Station 1

workpiece detection

Inductive Indicator Indicates that the inductive

sensor was actuated

Station 1,

workpiece detection

Light Indicator Indicates that the optical

sensor was actuated

Station 1,

workpiece detection



Pin Press Stop, drop Cylinder Separating rack:

Extends stop cylinder

Station 2,

workpiece processing

Pin Press Insert cylinder Separating rack:

Extends feed cylinder

Station 2,


Pin Press Pin Cylinder Separating rack:

Extends pin separation cylinder

Flashing when rack empty.

Station 2,


Pin Press Press Cylinder Separating rack:

Extends pin press cylinder

Station 2,


Portal Vertical Cylinder Portal: Extends Z axis Station 2,


Portal Horizontal Cylinder Portal: Extends X axis Station 2,


Portal Vacuum Portal: Activates vacuum

sucker

Station 2,


Cube Press Case Cylinder Press: Retracts push-in

cylinder

Station 2,


2x Cube Press Press Cylinder Press: Two-handed version;

extends press cylinder.

Only in Hand mode.

Station 2,


Axis Axis

X+ X-

High rack storage: Moves

the X axis service axis

Station 3

workpiece to stock

Axis Axis

Y+ Y-

High rack storage: Moves

the Y axis service axis

Station 3

workpiece to stock

Cylinder Retract Z+

Cylinder Retract Z-

High rack storage:

Moves the Z axis pneumatic

cylinder

Station 3

workpiece to stock

Gripper Turn To Belt High rack storage: Moves

the gripper into the home

position 0°

Station 3

workpiece to stock

Gripper Turn To Stock High rack storage: Moves the

gripper into the working

position 180°

Station 3

workpiece to stock

Gripper Open / Close High rack storage:

Opens/closes gripper

Station 3

workpiece to stock

Cube implement High rack storage:

Workpiece to storage

Station 3

workpiece to stock

Cube outsource High rack storage:

Workpiece from storage

Station 3

workpiece to stock

Stock is full High rack storage:

Displays storage full and

moves the workpieces past

the warehouse

Station 3

workpiece to stock

Check stock High rack storage:

Checks for free warehouse

positions

Station 3

workpiece to stock


Fault assistance

11 Fault assistance

This chapter contains information that can help you further when faults arise in

the mMS 4.0 training system.

11.1 Faults

The following faults may occur:

Table 10: Possible faults

Display Cause Remedy

The Supply, K1 and K2

LEDs on the

emergency stop relay -

51K1 do not light up.

The emergency stop

circuit is open locally

at this station

Checks whether

the pressure switch

has enough air

pressure, that an

emergency stop is

not pressed and all

connecting cables

are connected.


LEDs on the



The emergency stop

circuit is open locally at

the station to the right of

this station

Checks the right station

to see whether the

pressure switch has

enough air pressure,

that an emergency stop

is not pressed and all

connecting cables

are connected.


LEDs on the



The emergency stop

circuit is open locally

at the station to the left

of this station

Checks the left station

to see whether the

pressure switch has




connecting cables

are connected.


LEDs on the

emergency stop relays

-51K2 and -51K3

do not light up.

The emergency stop

circuit is open at all

stations

Checks all stations

to see whether the

pressure switch has




connecting cables

are connected.

LED at relay -54K1

is not lit.

Pressure switch did not

switch.

No pressure present

or the pressure switch

is in the wrong position.

LED at relay -K0.3

is not lit.

Reset pushbutton 2S3

was not pressed.

Press Reset

pushbutton 2S3.

An increase in pressure

could not be found at

the pressure gage.

Hydraulic power unit is

faulty, too little oil in the

system or the pressure

relief valve is configured

incorrectly.

Check the oil level,

replenish with oil when

needed.

Get in touch with Bosch Rexroth After-sales care if the causes of the fault cannot

be identified and remedied.

www.boschrexroth.com/training

http://www.boschrexroth.com/training


Fault assistance

11.2 Troubleshooting

Basic procedure

Remove all workpieces from the stations.

Check

- All electrical connections for possible faults,

- The pneumatic and mechanical components for possible faults.

After the fault has been removed:

1. Actuate the reset button.

The reset button is lit.

If the reset pushbutton continues to flash, this means there is a fault.

2. Remedy the fault, then go to Step 1.

3. Press the Start button.

Process can be continued.

Restarting after a power failure

Remove all cubes and cube halves from the stations.

Empty the high-stack storage.

Re-establish the voltage.

The programmable logic controllers are rebooted.

Once they are ready, the reset and start buttons will flash.


Maintenance and inspection

12 Maintenance and inspection

This chapter describes the maintenance and inspection work which may

be carried out by trained personnel on the mMS 4.0 training system.

Maintenance and inspection work which may only be performed by specially

trained and qualified personnel is described in 13 “Maintenance work”.


Report the faults which were identified to the responsible manager immediately

so as to be able to remedy them immediately. Note that small faults can lead

to big ones if these are not remedied in time.

Only clean the plastic parts with a lightweight, damp cloth. Only use water

and a mild cleaning agent without chemical additives. Never use solvents or

aggressive cleaning agents.

Before using a cleaning agent, examine the usage instructions and possible

hazards in the user information and DIN safety data sheet.

Never blow out the training system with compressed air as sensors and valves

of the functional assemblies may get damaged.

If you must remove oil, use suitable binding agents and cleaning cloths.

Protect the training system from dust and moisture to prevent it from being

contaminated and can be used for a long time.

Store and dispose of ejected and consumed working materials and

consumables appropriately in accordance with legal requirements.

In case of doubt, get information about the type of storage and disposal

provided by the material manufacturer/supplier.


Maintenance and inspection

12.2 Maintenance and inspection schedule

In the following table, the work is organized by maintenance interval and then by

assembly / part. The intervals are must be kept to.

Table 11: Maintenance and inspection work on the training system

When? What? Where? Comments

daily/

prior to

each use

Overall training system Clean environment

of the training

system

Clean and keep

the working

surfaces free.

Remove parts lying

around


Weekly

Overall training system Inspect electrical

connection cables

and lines for visible

damage (friction

marks, cracks, cuts).

Have damage

rectified by the

responsible

qualified electrician

right away

Connection elements Inspect electrical

devices, control

boxes and switches /

buttons for visible

damage (cracks)

Have damage

rectified by the

responsible

qualified electrician

right away

Inspect the visual

inspection for

damage and

firm fitting

Secure loose

screws etc again.

Have damage

rectified right away.

Notify Bosch

Rexroth After-sales

service.


Maintenance work

13 Maintenance work


Inadequate maintenance leads to

Faults,

Possible breakdown

High repair costs.

Observe the following instructions if anomalies, faults and wear is identified during

operation or during the inspection:

Immediately place the training system out of service.

Find the causes of the fault and fix the defects.

Replace the damaged part.

Do not put the mMS 4.0 training system back into operation where unsafe

to do so.


Maintenance work

13.2 Maintenance schedule

In the following table, the work is shown by maintenance interval and then by

assembly/part. The intervals contain.

Table 12: Training system maintenance schedule mMS 4.0

When the mMS 4.0 training system is out of service, the following applies:

Tighten loose connections such as screws, nuts, splints, clamps right away.

13.2.1 Working materials, consumables, tools, measuring devices

To work on the mMS 4.0 training system, the following is required:

Grease:

Standard lithium grease

Occupational safety clothing as required

Lubricants as per instructions

Cleaning and conservation compounds:

Cleaning rags

Container for disposal of lubricants/waste

Inspection and maintenance report, writing materials

1 set open-end wrench

1 set hexagon socket wrench

1 set screwdriver


Daily / prior

to each use

EMERGENCY STOP button Check function.

Effect of sampling

Does not start up when locked

In the event of malfunction:

Place the installation out of service

Notify a qualified electrician


Weekly Electronics Check all functions:

Fuses, FI-switches

sockets

buttons

Have any defect parts replaced

Qualified electricians are only

to do the replacement

Monthly

or

as needed

24V mains supply DC where

present

Check all functions:

Connection cable,

main switch,

24V power supply unit, voltage

OK?

Have any defect parts replaced

Qualified electricians are only

to do the replacement

Cleaning Overall training system Remove dirt or existing lubricant residues.

As per

company

regulations

The entire electric installation Inspection of protective

earthing conductor up-to-date?

Label present?

Inspection by qualified electrician only

Working materials

Aids

Tools


Disposal

13.2.2 Replace parts

Only use original spare parts.

When ordering spare parts, always specify the device type, material number,

year of manufacture and parts designation.

Get in touch with Bosch Rexroth After-sales.

For the address and other contact data, consult the reverse of this

operating manual.

www.boschrexroth.com/training

Immediately rectify the wear on the mMS 4.0 training system when

– Workplace safety and functions are not in place

– Subsequent damage is expected

If elements are damaged, check whether the wear limit has been reached.

Decide whether you need to replace the part or wait until the next

maintenance.

Only rectify wear when

– The mMS 4.0 training system is in an upright position safe for personnel and

– There is no risk to health (falling, slipping due to moisture, etc).

Have a skilled person check the following after rectification of the wear and

before the machine is put into operation

– Has the work been carried out properly

– Is the mMS 4.0 training system ready for operation without impairment.

14 Disposal

The training system is made of materials which are recyclable and can be reused.

Specialized firms cab recycle this training system to gain valuable materials from

it and to minimize the amount of material requiring disposal.

Dispose of the training system based on local and legal requirements.

Water-polluting materials such as hydraulic oil and cleaning liquids containing

solvents must not be allowed to contaminate the soil or get into the water supply.

Working materials and consumables must be placed in suitable containers,

stored, transported, collected and disposed of according to the legal

requirements. In case of doubt, obtain information about storage and disposal

types from the manufacturer / vendor.


Declaration of conformity

15 Declaration of conformity

Subject to change

Printed in Germany

Mat No. R901429162

Bosch Rexroth AG

Drive & Control Academy

Bahnhofplatz 2

D-97070 Würzburg, Germany

Phone: 09352 18 1920

Fax: 09352 18 6882

[email protected] www.boschrexroth.com\training

trainingssystem mms 4.0 | r901429162/04.16 - bosch rexroth

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