Prolog TripleStackMagazine A003

ProLog®
Manual
TripleStackMagazin
Festo Didactic
ProLog
04/2016
Order-No.:
Date: 04/2016
Layout: 04/2016, Schober
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2016
Internet: www.festo-didactic.com
E-Mail: did@de.festo.com
Reproduction, distribution and utilisation of this document, as well as the communication of its contents to
others without explicit authorisation, are prohibited. Offenders shall be held liable for payment of damages.
All rights reserved, in particular the right to file patent, utility model and registered design applications.
Note
Where only pronouns such as he and him are used in this manual, these pronouns are of course
intended to refer to both male and female persons. The use of a single gender should not be
construed as gender discrimination; it’s intended solely to make the manual easier to read and the
formulations easier to understand.
Intended use
This installation was developed and manufactured for use in basic and further training in the fields
of automation and communications. The training company and/or the training staff must ensure
that the trainees observe the safety precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations. It contains all
information and data required for commissioning, maintenance and operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any
third parties occurring when the installation is used for any purpose apart from training, except
Festo Didactic has caused such injury or harm intentionally or by grossly negligence.
2 © Festo Didactic ProLog

Content
1 General safety instructions __________________________________________________________________ 5

1.1 Pictograms ___________________________________________________________________________ 6
1.2 Safety sockets_________________________________________________________________________ 7
1.3 Handling the system ___________________________________________________________________ 8
1.3.1 Dangers in handling the machine _____________________________________________________ 8
1.3.2 Safety precautions in standard operation ______________________________________________ 8
1.3.3 Dangers due to electric current _______________________________________________________ 8
1.3.4 Dangers due to pneumatic energy ____________________________________________________ 9
1.3.5 Maintenance – Servicing – Malfunction removal _________________________________________ 9
1.3.6 Organizational measures ____________________________________________________________ 9
1.4 Personnel ____________________________________________________________________________ 9
1.4.1 Notes on personnel _________________________________________________________________ 9
1.4.2 Training operations _________________________________________________________________ 9
1.4.3 Outside training operations __________________________________________________________ 9
1.4.4 Obligations of the operating company _________________________________________________ 9
1.5 Obligations of the trainees ______________________________________________________________ 9
2 Introduction _____________________________________________________________________________ 10
2.1 Warranty and liability __________________________________________________________________ 10
2.2 Intended use _________________________________________________________________________ 10
2.3 Important notes ______________________________________________________________________ 10
2.4 General _____________________________________________________________________________ 11
2.4.1 Triple stackMagazine ______________________________________________________________ 12
2.5 System ______________________________________________________________________________ 14
2.6 Didactic structure _____________________________________________________________________ 15
3 Commissioning __________________________________________________________________________ 17
3.1 Transport ____________________________________________________________________________ 17
3.1.1 Unpacking _______________________________________________________________________ 17
3.1.2 Scope of delivery __________________________________________________________________ 17
3.2 Set up ______________________________________________________________________________ 18
3.2.1 General information _______________________________________________________________ 18
3.3 Commissioning _______________________________________________________________________ 19
3.3.1 Pneumatic commissioning __________________________________________________________ 19
3.3.2 Electric commissioning _____________________________________________________________ 20
3.3.3 Connecting communication cables ___________________________________________________ 20
3.4 Commissioning _______________________________________________________________________ 23
3.5 Workstation__________________________________________________________________________ 23
3.6 Adjust sensors _______________________________________________________________________ 24
3.6.1 Reflex light sensor (workpiece identification) __________________________________________ 24
3.6.2 Proximity sensor (ejecting cylinder) __________________________________________________ 26
3.7 Adjusting one-way flow control valves ____________________________________________________ 28
3.8 Visual check _________________________________________________________________________ 29
3.9 Cable connection _____________________________________________________________________ 30
3.10 Pneumatic connection ________________________________________________________________ 32
3.10.1 Manual override _________________________________________________________________ 32

3.11 Voltage supply ______________________________________________________________________ 32
3.12 Loading the PLC program _____________________________________________________________ 33
3.12.1 Siemens controller _______________________________________________________________ 33
3.13 Starting the sequence ________________________________________________________________ 34
3.14 Combination of stations ______________________________________________________________ 35
3.14.1 Networking _____________________________________________________________________ 35
4 Operation _______________________________________________________________________________ 36
4.1 General operation notes _______________________________________________________________ 36
4.1.1 Behaviour rules ___________________________________________________________________ 36
4.1.2 Operation rules ___________________________________________________________________ 36
4.2 Process description ___________________________________________________________________ 36
4.2.1 TripleStackMagazine ______________________________________________________________ 37
4.3 Start up MPS stations _________________________________________________________________ 38
4.3.1 Requirements ____________________________________________________________________ 38
4.3.2 Reset process of MPS-stations ______________________________________________________ 38
4.3.3 Default mode _____________________________________________________________________ 39
4.3.4 MES Mode _______________________________________________________________________ 39
4.4 TripleStackMagazine __________________________________________________________________ 40
4.4.1 Standalone mode _________________________________________________________________ 40
4.4.2 MES mode of triple stack magazine __________________________________________________ 41
4.4.3 Material flow _____________________________________________________________________ 43
5 Technology ______________________________________________________________________________ 44
5.1 Technical datas _______________________________________________________________________ 44
5.2 Stack magazine module ________________________________________________________________ 45
5.3 Conveyor ____________________________________________________________________________ 46
6 Pneumatic _______________________________________________________________________________ 47
6.1 Pneumatic supply _____________________________________________________________________ 48
7 Electrical System _________________________________________________________________________ 49
7.1 Power supply ________________________________________________________________________ 49
7.2 Controller ___________________________________________________________________________ 50
7.2.1 I/O-Components __________________________________________________________________ 51
8 Maintenance_____________________________________________________________________________ 53

1 General safety instructions
The laboratory or the classroom must be equipped in accordance with EN 50191:
 An emergency off device must be provided.
– At least one emergency off device must be located within, and one outside of the test area.
 The test area must be secured against unauthorised start-up.
– For example with a key switch
 The test area must be protected by residual current devices (RCDs).
– Type B residual current circuit breaker with a residual current rating of ≤ 30 mA
 The test area must be protected by overcurrent protection devices.
– Fuses or circuit breakers
 The test area must be overseen by a supervisor.
– A supervisor is a qualified electrician or a person who has received appropriate instruction, has
knowledge of the respective safety requirements and safety regulations and whose training has been
accordingly documented.
 No damaged or defective devices may be used.
– Damaged devices must be barred from further use and removed from the test area.
General requirements for safe operation of the devices:

 Do not lay cables over hot surfaces.
– Hot surfaces are identified with a corresponding warning symbol.
 Maximum permissible current loads for cables and devices must not be exceeded.
– Always compare the current ratings of the device, the cable and the fuse.
– In the event that these are not the same, use a separate upstream fuse in order to provide
appropriate overcurrent protection.
 Devices with an earth terminal must always be grounded.
– If an earth connection (green-yellow laboratory socket) is available, it must always be connected to
protective earth. Protective earth must always be connected first (before voltage), and must always be
disconnected last (after voltage).
 If not otherwise specified in the technical data, the device is not equipped with an integrated fuse.

General safety instructions
1.1 Pictograms
This document and the described hardware include warnings concerning possible hazards which may arise if
the system is used incorrectly. The following pictograms are used:
Warning
Non-observance of this pictogram may result in serious personal injury or damage
to property.
Caution
Non-observance of this pictogram may result in personal injury or damage to
property.
Warning
This pictogram indicates that the device must be switched off and its mains plug
must be removed from the electrical outlet before installation, repair, maintenance
and cleaning work. Observe the manual, in particular all safety instructions. Non-
observance may result in severe personal injury or damage to property.
Warning
This pictogram indicates danger of being burned if hot surfaces (up to roughly
85 C) are touched.
Important
This symbol emphasizes important information for correct machine handling.
Failure to pay attention to this symbol may result in damages to the machine or to
its surroundings.
i
Information
This symbol indicates operational tips and especially useful directions. This
symbol assists you to make optimal use of all of your machine’s functions.

1.2 Safety sockets

If not otherwise specified in the technical data, the following colour codes apply to the power supply and
signal connections for components included in Festo Didactic’s learning system for automation and
technology.
Colour Function Colour Function
Voltage greater than SELV 24 V DC

e.g. line voltage of 90 to 400 V AC per conductor (red)
(grey)
Neutral conductor 0 V DC
(blue) (blue)
Protective conductor Safety extra-low voltage,

(green-yellow) signal input/output
(black)
The specified protection class and safe use can only be assured if laboratory safety cables supplied by Festo
Didactic are used.
 Warning
Damaged laboratory safety cables must be immediately barred from further use and
removed from the test area.
© Festo Didactic ProLog 7

1.3 Handling the system

1.3.1 Dangers in handling the machine
The installation has been constructed technologically up to date and in conformance with the recognized
rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the
user or third parties or that the installation or other property might get damaged. Therefore, the installation
has to be handled according to specified operational use in perfect technical condition only.
Safety endangering malfunctions cannot be tolerated during training and have to be removed immediately.
The system is to be used only:
 for its intended purpose and
 In absolutely safe conditions.
Warning
Faults impairing safety must be rectified immediately!
1.3.2 Safety precautions in standard operation

Put the installation into operation only, once all of the protection settings are completely functional.
At least, before starting operation, check the installation for externally visible damages and for the reliability
of the safety devices.
Do not grip into the installation while in operation.
Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power
supply.
General safety regulations are to be observed: DIN 58126 and VDE 0100.
1.3.3 Dangers due to electric current

As soon as maintenance is completed, check the function reliability of the safety devices.
Only trained experts in electric or electronic engineering are permitted to carry out work on the electric
supply system.
The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a
member of the training staff.
Do not activate electric limit switches manually during fault search. Tools are to be used.
Only low voltage 24VDC is to be used.

1.3.4 Dangers due to pneumatic energy

Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply
immediately. Caution! When the air pressure supply is activated, cylinders may move in or out.
Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding
the end of the tube. Do not exceed the permitted operating pressure. See data sheets.
1.3.5 Maintenance – Servicing – Malfunction removal

Carry out adjustments and inspections as instructed, in accordance with the specified intervals.
Secure the compressed air and electricity supplies to prevent unintentional start-up.
During inspections, maintenance and repair work, the machine must be de-energized, de-pressurized and
secured against unexpected restart. All screw connections released during maintenance, inspection or
repair work must be checked to ensure correct re-tightening.
1.3.6 Organizational measures

All existing safety devices must be checked at regular intervals.
1.4 Personnel
1.4.1 Notes on personnel
Basically two situations have to be considered, concerning matters on personnel.
 Activities during training operations
 Activities outside training operations
1.4.2 Training operations

Trainees are permitted to work with the machine only under strict supervision of an experienced person or
an instructor.
Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be
taken regarding safety aspects.
1.4.3 Outside training operations

Activities in the areas of maintenance, service and repair are to be carried out by only persons with
appropriate technical qualifications.
1.4.4 Obligations of the operating company

The operating company undertakes to allow only those persons to work with the system who:
 Are familiar with the basic regulations regarding work safety and accident prevention and have been
instructed in the use of the system
 Have read and understood the chapter concerning safety and the warnings in this manual
Personnel should be tested at regular intervals for safety-conscious work habits.
1.5 Obligations of the trainees

All persons who have been entrusted to work with the system undertake to complete the following steps
before beginning work:
 Read the chapter concerning safety and the warnings in this manual

2 Introduction
2.1 Warranty and liability
In principle all our „Terms and Conditions of Sale“ apply. These are available to the operating authority
upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage
are excluded if these can be traced back to one or several of the following causes:
 Use of the system not in accordance with its intended purpose
 Incorrect assembly, commissioning, operation and maintenance of the system
 Operation of the system using faulty safety equipment or incorrectly fitted or non-operational safety or
protective devices

Non observance of notes in the manual regarding transport, storage, assembly, commissioning,
operation, maintenance and setting up of the system
 Unlawful constructional modifications on the system
 Inadequate monitoring of components subject to wear
 Incorrectly carried out repairs
 Catastrophes as a result of foreign bodies and vis major.
Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and/or
other third parties which may occur during the use/operation of the system other than purely in a training
situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.
2.2 Intended use

This installation was developed and manufactured only for use in basic and further training in the fields of
automation and communications. The training company and/or the training staff must ensure that the
trainees observe the safety precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations. It contains all
information and data required for commissioning, maintenance and operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any third
parties occurring when the installation is used for any purpose apart from training, except Festo Didactic has
caused such injury or harm intentionally or by grossly negligence.
The use of the system for its intended purpose also includes:
 Following all advice in the manual and
 Carrying out inspection and maintenance work.
2.3 Important notes

The basic requirement for safe use and trouble-free operation of the system is to observe the fundamental
safety recommendations and regulations.
This manual contains important notes concerning the safe operation of the system.
The safety recommendations in particular must be observed by anyone working on the system.
Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be
observed.

Introduction
2.4 General
In the development of the system, various production technologies have been combined into one
installation. The aim of the installation is the increase of competence, from a simple setting of examples up
to a complete production process, including all features.
Additionally, to technical and social competence, the comprehension of the process and the interaction of
the respective components appear in clear presentation.
This manual describes working with the ProLog-factory system. Everything is explained and described for
the operation of necessary events. With the help of graphics or pictures a simple communication should be
obtain.
Complete operating instructions which explain the processes of the system are available for working with
the system. Station manuals are also available for the individual stations.
Festo Didactic succeeded in using the most updated industrial hard- and software for this model production.
The ProLog Factory consists of 3 main areas:
 The Production Line, where the products are produced
 The Commissioning station, where the customer orders are picked
 The Warehouse Area, where the customer orders (pallets) are buffered until delivery
Additionally there is an robotino, to bring the parts from sorting to distribution station.
The production line itself consists of up to 8 MPS Stations. Each Station has its own controller to support a
decentralized control structure.
The Commissioning Station consists of a 6 axis robot. The customer orders are completed according the
order data in this station. After completion, the pallets (orders) are put to the warehouse input slide.
The warehouse is served by mobile robots. The mobile robots receive their transport orders from the MES4
according to the warehouse management data.
They move
 Empty pallets to the commissioning robot
 Completed orders from the warehouse input slide to the high-bay storage
 Deliveries from the storage to the warehouse output slides

Introduction
2.4.1 Triple stackMagazine
The Distributing station is a feed device. According to VDI 3240, feed devices are defined as units which
fulfil the function of bunkering, sorting and feeding of components. In addition, feed devices can facilitate
the sorting of components according to various sorting characteristics (shape, weight etc. of the
component).
The following are feed devices:
 Magazines with feed limiting,
 Vibratory bowl feeder,
 Inclined conveyors and
 Hoppers with sorting devices.
Workpieces handled by feed devices are

 Electroplated parts,
 Shaped parts made of plastic,
 Punched parts and
 Turned components.

Introduction
The function of the Distributing station is

 to separate out workpieces from a magazine and
 to transfer workpieces by means of a rotary drive using a suction cup.
The Distributing station consists of the following:

 Stack magazine module
 Changer module
 Profile plate
 Trolley
 Control console
 PLC board
Station 3fach Magazin mit Wagen, Bedienpult und SPS Board

Introduction
2.5 System
Overview prolog-factory system
Position Description Position Description
1 Triple stack magazine station 8 Sorting station
2 Testing station with colour sensor 9 Log area
3 Processing station 10 Robotino 2
4 Pick and place station 11 Robotino 1
5 Fluid muscle station 12 Commissioning station
6 Storing station 13 Connecting conveyor 3
7 Separating station

Introduction
2.6 Didactic structure

The installation is structured, to enable methodical learning, i.e. from single use of modules to the complex
and complete installation. Perhaps even in combination with further systems.
For example, it is possible to pick out a single module to start with the first steps, e.g. the robot.
 First the mechanical assembly is considered. The robot’s radius of action requires integration into the
location of the robot.
 The following step could be the connection of all cables required for operation and the set-up of the
robot.
 Moving the robot and teaching the required positions are the first real operations with the robot, which
introduces the user how to deal with the teach-box.
 The robot’s programming can be started, as soon as the robot can be moved by the teach-box. Small
programs, which can be created by using the Cosimir/Cosirob software, are expandable for the complex
programs.
 Orders to further stations and from other controls can be installed in the programs.
Once the learning process of this module has been concluded, these learning steps can be transferred to the
next module. As soon as all of the modules have been processed individually, the modules can be
interconnected and the programs can be adapted. A complete production process can be simulated.
This is an ideal training area for the professional practice of mechatronics, as well as all of the technical
ranges (mechanical, electrical and pneumatic processes) are represented in a simple and clearly way,
concerning each one of the modules and the complete system.
The installation permits to face students to the reality of manufacturing processes by allowing them to apply
individual technologies already taught in the preliminary phases of engineering studies. Thus, each
technology is considered first separately and then combined together to optimize the manufacturing
processes.
Training contents covering the following subjects can be taught:

Mechanic:
 Adjusting of a handling system
 Assembly of singular station
 Using mechanical interfaces
Electronic:
 Wiring and testing electrical components
 Reading and designing electrical circuit diagrams
 Getting familiar with electrical drives
 Working with electrical interfaces
Robotic:
 Use of industrial robots
 Fundamentals of robot technology
 Robot programming

Introduction
Sensoric:
 Using limit switches and sensors
 Getting to know different types of sensors (inductive, optical, capacitive, analogue)
Pneumatic:
 Professional tubing of pneumatic components according to circuit diagrams
 Getting to know and using pneumatic components (different cylinders, valves, grippers)
 Using vacuum technology
Ident system:
 Getting familiar with the Identification system
 Data processing via Ident and PLC
PLC:
 Getting to know the structure and mode of operation of a PLC
 Programming a PLC in different PLC languages
 Interfacing a PLC to a Robot Controller and a visualization system
 Getting to know special function modules for positioning, counting
Vision system
 Collect and process from measure datas and analogue values with a PLC
 to become acquainted and work with a vision testing system
 To become acquainted with lightsystems
 To become acquanted with lens charactes
 Flash synchronisation
 Programming a vision testing system
Maintenance and Troubleshooting:

 Locating and rectifying faults and malfunctions
 Optimizing automated systems
Commissioning:
 Adjusting mechanical and electrical components
 Adjusting sensors and limit switches in automated systems
 Commissioning systems by means of a PLC

3 Commissioning
3.1 Transport
Care is to be taken that the transport of the stations is to be executed only by a suitable transport vehicle.
The weight amounts up to 500 kg, depending on the station.
The route of transport is to be cleared in advance, to be accessible to the transport vehicle. Installation of
warning signs or barriers may be required.
The transport boxes are to be opened with care, as additional components, such as computers may be
contained in the delivery, which are to be protected from falling out.
Once the transport box has been opened and the possibly contained additional
i components removed, the station can be taken out to be transported to its destination by
means of two fork-lifts or one fork-lift truck.
Please check the stability of all of the profile connectors by means of an Allen key size 6.
The connectors may have come loose during transport, due to inevitable vibration.
Once the transport box has been opened and the possibly contained additional
components removed, the station can be taken out to be transported to its destination by
means of two fork-lifts or one fork-lift truck.
Please check the stability of all of the profile connectors by means of an Allen key size 6.
The connectors may have come loose during transport, due to inevitable vibration.
Pay special attention to all overhanging components. Sensors and similar small parts are
very easily damaged in case of improper transport.
The stations are not to be picked up by or even under the mounted feet – increased risk of
becoming trapped or contused.
Check the station for any possible damaged once unpacked. The carrier and Festo Didactic
are to be notified immediately of any damage.
3.1.1 Unpacking
Carefully remove the padding material in the container box when unpacking the station. When unpacking
the station, make sure that none of the station assemblies have been damaged.
Check the station for any possible damaged once unpacked. The carrier and Festo Didactic are to be notified
immediately of any damage.
3.1.2 Scope of delivery

Check the scope of delivery against the delivery note and the order. Festo Didactic must be notified
immediately of any discrepancies.

Commissioning
3.2 Set up
3.2.1 General information
The installation is to be set up in a frost-free room with maximum relative air humidity of 70%. In countries
with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius are the premises to
provide an air-conditioning system for constant surroundings conditions.
To comply with the regulatory guidelines, sources of electrical interference such as welding plants, large
motors and contactors are to be checked for electromagnetic compatibility in advance and screened where
necessary.
To ensure fault-free operation a load-bearing floor is required to avoid settling.
Allow sufficient distance between the installation and the wall of the room.
Any dust originating from construction work has to be kept off the installation (by covering).
For a more simple room planning the complete installation design is shown in the following.
Installation design prolog factory

Commissioning
Dimension drawing
3.3 Commissioning
Commissioning of the system can ensue only, if once all of the stations are connected to their final position.
The system possesses several components, which require connection before start-up. This process is
described in the following chapters.
3.3.1 Pneumatic commissioning

The mechanic set-up must be completed. In the beginning, the station is to be connected to the pneumatic
system in the room. The maintenance unit for the system is placed at one of the feet of the basic frame. The
quick coupling plug has a nominal size of 5 mm. In case the existing air supply system is equipped with 7.9
mm nominal size, it is possible to exchange the quick coupling plug of the maintenance unit with a larger
one (adapter 1/8 on 1/4 required).
Once this has ensued, the station can be supplied with 6 bar and the pneumatic commissioning is
concluded.

Commissioning
3.3.2 Electric commissioning

At this point, the system requires to be supplied with electric voltage
The cable included in the delivery has a standard plug for 230V/400V with protective covering, which is to
be plugged into a sufficiently secured socket. Distribution boards are included in the delivery, for the
connection of other components as well. In case an extension is required for the cable of the distribution
board, it is to be executed only by a trained expert. For the operators, the socket is to be secured.
To avoid problems during the operational process, individual protection (16A-230V / 40A-400V) of the
installation is recommended.
3.3.3 Connecting communication cables

The PRO-LOG Factory covers all state of the art industrial communication levels and control technologies.
The control levels are:
 Factory level: Order Entry
 Plant level: SCADA
 Device level: PLC, RC
The communication systems are:

 Ethernet (LAN/WLAN) for communication between PLC and PC (see also following graphic)
 RFID for communication between external I/O parts and PLC (see also following graphic)
 Profibus for communication between Siemens PLC and Turck IO extension

Commissioning
The communication inside the system takes place via Ethernet and Profibus DP. All connections are
pluggable, the exception is the cable from the Drive unit, the cable is fixed in the drive unit and not
pluggable.
Ethernet communication cables

Commissioning
Position Station Ethernet address
1 MES PC 192.168.10.50
2 WinCC 192.168.10.51
3 Triple stack magazine station 192.168.10.1
4 LAN-switch
5 WLan router 192.168.101.2
6 Testing station with color sensor 192.168.10.2
7 Processing station 192.168.10.3
8 Pick and place station 192.168.10.4
9 Fluid muscle station 192.168.10.5
10 Storing station 192.168.10.6
11 Separating station 192.168.10.7
12 Sorting station 192.168.10.8
13 Commissioning station 192.168.10.20
14 Drive Unit CR750 roboter 192.168.10.99
15 Robotino 1 192.168.10.101
16 Robotino 2 192.168.10.102

Commissioning
3.4 Commissioning
Commissioning of the system can ensue only, if once all of the stations are connected to their final position.

The stations of the MPS are generally delivered
 completely assembled
 operationally adjusted as single station
 commissioned
 tested
Note
If stations are combined changes of the mechanical set-up and the position and setting of sensors may be
necessary.
The commissioning is normally limited to a visual check to ensure correct tubing connections/wiring and
supply of operating voltage.
All components, tubing and wiring is clearly marked so that all connections can be easily re-established.
3.5 Workstation

The following is required to commission the MPS station:
 The assembled and adjusted MPS station
 A control console
 A PLC board
 A power supply unit 24 V DC, 4.5 A
 A compressed air supply of 6 bar (600 kPa), approx. suction capacity of 50 l/min
 A PC with installed PLC programming software

Commissioning
3.6 Adjust sensors

3.6.1 Reflex light sensor (workpiece identification)
Pos Description
1 Reflex light sensor
Fibre optic device (2B1)
The reflex light sensor is used for detection of the work pieces. A fibre optic cable is connected to a fibre
optic device. The fibre optic device emits visible red light. The diffuse sensor detects the light reflected by
the workpiece. Different surfaces or colors are changing the amount of reflected light.

Commissioning
Prerequisites
– Fibre optic device is assembled.
– Fibre optic device is wired up.
– Connect module with 24V (see chapter mechanical setup)
Execution
1. Mount the fibre optic cable head to the housing of the stack magazine. The head of the sensor should be
concise with the inside of the housing.
2. Connect the fibre optic cables to the fibre optic device.
3. Place a black workpiece at the stack magazine.
4. Adjust the potentiometer of the fibre optic device by means of a screwdriver until the switching status
display changes to on.
Note
Maximal 12 revolutions of the adjusting screw are permissible.
5. Check the setting of the fibre optic device for black, red and silver work pieces.
Note
All work pieces should be detected securely.
Documents
 Data sheets
Fibre optic device SOEG_L (165327) and reflex light sensor SOEZ-RT (165358)
 Operating instructions
Fibre optic device (369669) and reflex light sensor RT (369682)

Commissioning
3.6.2 Proximity sensor (ejecting cylinder)
Pos Description
1 Sensor magazine cylinder retracted (1B1)
The proximity sensors are used for end position sensing of the cylinder. The proximity sensor is sensitive to
a permanent magnet mounted on the piston of the cylinder.

Commissioning
Prerequisites
– Stack magazine module is assembled, proximity sensors are pre-assembled.
– Cylinder is tubed up.
– Compressed air supply switched on.
– Proximity sensor is wired up.
– Connect module with 24V (see chapter mechanical setup)
Execution
1. Use the manual override of the solenoid valve to place the cylinder piston in the position which you wish
to interrogate.
2. Shift the sensor along the cylinder axis until it switches, switching status display (LED) is on.
3. Shift the sensor a few millimetres further in the same direction until it switches back (LED is off).
4. Place the switch half the way between the switch-on and the switch-off position.
5. Tighten the clamping screw of the sensor with a hexagon screwdriver A/F 1.3.
6. Start a test run to check if the sensor switches at the correct point (advance/retract cylinder piston).
Documents
 Data sheets
Proximity sensor SMT-8 (531145)
 Operating instructions
Proximity sensor SMT-8 (531145)

Commissioning
3.7 Adjusting one-way flow control valves
Example one way flow control valve
Pos Description
1 One way flow control valve GRLA
One-way flow control valves are used to regulate exhaust air flow rates with double-acting cylinders. In the
reverse direction, air flows through the non-return valve with full cross-sectional flow.
Uncontrolled supply air and controlled exhaust hold the piston between air cushions (improves motion,
even with load changes).

Commissioning
Prerequisite
– Cylinder is tubed up
Execution
1. Screw in the restrictors of the one-way flow control valves at first completely and then loosen again one
turn.
2. Start a test run.
3. Slowly open the one-way flow control valves until the desired piston speed is reached.
Documents
 Data sheets
One-way flow control valve (175056)
3.8 Visual check

A visual check must be carried out before each commissioning!
Prior to starting up the station, you will need to check:
 The electrical connections
 The correct installation and condition of the compressed air connections
 The mechanical components for visual defects
(tears, loose connections etc.)
 The function of the EMERGENCY STOP devices
Eliminate any damage detected prior to starting up the station!

Commissioning
3.9 Cable connection
Cable connections from PLC board to control console and station (Standard Version)
1. PLC board – station

Plug the XMA2 plug of the PLC board into the XMA2 socket of the I/O terminal of the station.
2. PLC board – control console
Plug the XMG1 plug of the PLC board into the XMG1 socket of the control console.
3. PLC board – power supply unit
Plug the 4 mm safety plugs into the sockets of the power supply unit.
4. PC – PLC
Connect your PC to the PLC by means of a programming cable.

Commissioning
Cable connections from PLC board to control console and station (Version with EDU-Trainer)
Pos. Station
1 Sensor connected to the MicroFMS station (option)
2 SysLink plug XMG at control consol
3 SysLink plug XMA at station
4 Controller PLC 314 – hard wired to EDU Trainer
5 SysLink plug A at EduTrainer
6 SysLink plug B at EduTrainer
1. EDU Trainer – control console

Plug the cable from B plug of the EDU Trainer into the XMG1 socket of the control console.
2. EDU Trainer – station
Plug the cable from A plug of the EDU Trainer into the XMA2 socket of the I/O terminal of the station.
3. PLC board – power supply unit
Plug the 4 mm safety plugs into the sockets of the power supply unit.
4. PC – PLC
Connect your PC to the PLC by means of a programming cable.

Commissioning
3.10 Pneumatic connection

 Observe technical data!
 Connect the compressed air supply to the start-up valve with filter-control valve.
 Set the start-up valve with filter-control valve at 6 bar (600 kPa).
3.10.1 Manual override

The manual override is used to check the functioning and operation of the valves and valve-drive unit
combination.
Prerequisite
– Power supply unit switched on.
Execution
1. Switch on the compressed air supply.
2. Press down the stem of the manual override with a blunt pencil or a srewdriver.
(max. width of blade:2,5mm)
3. Release the stem (the spring resets the stem of the manual override back to the starting position), the
valve moves back to the starting position.
(not with double solenoid valves!)
4. For locking manual override usage: Controll all manual overrides for being in starting position after
testing the valves.
5. Before commissioning the station make sure that all valves of the valve terminal are in starting position.
3.11 Voltage supply

 The stations are supplied with 24 V DC voltage (max. 5 A) via a power supply unit.
 The voltage supply of the complete station is effected via the PLC board.

Commissioning
3.12 Loading the PLC program

3.12.1 Siemens controller
 Controller: Siemens S7-314 PN/DP
 Programming software: Siemens TIA Portal V13 SP1 or higher
1. Connect PC and PLC using the RS232 programming cable with PC adapter
2. Switch on power supply unit
3. Switch on the compressed air supply
4. Release the EMERGENCY-STOP pushbutton (if available)
5. Overall reset PLC memory:
6. mode selector switch in STOP position
7. Start the PLC programming software
8. Retrieve the file ProLogMES4_S7-1500_20150212.zap13
9. File  Retrieve …  Select an archive ProLogMES4_S7-1500_20150212.zap13 Open  Select

destination directory OK  Retrieving: The retrieved data were stored in the project directory. OK 
Retrieve: The following objects were retrieved. Do you want to open these now? Yes
10. Load the project into the controller
11. PLC  Download  Follow the instructions on the screen

12. Turn the mode selector switch of the CPU to RUN position

Commissioning
3.13 Starting the sequence

1. Check the voltage supply and compressed air supply.
2. Remove the workpieces at the module or station transfer positions prior to manual reset.
3. Carry out the reset sequence. The reset sequence is prompted by an illuminated RESET pushbutton and
executed once the pushbutton has been actuated.
4. Insert the workpiece in the workpiece retainer.
5. Start the sequence of the Testing station. The start is requested via the illuminated START pushbutton
and executed once the pushbutton has been actuated.
Notes
 The sequence can be stopped at any time by pressing the EMERGENCY-STOP pushbutton or the STOP
pushbutton.
 The key-operated switch AUTO/MAN enables you to select between continuous cycle (AUTO) and
individual cycle (MAN).
 In the case of a combination of several stations the following applies:
The individual stations are set against the material flow.
 The warning light COLOUR is not illuminated if the sensing module contains black workpieces. However,
the warning light COLOUR is illuminated if the sensing module contains red or silver workpieces.

Commissioning
3.14 Combination of stations

3.14.1 Networking

In the standard version, the MPS stations are linked using optical sensors. This type of linking is known as
StationLink, which uses through-beam sensor transmitters and receivers as sensors. The StationLink
transmitter is mounted on the incoming material side and the StationLink receiver on the outgoing material
side. By switching on or off the StationLink transmitter, the station signals the upstream station whether it is
ready to receive a workpiece or busy.
The sensors for linking several stations must be arranged face to face in alignment. The linked stations must
be securely interconnected by means of hammer head screws.
Note
In the case of the Distributing station, only the StationLink receiver is mounted and on the Sorting station
only the StationLink transmitter.

4 Operation
The chapter Operation describes the control units required for the operation, as well as start-up and close-
down of the system.
4.1 General operation notes

The stations require some rules of operation which should be observed. If they are not complied, faults in
the processes are possible. Dangers for the physical health also cannot be excluded.
It is recommended to observe the following rules strictly.
4.1.1 Behaviour rules

 During the operation of the stations it is forbidden to grip in by hand.
 With larger audience a mechanical protection of the stations is necessary.
 Removing any cable under tension is forbidden.
 Water has to be kept away from the plant.
4.1.2 Operation rules

 The stations only may be used by introduced persons.
 The operation has to be carried out according to the operating instructions.
 A pushing the different switches/push buttons of all control units unchecked has to be stopped.
 No workpiece carriers may be taken by the system.
4.2 Process description

Orders are entered and started in MES4 software.
The commissioning station has to equip a pallet like defined in the order. It is possible to equip the pallet
with 1-4 different work pieces.
The commissioning station requests the necessary work pieces at the separating and testing station. The
separating station gets the work pieces from the Storing station and the testing station gets the work pieces
from the distribution station. There the work piece is checked for height and the colour – the colour must fit
to the respective order, otherwise the work piece is sorted out on the slide.
If the pallet is equipped, the robot takes the pallet and places it down at the outlay slide from the station.
Robotino 1 takes the pallet from the slide and moves it to the high bay racking for temporary storage. From
there robotino 2 moves the pallet to the respective outlay slide (Slide 1-3) of the system. The requirement
therefore is that the slides are not occupied – in case the slides are occupied, it is necessary to put out the
pallets by hand. The RFID sensors announce this in MES software, there the orders are deleted.

Operation
4.2.1 TripleStackMagazine
The PLC is getting an order from the MES Software, for each order the PLC is organizing the responsible
instructions. Then the instructions are carried out.
Function
The triple stack magazine separates different workpieces from the stack magazine modules. The magazine
barrel of the stack magazine holds up to 10 workpieces. The filling level of the stack magazine is monitored
by means of a through-beam sensor. A double-acting cylinder pushes out the workpieces individually.
The workpieces are pushed out on the conveyor directly. The conveyor begins to start and the workpieces
are transported to the following station.
Position Magazine
1 Magazine 1 for red work pieces
2 Magazine 2 for black work pieces
3 Magazine 3 for silver work pieces

Operation
4.3 Start up MPS stations

4.3.1 Requirements
The reset process is the same for each MPS station. Execute the reset process at each station. The reset
process is also to be executed after STOP- or EMERGENCY-STOP activation.
 Fill up all magazines
 Clear all working positions
4.3.2 Reset process of MPS-stations

The MPS-stations can be started with the reset process, as following.

Operation
4.3.3 Default mode

The default mode is helpful to check the complete system. If the default mode works without an error, all
sensors and actors work faultless. In default mode all stations starting automatically if the START button at
the stations are pressed and all stations are started without error.
Default mode MPS

1. Turn Key switch at all stations to default mode
2. Fill up all magazines at MPS stations
3. Start all stations with START button
4. If the start button at the triple stack magazine is pressed, the station is starting to work. If the following
station has now congestion jam, the first workpiece is separated and transported to the next station.
The sequence is starting with a red workpiece, then a black, then silver and again a red workpiece etc.
5. The testing station checks the height from the workpiece. If the height is ok., the workpiece has the
right orientation and is transported to the next station. If the height is not ok. the workpiece is sorted
out on the slide
6. The processing station is processing the workpiece
7. The pick and place station implements an instrument into the workpiece
8. The Fluid muscle station is pressing the instrument into the workpiece
9. The storage station moves the red workpieces into the top row, the black workpieces into the middle
and the silver workpieces into the lower row. If the following station is not occupied a workpiece is
released from the storage. The station takes the color with the most workpieces in stock
10. The sorting station is sorting out the red workpieces to the first slide. The black and silver workpieces
are transported to the commission station
4.3.4 MES Mode

The MES mode is for automatic mode of the complete system. Operation and order handling is done by the
MES4 Software.
1. Turn Key switch at all stations to MES mode (vertical – Auto)

2. Fill up magazine at distributing stations (MPS)
3. Prepare storage (MPS) equal the settings in MES
4. Remove all workpieces from storage
5. Remove all workpieces from working positions
6. Remove all workpieces from conveyor positions
7. Remove all workpieces from buffer at Log Area
8. Place empty pallet to input slide at log area
9. Start all stations with START button
10. Operation is done by MES Software (See chapter process description)
11. Announcement is done in WinCC

Operation
4.4 TripleStackMagazine
4.4.1 Standalone mode
In standalone mode the triple stack magazine distributes different types of workpieces one after another.
First red, then black, silver, red again, and so on. If a magazine is empty, it automatically jumps to the next
type of workpiece.
Sequence of distribution
 First we select the color. For example if the station distributes a red previously, then it changes to black
[spAuto].
 According to the color of the workpiece to distributed, different cylinders will be extended
[spExtRed / spExtBlack / spExtSilver]. If the magazine is empty, the station will be on Idle state [stIdle].
 When the workpiece arrives at the end of conveyor, the cylinder will be retracted [spRetract].
 Simultaneously the conveyor will stop 1 sec after the workpiece passes the sensor at the end of
conveyor [spStopConv].
 Then the station will be on Idle state [spIdle].
spIdle
Station on Idle state
Station in standalone mode,

and next station is free
spAuto
Change color to the
next.
Red, and magazine 1 Black, and magazine 2 Silver, and magazine 3

Else
is not empty is not empty is not empty
spExtRed spExtBlack spExtSilver spMagEmpty

Extend cylinder at Extend cylinder at Extend cylinder at Empty: Jump back to
magazine 1 magazine 2 magazine 3 spIdle
Workpiece at
conveyor end (-3B1)
spRetract spWait1s
Retract the cylinder at
Empty: Wait 1 sec
the magazine
Cylinder is retracted 1 sec later
spStopConv
Stop the conveyor
motor

Operation
4.4.2 MES mode of triple stack magazine

In MES mode the triple stack magazine cyclically asks for the task from the MES server (in every second). It
sends, the colors it has, and gets a task for one of these colors.
Sequence of distribution
 Firstly the station asks for the next task. It is done by a program called MES_CyclicRequestForOrder.
This program asks for a task, if the station is on Idle state [spIdle]. It means the station sends an “Ask
for a Task” message (M100.1).
 If it has a workpiece with the selected color, it sends a “Task Started” message (M100.10).
[spRedStart / spBlackStart / spSilverStart].
 According to the color of the workpiece to distributed, different cylinders will be extended
[spExtRed / spExtBlack / spExtSilver].
 When the workpiece arrives at the end of conveyor, the “Task Finished” message (M101.1) will be sent
by the station to the MES server [spSendFinished].
 Then the cylinder will be retracted [spRetract].
 Simultaneously the conveyor will stop 1 sec after the workpiece passes the sensor at the end of the
conveyor [spStopConv].
 After that the station waits for next station [spWaitForValidation]. It has to wait for validation, because,
if the validation fails, it has to reproduce the part.
 Then the station will be on Idle state [spIdle].

Operation
spIdle MES_CyclicRequestForOrder
Cylcically request for task in
Station on Idle state every second.
Station in MES mode, task received, and

next station is free
spMES
Registrate the color
Red, and magazine 1 Black, and magazine 2 Silver, and magazine 3

Else
is not empty is not empty is not empty
spRedStart spBlackStart spSilverStart spMagEmpty

Entry: Send "Task Entry: Send "Task Entry: Send "Task Empty: Jump back to
Started" (M100.10) Started" (M100.10) Started" (M100.10) spIdle
Answer received Answer received Answer received
spExtRed spExtBlack spExtSilver

Extend cylinder at Extend cylinder at Extend cylinder at
magazine 1 magazine 2 magazine 3
Workpiece at
conveyor end (-3B1)
spSendFinished
Entry: Send "Task
Finished" (M101.1)
Answer received
spRetract spWait1s
Retract the cylinder at
Empty: Wait 1 sec
the magazine
Cylinder is retracted 1 sec later
spStopConv
Stop the conveyor
motor
spWaitForVali...
Empty: Wait for next
station (validation)
Next station finished

Operation
4.4.3 Material flow

The processes and the material flow in PRO-LOG Factory is an image of a real production and distributing
enterprise. There are buffers and magazines for the raw materials, and a storage for the single products.
According to the customer orders, the products are transported JIS (just in sequence) to the commissioning
robot. The pallets are stored in a high bay storage.
The mobile robots are equipped with a fork on a telescope arm and work as a fork lift to reach the upper
positions of the high-bay racking.
Position Material flow Station
1 Equipped pallets to outlay slide 1 Robotino 2
4 Equipped pallets to high bay storage Robotino 1
5 Equipped pallets from high bay rack to outlay slides Robotino 2
6 Equipped pallets from commissioning station Robotino 1
7 Work pieces from MPS-System MPS Stations
8 Sort out work pieces Sorting Station
9 Empty pallets from AS/RS to slide 4 AS/RS Station
10 Empty pallets Robotino 1
11 Work pieces from MPS-System to commissioning station MPS Stations

5 Technology
This chapter refers to the technology of the station.
For better construction understanding of the station, the technical drawings should be a very helpful data.
The rooms must be checked for their technical datas before built up the station/system. The size of the door
openings and the entrance must be big enough for the measurements of the system. Even the load-capacity
of the floor must be high enough for the system.
5.1 Technical datas

Parameter Value
Operating pressure 6 bar (600 kPa)
Voltage supply 24 V DC, 4.5 A
Digital inputs 7
Digital outputs 8

Technology
5.2 Stack magazine module
The Stack magazine module separates workpieces from a magazine. Up to 10 workpieces can be stacked in
the magazine barrel. The workpieces must be inserted with the open side facing upwards.
A double-acting cylinder pushes the lowest workpiece from the gravity-feed magazine up to the mechanical
stop. This position serves as a transfer point to the conveyor.
The available workpiece in the magazine barrel is detected by means of a through-beam sensor. The
position of the ejecting cylinder is sensed electrically via inductive sensors. The advancing and retracting
speed of the ejecting cylinder is infinitely adjustable by means of one-way flow control valves.

Technology
5.3 Conveyor
The length of conveyor is 700mm and the belt is 40mm wide. The motor is a 36V gear motor and a current
limiter is triggered before.

6 Pneumatic
With the help of the cylinder, the workpiece is distributed from the magazine.
Cylinder to distribute workpiece
Pos. Name
1 Order number 164012
2 Order name DZF-18-60-P-A

Electrical System
6.1 Pneumatic supply

The pressure in the supply line must not exceed 10 bar.
A fine filter has to be installed, to prevent contamination by rust or similar.
A stop cock is required for the supply of the installation.
The pressure regulators should be set in between 5 and 6 bar. The filter and water separators require
maintenance according to the instructions of the documentation of these components.
The exact allocation of the valve terminal can be found in the pneumatic plan.
Service unit
Position Name
1 Order number 152894
2 Order name D S-PWR-LFR

7 Electrical System
To operate the system it is required to connect all of the supply cables and communication lines included.
The cables used to program the system are explained additionally.
To give you a better survey of the being lines used in the plant, these are explained in the following.
7.1 Power supply

The devices are delivered together with the respective power supply plugs, protectively contact covered, in
case they require power supply.
The customer must ensure that the power supply is earthed correctly and is equipped with a fault current
monitor.
If it is required for several devices to be in operation at the same time, it is possible to connect these to a
switchboard containing distribution board, provided that the permissible maximum rating is not exceeded.
Each station contains its own individual EMERGENCY STOP switch, which at first reacts to its respective
station only. It has to be clarified in advance, if a central ROOM EMERGENCY STOP switch is required.

Electrical System
7.2 Controller
Siemens S7 – 314-2PN/DP

Pneumatic
7.2.1 I/O-Components
The modules from the station are pluggable connected via I/O-terminals to the
I/O-cards from the control.
So that a perfect communication can be ensured, the I/O interface is standardized. The I/O terminal is at all
work positions at the disposal.
I/O-Terminal
Technical data
Plug type IEEE 488 24 pins
Inputs 8
Outputs 8
Current consumption Max. 1A/PIN
Power supply 24 VDC

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

8 Maintenance
The triple stack magazine is largely maintenance-free. The following should be cleaned at regular intervals
using a soft fluff-free cloth or brush:
 The lenses of the optical sensors, the fibre-optics and reflectors
 The active surface of the proximity sensor
 The entire station
Do not use aggressive or abrasive cleaning agents.
Festo Didactic GmbH & Co. KG

Rechbergstraße 3
73770 Denkendorf
Germany
Internet: www.festo-didactic.com
E-mail: did@de.festo.com

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ProLog®

2 © Festo Didactic ProLog

1 General safety instructions __________________________________________________________________ 5

3 © Festo Didactic ProLog

4 © Festo Didactic ProLog

General requirements for safe operation of the devices:

5 © Festo Didactic ProLog

6 © Festo Didactic ProLog

1.2 Safety sockets

Colour Function Colour Function

Voltage greater than SELV 24 V DC

Protective conductor Safety extra-low voltage,

© Festo Didactic ProLog 7

1.3 Handling the system

1.3.2 Safety precautions in standard operation

1.3.3 Dangers due to electric current

8 © Festo Didactic ProLog

1.3.4 Dangers due to pneumatic energy

1.3.5 Maintenance – Servicing – Malfunction removal

1.3.6 Organizational measures

1.4.2 Training operations

1.4.3 Outside training operations

1.4.4 Obligations of the operating company

Personnel should be tested at regular intervals for safety-conscious work habits.

1.5 Obligations of the trainees

© Festo Didactic ProLog 9

2.2 Intended use

2.3 Important notes

10 © Festo Didactic ProLog

© Festo Didactic ProLog 11

2.4.1 Triple stackMagazine

Workpieces handled by feed devices are

12 © Festo Didactic ProLog

The function of the Distributing station is

The Distributing station consists of the following:

Station 3fach Magazin mit Wagen, Bedienpult und SPS Board

© Festo Didactic ProLog 13

Overview prolog-factory system

Position Description Position Description

1 Triple stack magazine station 8 Sorting station

2 Testing station with colour sensor 9 Log area

3 Processing station 10 Robotino 2

4 Pick and place station 11 Robotino 1

5 Fluid muscle station 12 Commissioning station

6 Storing station 13 Connecting conveyor 3

14 © Festo Didactic ProLog

2.6 Didactic structure

Training contents covering the following subjects can be taught:

© Festo Didactic ProLog 15

Maintenance and Troubleshooting:

16 © Festo Didactic ProLog

3.1.2 Scope of delivery

17 © Festo Didactic ProLog

Installation design prolog factory

18 © Festo Didactic ProLog

3.3.1 Pneumatic commissioning

© Festo Didactic ProLog 19

3.3.2 Electric commissioning

3.3.3 Connecting communication cables

The communication systems are:

20 © Festo Didactic ProLog

Ethernet communication cables

© Festo Didactic ProLog 21

Position Station Ethernet address