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MECHATRONICS HANDS-ON SKILLS FOR MODULE 4:

GAUGING (Siemens S7-3xx/Siemens STEP 7)

ITEMS NEEDED FOR HANDS-ON SKILLS Amatrol Supplied 87-MS2 Mechatronics Gauging Station 870-PS7313-AAU, 870-PS7314-AAU, or 870-PS7315-AAU Mechatronics Learning System for Siemens S7-300 - one per station 72024 Siemens S7-300 Programming Cable 82-900 Siemens Step 7 Programming Software

School Supplied Computer with Windows 7 Operating System

Amatrol or School Supplied 41222 Hand Tool Kit or Equivalent

FIRST EDITION, MODULE 4, REV. A Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their respective companies. Copyright © 2016 by AMATROL, INC. All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any means, electronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying, recording or any information storage and retrieval system, without written permission of the copyright owner. Amatrol, Inc., 2400 Centennial Blvd., Jeffersonville, IN 47130 USA, Ph 812-288-8285, FAX 812-283-1584 www.amatrol.com

S01-1

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

Procedure Overview

In this procedure, you will adjust the sensitivity of the ultrasonic sensor on the 87-MS2 Gauging station. This will adjust the level at which a discrete output is supplied by the sensor. This will familiarize you with adjusting analog sensor sensitivity.

 1. Locate the 87-MS2 Gauging station, shown in fi gure 1-1.

Figure 1-1. Gauging Station

S01-2

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

 2. Verify that this station has been separated from any other stations. If it has not, then separate it from the other stations.

 3. Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 1-2. Mechatronics Safety Check

 4. Perform the following substeps to open the PLC programming software.

A. Make sure that the interface from the personal computer to the PLC is connected.

B. Power up the PC and monitor.

C. Start the SIMATIC Manager.  5. Plug the station’s power cable into a wall outlet.  6. Perform the following substeps to power up the 87-MS2 Gauging Station.

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electrical power source.

C. Turn the station’s Main Power Switch to the On position.  7. Perform the following substeps to open project Gauging.

A. Click the Open Project/Library button.

The Open Project/Library dialog should open.

B. Locate project Gauging.

The project Gauging is provided on a supplemental disk.

If it is not listed on the dialog, click the Browse button on the dialog to view the projects located in the S7Proj folder.

C. Double-click the Gauging icon to open the project.

D. Select Expand All from the View menu to expand the project’s contents.

The option is “Expand All” if using STEP 7 Version 5.2 or “Show All Levels” if using STEP 7 Version 5.3.

S01-3

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

 8. Perform the following substeps to download the PLC project named Gauging to the PLC.

A. Place the PLC’s Mode Selector switch in the RUN position.

B. Reset the PLC.

C. Download the SIMATIC 300 Station object to the PLC.

Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart.

D. Click Yes on the dialog to complete a warm restart.  9. Press the Output Power pushbutton to enable the PLC’s outputs.  10. Perform the following substeps to adjust an analog sensor.

A. Obtain from your instructor several good and bad valve bodies.

Good valve bodies have ports drilled in them and measure 0.91-0.99 inches in height. Bad valve bodies measure less than 0.895 inches and/or do not have ports drilled in them.

B. Locate the Ultrasonic sensor, shown in fi gure 1-3, on the Gauging station.

In this application, the ultrasonic sensor looks for valve bodies that are the correct height. If a valve body passes under the sensor, but it does not fall within the upper and lower boundary windows, the station rejects the valve body as a bad part.

Figure 1-3. Ultrasonic Sensor

ULTRASONIC SENSOR

S01-4

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

Figure 1-4. Good and Bad Valve Bodies

C. Obtain from your instructor the gauge blocks, which are solid aluminum blocks with a U (upper) and an L (lower) stamped on them. The one with the U is the tallest and the one with the L is the shortest.

They will be used to program the range or window of acceptable part heights into the sensor.

D. Place the tallest gauge block, the one stamped with a U, into the recess on the traverse axis, as shown in fi gure 1-5.

Figure 1-5. Valve Body on the Traverse Axis

UPPER BOUNDARY

LOWER BOUNDARY

UPPER BOUNDARY

LOWER BOUNDARY

GOOD PART BAD PART

S01-5

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

E. Use the motor starter’s manual overrides, shown in fi gure 1-6, to position the traverse axis so that the valve body is directly under the ultrasonic sensor, as shown in fi gure 1-7.

Figure 1-6. Motor Starter Manual Overrides

Figure 1-7. Traverse Axis Position

SENSOR

CARRIAGE

PART

INDUCTIVE SENSOR TAB

REVERSE MANUAL

OVERRIDE M2

FORWARD MANUAL

OVERRIDE M1

S01-6

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

F. Verify the inductive sensor is triggered by the tab on the carriage. The yellow LED should be on.

G. Locate the Digital I/O Interface module terminals shown in fi gure 1-8.

The + and - signal pins will be used to provide the 24VDC and common respectively to program the sensor.

Figure 1-8. Digital I/O Interface Module

H. Locate the gray conduit behind the I/O module as shown in fi gure 1-8.

I. Remove the cover from the conduit assembly by sliding it to the right.

J. Locate where the cable from the ultrasonic sensor as it enters the conduit.

This can be done by following the cable from the ultrasonic sensor.

SIGNAL PINS

GRAY CONDUIT

S01-7

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

K. Locate the white wire with connector that ends in the conduit assembly, as shown in fi gure 1-9.

The white wire is the programming input for the ultrasonic sensor. It is unused during normal use.

Figure 1-9. Ultrasonic Sensor Programming Input

L. Remove the end cap from the connector by pulling it off.

M. Touch the connector tip to the (-) negative terminal for one second.

This programs the upper window boundary (the distance from the sensor face to the top of the part) into the sensor. The green LED on the sensor should fl ash to indicate that the boundary has been successfully stored.

WHITE WIRE

CONNECTOR

END CAP

S01-8

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

N. Remove the U gauge block and replace it with the L gauge block.

O. Touch the end of the connector to the + terminal, as shown in fi gure 1-10, for 1 second.

This programs the lower window boundary (the distance from the sensor face to the top of the part) into the sensor. The green LED on the sensor should fl ash to indicate that the boundary has been successfully stored.

Figure 1-10. Programming the Ultrasonic Sensor

P. Replace the end cap of the connector by pushing it on.

Q. Replace the cover on the conduit.

R. Replace the gauge block with a known good valve body on the traverse carriage.

CONNECTOR INSERTED INTO

+ TERMINAL

S01-9

SKILL 1 ADJUST AN ANALOG SENSOR WITH A DISCRETE OUTPUT

 11. Perform the following substeps to test the calibration of the sensor.

A. Use the motor starter’s manual overrides to position the traverse axis at the beginning of travel (BOT) position, as shown in fi gure 1-11.

Figure 1-11. Traverse Axis at Beginning of Travel Position

B. Move the traverse axis to the right by pressing motor starter M1’s manual override.

Notice the status of the ultrasonic sensor’s LEDs as the part passes under the sensor.

The LEDs should only turn on if the valve body is determined to be within the boundaries of the programmed window. In this substep, the LED should turn on because the valve body is good.

C. Reposition the traverse axis to the BOT position by pressing motor starter M2’s (reverse motor starter) manual override. Keep it pressed until the traverse axis reaches the BOT position, then release it.

D. Replace the good valve body with a bad valve body.

The bad valve body should be shorter than the good valve body. If you need to measure the valve bodies, the bad ones measure less than 0.94 inches.

E. Move the traverse axis to the right by pressing motor starter M1’s manual override.

Notice the status of the sensor’s LEDs as the part passes under the sensor.

In this substep, the LEDs should not turn on because the valve body is bad. If it does turn on, repeat Step 10 to calibrate the sensor until it operates correctly with both the good and bad valve bodies.

 .12. Perform the following substeps power down the station.

A. Close the SIMATIC Manager. B. Turn off the PC and monitor. C. Turn the Main Power switch Off. D. Perform a lockout/tagout on the system’s electrical power source.

BOT POSITION

PART

ULTRASONIC SENSOR

S02-1

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

Procedure Overview

In this procedure, you will operate the 87-MS2 Gauging station. You will verify that the components of the station are properly adjusted, and run the station in both the manual and automatic modes. You will also observe how the station recovers from an emergency stop and a loss of power. This will familiarize you with the layout and operation of the Gauging station.

 1. Locate the 87-MS2 Gauging station.  2. Verify that this station has been separated from any other stations. If it has

not, then separate it from the other stations.  3. Perform the following safety check before you begin working on the station.

Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 2-1. Mechatronics Safety Check

S02-2

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

 4. Perform the following substeps to mount the parts bin.  The bin is used when the station is separated from the other stations.

A. Locate the mounting bracket, red plastic parts bin, 2 T-nuts, and 2 thumbscrews, shown in fi gure 2-2.

Figure 2-2. Parts Bin and Mounting Hardware

S02-3

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

B. Loosen the end cap on the right side of the work surface (as you are facing the station) by prying it off.

A screwdriver may be required as the end cap may have a tight fi t. In fi gure 2-3, the rear end cap was loosened.

Figure 2-3. Loosen the End Cap

C. Slide the two T-nuts along the inside of the aluminum extrusion so that they are positioned in line with the end of the traverse.

Figure 2-4. Positioning the T-Nuts

T-NUTS

S02-4

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

D. Reattach the end cap by pushing it into the extrusion.

E. Position the mounting bracket so it is in line with the traverse. The transfer cylinder will push the parts off the carriage and into the parts bin.

The milled area of the bracket faces the traverse.

F. Use a screwdriver to position the T-nuts so they are in line with the holes in the mounting bracket.

G. Insert the thumbscrews through the outside of the bracket so that the threads engage the T-nuts. Then tighten the thumbscrews by turning them CW until snug so the bracket is secure.

The T-nuts have a tendency to angle back away from vertical, so this step may take several tries.

Figure 2-5. Parts Bin Mounting Bracket Attached to the Station

MILLED AREA

S02-5

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

H. Mount the plastic parts bin to the bracket as shown in fi gure 2-6.

Figure 2-6. Parts Bin Mounted to the Bracket

 5. Connect an air supply line to the station’s air manifold quick connect.  6. Plug the station’s power cable into a wall outlet.  7. Perform the following substeps to power up the 87-MS2 Gauging station.

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electrical power source.

C. Remove the lockout/tagout device from the pneumatic power source.

D. Turn air on to the station by shifting the lever on the lockout valve.

E. Set the station’s air supply regulator to 50 psi/345 kPa.

F. Turn the station’s Main Power Switch to the On position.  8. Perform the following substeps to open the PLC programming software.

A. Make sure that the interface from the personal computer to the PLC is connected.

B. Power up the PC and monitor.

C. Start the SIMATIC Manager.  9. Perform the following substeps to open project Gauging Station.

A. Click the Open Project/Library button.

The Open Project/Library dialog should open.

GOOD PARTS

BIN

REJECT PARTS

BIN

S02-6

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

B. Locate project Gauging.

The project Gauging was provided on a supplemental disk.

If it is not listed on the dialog, click the Browse button on the dialog to view the projects located in the S7Proj folder.

C. Double-click the Gauging icon to open the project.

D. Select Expand All from View menu to expand the project’s contents.

The option is “Expand All” is using STEP 7 Version 5.2 or “Show All Levels” if using STEP 7 Version 5.3.

 10. Perform the following substeps to download the project Gauging Station to the PLC.

A. Place the PLC’s Mode Selector switch in the RUN position.

B. Reset the PLC.

C. Select the SIMATIC 300 Station object by clicking it so that it is highlighted.

D. Click the Download button to download the project to the PLC.

Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart.

E. Click Yes on the dialog to complete a warm restart.  11. Press the Output Power pushbutton to enable the PLC’s outputs.  12. Perform the following substeps to home the station and set manual mode.

A. Turn the Mode Selector switch to Reset.

This will home all of the actuators.

The Start pushbutton should be off when all of the actuators are in the home position.

B. Turn the Mode Selector switch back to Manual.  13. Perform the following substeps to move the station through its sequence of

operations in the manual mode for a good part.  In the manual mode, each momentary press of the start pushbutton causes the

station’s next sequence step to be performed.  Observe the system and notify your instructor of anything that does not

function properly or needs adjustment.

A. Obtain a good valve body from your instructor.

A good valve body has the ports milled in it and measures 0.94-1.00 inch in height.

B. Manually place a good valve body in the recess provided on the traverse carriage with the side with two holes facing PE1.

The photoelectric sensor should detect the left of the two holes on the valve body and determine the part is good.

S02-7

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

C. Press and release the Start pushbutton to activate Step 1 of the sequence.

The traverse carriage should begin moving toward the EOT position. As the traverse moves, the ultrasonic sensor should make a measurement as the valve body passes underneath and send the data to the PLC. The yellow LED on the ultrasonic sensor should turn on as the part passes beneath it. The carriage should move until it reaches the hard stop at the EOT position. LS2 should activate and the motor should turn off.

You should see the following sequence occur.

1. Extend Traverse

2. Stop motor/Extend Lift cylinder

3. Extend Transfer cylinder

4. Retract Transfer cylinder

5. Retract Lift cylinder

6. Retract Traverse

7. Cycle ends

D. Press and release the Start pushbutton to activate step 2 of the sequence.

The Lift Cylinder should extend fully and stop, raising the valve body.

E. Press and release the Start pushbutton to activate step 3 of the sequence.

Because the PLC compared the data from the ultrasonic sensor and determined the part was good, the transfer cylinder should extend and push the valve body off of the carriage.

F. Press and release the Start pushbutton to activate step 4 of the sequence.

The transfer cylinder should retract fully.

G. Press and release the Start pushbutton to activate step 5 of the sequence.

The lift cylinder should retract fully.

H. Press and release the Start pushbutton to activate step 6 of the sequence.

The carriage should move toward the BOT position. When the carriage reaches limit switch LS1, it should activate and the motor should turn off. This is step 7 of the sequence.

 14. Perform the following substeps to move the station through its sequence of operations in manual mode for a bad valve body.

A. Obtain a short valve body from your instructor.

A short valve body measures less than 0.94 inch.

B. Manually place the bad valve body in the recess provided on the traverse carriage with the side with two holes facing PE1.

The photoelectric sensor should detect the right of the two holes on the valve body and determine the part is good.

C. Press and release the Start pushbutton to activate Step 1 of the sequence for a bad or rejected part.

S02-8

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

The traverse carriage should begin moving toward the EOT position. As the traverse moves, the ultrasonic sensor should make a measurement as the valve body passes underneath and send the data to the PLC. The yellow LED on the ultrasonic sensor should not turn on as the part passes beneath it. The carriage should move until it reaches the hard stops at the EOT position. LS2 should activate and the motor should turn off.

You should see the following sequence occur.

1. Extend traverse

2. Stop motor/extend lift cylinder

3. Extend reject cylinder

4. Retract reject cylinder

5. Retract lift cylinder

6. Retract traverse

7. Cycle ends

D. Press and release the Start pushbutton to activate step 2 of the sequence.

The lift cylinder should extend fully and stop, raising the valve body.

E. Press and release the Start pushbutton to activate step 3 of the sequence.

Because the PLC compared the data from the ultrasonic sensor and determined the part was not good, the reject cylinder should extend and push the valve body off of the carriage.

F. Press and release the Start pushbutton to activate step 4 of the sequence.

The reject cylinder should retract fully.

G. Press and release the Start pushbutton to activate step 5 of the sequence.

The lift cylinder should retract fully.

H. Press and release the Start pushbutton to activate step 6 of the sequence.

The carriage should move toward the BOT position. When the carriage reaches limit switch LS1, it should activate and the motor should turn off. This is step 7 of the sequence.

 15. Turn the Mode Selector switch to Auto.  If you successfully single-stepped through the complete sequence and all

of the actuators are back in their home position, the Start pushbutton lamp should be off at this time and you can move on to Step 17. If it is not, perform Step 16 to reset the actuators.

 16. Perform the following substeps to home the station and set automatic mode.

A. Turn the Mode Selector switch to Reset.

This will move all of the actuators back to their home positions.

B. Turn the Mode Selector switch to Auto.

Once the actuators are reset and automatic is selected, the Start pushbutton lamp should be off.

 17. Place a valve body in the recess provided on the carriage. Make sure the valve body is oriented as in Step 13B.

S02-9

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

 18. Press the Start pushbutton to start the automatic cycle.  Observe the station while it goes through one cycle. It is programmed to run

through one cycle and then stop. The Start pushbutton indicator is on solid during the whole cycle to indicate the station is operating.

 19. Perform the following substeps to record the operation of the station when the Stop pushbutton is pressed.

 This will show you how the system is programmed to respond to the Stop pushbutton.

A. Load the carriage with a valve body in the correct orientation.

B. Press the Start pushbutton to start an automatic cycle.

C. During the middle of the cycle press the Stop pushbutton to stop the system.

The Stop pushbutton is programmed as a halt function, which means the station will complete its current sequence step and stop with all power remaining on.

You should see the operation continue to the end of the current sequence step and stop.

D. Observe the operator panel indicators and record their status in the table below.

OPERATOR PANEL INDICATORS

Indicator Status (On/Off/Blinking)

Output Power Lamp

Start Lamp

Emergency Stop Lamp

Figure 2-7. Operator Panel Indicators

Since this is a halt, the machine can resume operation, so you should observe that Output power remains on and the Start pushbutton should be off. It has been programmed to do so when the auto program has been halted. The Emergency Stop lamp should be off because it is not pressed.

E. Observe the PLC processor’s status indicators and record their status.

PLC PROCESSOR STATUS INDICATORS

Indicator Status (On/Off)

DC5V

FRCE

RUN

STOP

Figure 2-8. PLC Processor Status Indicators

S02-10

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

You should see that the PLC processor’s DC5V and Run indicator lights are on, because the station is halted and ready to resume automatic operation.

F. Observe the PLC I/O modules’ status indicators to see if any of them are on.

You should see various input and output indicators on. Which ones are on depend on the point in the operation at which the Stop pushbutton was pushed.

G. Press the Start pushbutton to restart the system.

It should continue where it left off and fi nish the cycle.

NOTE

If any actuators are manually moved while the system is halted, the station may not resume operation when the start pushbutton is pressed. If this occurs, go to Step 20 and restart the system.

H. Repeat substeps A-G three times, stopping the cycle with the Stop pushbutton at different times to observe how it reacts.

I. Proceed to Step 21.  20. Perform the following substeps to restart the station if any of the inputs

change after the Stop pushbutton is pressed.  If any of the inputs were changed, like a part removed from the traverse

axis, or a cylinder moved physically, the system cannot be restarted with the Start pushbutton. This is because the input signals will no longer match those needed to begin the sequence. This is a protective measure to prevent damage to the system.

A. Remove any valve bodies from the carriage.

B. Turn the Mode Selector switch to Reset.

This will move all of the actuators back to their home positions.

Once the actuators are reset, the Start pushbutton should turn off.

C. Load the carriage with a valve body in the correct orientation.

D. Turn the Mode Selector switch back to Auto.

E. Press and release the Start pushbutton to start the automatic cycle.

Observe the system while it goes through a cycle before continuing to the next step.

 21. Perform the following substeps to record the operation of the station when the Emergency Stop pushbutton is pressed.

 This step will show you how the system is programmed to respond to the emergency stop pushbutton.

A. Load the carriage with a valve body in the correct orientation.

B. Press and release the Start pushbutton.

C. During the cycle, press the Emergency Stop pushbutton.

S02-11

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

D. Observe the operator panel indicators and record their status in the table below.

OPERATOR PANEL INDICATORS

Indicator Status (On/Off/Blinking)

Output Power Lamp

Start Lamp

Emergency Stop Lamp

Figure 2-9. Operator Panel Indicators

Since this is an Emergency Stop, the machine cannot resume operations. You should observe that the Output Power is off, the Start pushbutton lamp is off, and the Emergency Stop lamp is on. The Emergency Stop function does not remove the air supply.

E. Observe the PLC processor’s status indicators and record their status.

PLC PROCESSOR STATUS INDICATORS

Indicator Status (On/Off)

DC5V

FRCE

RUN

STOP

Figure 2-10. PLC Processor Status Indicators

You should see the PLC processor’s DC5V and Run indicator lights on.

F. Observe the PLC I/O modules’ status indicators to see if any of them are on.

You should see various input indicators on, but all output indicators are off. This is because the Emergency Stop circuit breaks power to the Output Power contactor, which drops all output power.

 22. Perform the following substeps to recover from the Emergency Stop.

A. Remove any valve bodies on the carriage.

B. Pull the Emergency Stop pushbutton out.

C. Press the Output Power pushbutton to turn the outputs back on.

You should hear the contactor pull in to re-establish the power to the outputs.

D. Turn the Mode Selector switch to Reset.

This will move all of the actuators back to their home positions. Once the actuators are reset, the Start pushbutton lamp should be off.

E. Place a correctly oriented valve body into the recess on the carriage.

F. Turn the Mode Selector switch back to Auto.

G. Press and release the Start pushbutton to start the automatic cycle.

S02-12

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

Observe the system while it goes through a cycle.

H. Press the Stop pushbutton after the cycle completes.

I. Load the carriage with a correctly orientated valve body after the cycle completes.

 23. Perform the following substeps to record the operation of the station when it experiences a power loss.

 This will show you how the station is programmed to respond to a power loss.

A. Press the Start pushbutton to start an automatic cycle.

B. During the middle of the cycle turn the Main Power switch to Off to remove power to the system.

C. Observe the operator panel indicators and record their status in the table below.

OPERATOR PANEL INDICATORS

Indicator Status (On/Off/Blinking)

Output Power Lamp

Start Lamp

Emergency Stop Lamp

Figure 2-11. Operator Panel Indicators

Because this is a power loss, simulated by turning the Main Power switch off, power to everything past the Main Power switch is turned off. You should see all operator panel indicator lamps and PLC indicators are off, but you will notice that the pneumatic power remains. You should also have seen any cylinders complete their strokes because they are pneumatically operated.

D. Observe the PLC processor’s status indicators and record which indicators are on.

PLC PROCESSOR STATUS INDICATORS

Indicator Status (On/Off)

DC5V

FRCE

RUN

STOP

Figure 2-12. PLC Processor Status Indicators

You should see all indicators off because there is no power to the PLC.

E. Observe the PLC I/O modules’ status indicators to see if any of them are on.

Again, you should see all input and output indicators off because the modules have no power.

S02-13

SKILL 2 OPERATE AN AUTOMATED GAUGING STATION

 24. Perform the following substeps to recover from the power loss.

A. Remove any valve bodies that are on the carriage.

B. Place the Mode Selector switch in the Manual position.

C. Turn the station’s Main Power switch to the On position.

D. Press the Output Power pushbutton to enable the PLC’s outputs.

You should also hear the contactor located next to the PLC module pull in. The Start pushbutton should be blinking because the station is not ready for operation.

E. Turn the Mode Selector switch to Reset.

This will move all of the actuators back to their home positions.

F. Turn the mode selector switch to Auto.

Once the actuators are reset, the Start pushbutton should turn off.

G. Place a correctly oriented valve body onto the carriage.

H. Press the Start pushbutton to restart the operation.

You should see the system start through its sequences.

I. Run the system through two complete cycles to make sure it has recovered correctly.

 25. Perform the following substeps to power down the station.

A. Turn the Main Power switch Off.

B. Close the SIMATIC Manager.

C. Turn off the PC and monitor.

D. Perform a lockout/tagout on the system’s electrical power source.

E. Perform a lockout/tagout on the system’s pneumatic power source.

S03-1

SKILL 3 ADJUST NON-SERVO LINEAR TRAVERSE AXIS TRAVEL

Procedure Overview

In this procedure, you will adjust the traverse distance of the linear traverse axis by changing the position of the stop. This will familiarize you with adjusting the stops on the linear traverse axis and with its operation.

 1. Locate the 87-MS2 Gauging station.  2. Verify that this station has been separated from any other stations. If it has

not, then separate it from the other stations. If it has, then proceed to Step 3.  3. Perform the following safety check before you begin working on the station.

Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 3-1. Mechatronics Safety Check

 4. Verify the red plastic parts bin is attached onto the mounting bracket at the EOT position.

 The bin is used when the station is separated from the other stations.  5. Connect an air supply line to the station’s air manifold quick connect.  6. Plug the station’s power cable into a wall outlet.  7. Perform the following substeps to power up the 87-MS2 Gauging station.

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electrical power source.

C. Remove the lockout/tagout device from the pneumatic power source.

D. Turn on the air to the station by shifting the lever on the lockout valve.

E. Set the station’s air supply regulator to 50 psi/345 kPa.

F. Turn the station’s Main Power Switch to the On position.

S03-2

SKILL 3 ADJUST NON-SERVO LINEAR TRAVERSE AXIS TRAVEL

 8. Perform the following substeps to open the PLC programming software.

A. Make sure that the interface from the personal computer to the PLC is connected.

B. Power up the PC and monitor.

C. Start the SIMATIC Manager.  9. Perform the following substeps to open project Gauging Station.

A. Click the Open Project/Library button.

The Open Project/Library dialog should open.

B. Locate project Gauging.

The project Gauging Station was provided on a supplemental disk.

If it is not listed on the dialog, click the Browse button on the dialog to view the projects located in the S7Proj folder.

C. Double-click the Gauging icon to open the project.

D. Select Expand All from the View menu to expand the project’s contents.

The option is “Expand All” is using STEP 7 Version 5.2 or “Show All Levels” if using STEP 7 Version 5.3.

 10. Perform the following substeps to download the project Gauging to the PLC.

A. Place the PLC’s Mode Selector switch in the RUN position.

B. Reset the PLC.

C. Select the SIMATIC 300 Station object by clicking it so that it is highlighted.

D. Click the Download button to download the project to the PLC.

Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart.

A. Turn the Mode Selector switch to Reset.

This will home all of the actuators.

B. Turn the Mode Selector switch back to Manual.

S03-3

SKILL 3 ADJUST NON-SERVO LINEAR TRAVERSE AXIS TRAVEL

 13. Perform the following substeps to adjust the EOT hard stop on the traverse axis.

 The stop will be adjusted so that the carriage stops earlier in its travel.

Figure 3-2. Adjustable Clamp Collars

A. Use the motor starter manual overrides to position the carriage in its EOT position. This is the end opposite the motor

B. Mark the position of the carriage on the guide rod using tape or a grease pencil. You will need to move it back to its original position later in the skill.

C. Loosen the set screws on the clamp collar using a 7/64 in. hex wrench.

D. Slide the clamp collar to the right so it is out of the way.

MOVE CLAMP

COLLAR RIGHT

LS2

S03-4

SKILL 3 ADJUST NON-SERVO LINEAR TRAVERSE AXIS TRAVEL

E. Using the motor starter manual overrides, position the carriage in the new EOT position, as shown in fi gure 3-3.

The carriage should almost touch the bracket for the transfer bin.

Figure 3-3. Carriage in New EOT Position

F. Slide the clamp collar up against the carriage.

G. Tighten the set screw.

H. Locate the limit switch LS2.

This limit switch, shown in fi gure 3-2, is on the back side of the traverse axis frame near the hard stop you just adjusted.

I. Mark the current location of the limit switch with a pencil or tape.

J. Loosen the set screws that attach the limit switch to the rail.

K. Move the switch toward the carriage.

L. Move the switch body forward until the limit switch actuator arm is just touching the carriage.

M. Monitor PLC input status indicator I1.6 and move the limit switch forward until you now see that the PLC indicator turns on.

N. Tighten the set screws that attach the limit switch to the rail.  14. Perform the following substeps to test the adjustment.

A. Turn the Mode Selector switch to the Reset position.

B. Turn the Mode Selector switch to Auto.

C. Load the traverse carriage with a valve body.

D. Press and release the Start pushbutton.

Observe the operation of the station. The carriage should move to the right until it strikes the hard stop. If the limit switch is properly adjusted, it should actuate and the motor should stop. If it does not stop, repeat Step 13 substeps J through N to adjust the limit switch. Otherwise the station should perform the rest of its sequence.

BRACKET FOR BIN

S03-5

SKILL 3 ADJUST NON-SERVO LINEAR TRAVERSE AXIS TRAVEL

 15. Perform the following substeps to adjust the hard stop to its original position.

A. Loosen the set screw on the clamp collar.

B. Move the clamp collar back to the right so it is out of the way.

C. Use the motor starter manual overrides to move the carriage back to its original EOT position, which you marked previously.

D. Move the clamp collar to the left so that it is against the carriage.

E. Tighten the set screw.

F. Adjust limit switch LS2.

PLC input status indicator I1.6 should turn on just as the carriage reaches the hard stop.

 16. Perform the following substeps to test the adjustment.

A. Turn the Mode Selector switch to the Auto position.

B. Place a valve body onto the traverse axis.

C. Press and release the Start pushbutton.

Observe the operation of the station. It should perform its sequence. The carriage should move to the right, the Lift cylinder should extend to lift the part, and either the Reject or Transfer cylinder should extend to place the part in either the Reject bin or Transfer bin.

Make sure that the carriage is in the correct position when the part is being removed from the traverse axis.

D. Press the Stop pushbutton after the carriage stops.

If the adjustment is correct, continue to Step 17, otherwise repeat Steps 15 and 16 until the hard stop is properly adjusted.

 17. Perform the following substeps to power down the station.

A. Close the SIMATIC Manager.

B. Turn off the PC and monitor.

C. Turn the Main Power switch Off.

D. Perform a lockout/tagout on the system’s electrical power source.

E. Perform a lockout/tagout on the system’s pneumatic power source.

S04-1

SKILL 4 ADJUST A SYNCHRONOUS BELT DRIVE

Procedure Overview

In this procedure, you will adjust both the tension and alignment of the synchronous belt drive. This will familiarize you with performing the adjustments required by a synchronous belt drive.

 1. Locate the 87-MS2 Gauging station.  2. Verify that this station has been separated from any other stations. If it has

not, then separate it from the other stations. If it has, then proceed to Step 3.  3. Perform the following safety check before you begin working on the station.

Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 4-1. Mechatronics Safety Check

 4. Perform the following substeps to prepare the belt drive to be adjusted.

A. Using a grease pencil, mark the motor mount location on the extruded aluminum work surface so it can be returned to the same location after it has been moved.

S04-2

SKILL 4 ADJUST A SYNCHRONOUS BELT DRIVE

B. Loosen the motor mounting screws, shown in fi gure 4-2, using a 1/8 inch hex wrench.

Figure 4-2. Motor Mounting Screws

C. Slide the motor towards the traverse axis so that the belt loosens.

D. Remove the belt from the pulleys

E. Inspect both of the pulleys for cleanliness and wear. Clean the pulleys if they are dirty.

 5. Perform the following substeps to mount the belt.

A. Move the motor toward the traverse axis.

B. Place the belt over both of the pulleys.  6. Perform the following substeps to align the pulleys.

A. Reposition the motor so that it is back in its original position, which you marked earlier with a grease pencil.

B. Tighten the motor mounting screws.

MOTOR MOUNTING SCREWS

S04-3

SKILL 4 ADJUST A SYNCHRONOUS BELT DRIVE

C. Place a straight edge against the face of both pulleys.

If both pulleys are aligned, all four edges of the pulleys (PT1-PT4) should be touching the straight edge, as shown in fi gure 4-3.

Figure 4-3. Properly Aligned Pulleys

 7. If the pulleys are aligned, continue to Step 8. Otherwise, perform the following substeps to align the pulleys.

A. Loosen the motor mounting screws.

B. Adjust the motor so that all four edges of the pulleys touch the straight edge as shown in fi gure 4-3.

C. After the pulleys are aligned, tighten the motor mounting screws.

D. Check the alignment after the mounting screws have been tightened.

If the alignment is correct, continue to Step 8. If it is not correct, repeat substeps A through D.

 8. Perform the following substeps to check belt tension.

A. Press on the top of the belt with your fi nger.

It should defl ect no more than 1/4 inch.

B. If the tension is OK, proceed to Step 9. Otherwise, perform the following substeps.

C. Loosen the motor mounting screws.

0 1

2 3

4 5

6 7

8 9

10 11

PT1

PT2

PT3

PT4

S04-4

SKILL 4 ADJUST A SYNCHRONOUS BELT DRIVE

D. Move the motor away from the traverse axis so that the belt tightens.

Make sure that you do not move it so that the pulleys are misaligned.

E. Tighten the motor mounting screws.

F. Check the pulley alignment.

If it is OK, proceed to substep G. Otherwise, perform the pulley alignment procedure.

G. Press on the top of the belt with your fi nger.

The belt should defl ect no more than 1/4 inch.

If the tension is OK, proceed to Step 9. Otherwise, repeat substeps C through G.

 9. Plug the station’s power cable into a wall outlet.  10. Perform the following substeps to power up the 87-MS2 Gauging station.

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electrical power source.

C. Turn the station’s Main Power Switch to the On position.  11. Press the Output Power pushbutton to enable the PLC’s outputs.  12. Perform the following substeps to test the belt drive.

A. Locate motor starters M1 and M2.

B. Press motor starter M1’s manual override to drive the traverse table away from the BOT position.

C. Watch the belt as the motor is rotating.

Make sure that the belt operation is smooth and that the belt is not rubbing against one side of either pulley.

D. Press motor starter M2’s manual override to drive the traverse table back to the BOT position.

E. If the alignment seems correct, proceed to Step 13. Otherwise, turn off power and repeat Steps 7 through 12 to readjust and test the belt.

 13. Perform the following substeps to power down the station.

A. Turn the Main Power switch Off.

B. Perform a lockout/tagout on the system’s electrical power source.

S05-1

SKILL 5 ADJUST A CLUTCH ON A BALL SCREW DRIVE

Procedure Overview

In this procedure, you will adjust the clutch on the ball screw drive to different levels and test the operation of the clutch. This will familiarize you with the operation and adjustment of the clutch on the ball screw drive.

 1. Locate the 87-MS2 Gauging station.  2. Verify that this station has been separated from any other stations. If it has

not, then separate it from the other stations. If it has, then proceed to Step 3.  3. Perform the following safety check before you begin working on the station.

Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 5-1. Mechatronics Safety Check

 4. Plug the station’s power cable into a wall outlet.  5. Perform the following substeps to power up the 87-MS2 Gauging Station.

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electrical power source.

C. Turn the station’s Main Power Switch to the On position.

S05-2

SKILL 5 ADJUST A CLUTCH ON A BALL SCREW DRIVE

 6. Perform the following substeps to reduce the torque setting on the multi-plate slip clutch.

A. Locate the clutch assembly and motor starters shown in fi gure 5-2.

Figure 5-2. Clutch Assembly and Motor Starters

B. Turn the knurled adjustment knob, shown in fi gure 5-3, CCW (looking at the rear of the clutch assembly) two or three turns.

You should be able to see that the tension on the springs is being reduced as you turn the knob.

Figure 5-3. Clutch Torque Adjustment Knob

C. Press motor starter M1’s manual override.

The torque setting should be very low. The motor may rotate, but the clutch might slip, and the traverse axis will stay in position.

D. Release motor starter M1’s manual override.

E. If the clutch did not slip, reposition the axis to the left-hand side stops and turn the adjustment knob one more turn counter-clockwise. Repeat substeps C and D.

If the clutch did slip and the axis did not move, proceed to Step 7. Otherwise, repeat substeps A through E.

 7. Perform the following substeps to increase the torque setting on the multi- plate slip clutch.

A. Turn the knurled adjustment knob CW (looking at the rear of the clutch assembly) two or three turns.

You should be able to see that the tension on the springs is being increased as you turn the knob.

CLUTCH MOTOR

STARTERS

CLUTCH TORQUE ADJUSTMENT KNOB

S05-3

SKILL 5 ADJUST A CLUTCH ON A BALL SCREW DRIVE

B. Press motor starter M1’s manual override.

The torque setting should be high enough that the traverse axis should move.

C. Observe the movement of the traverse axis.

If the torque setting is high enough, the clutch will not slip and the axis should move smoothly until it hits the hard stops. If the clutch slips while the axis is moving the torque setting is not high enough. The clutch should slip after the axis hits the hard stop. If not the torque setting is too high.

D. Based on your observations, if the clutch is properly adjusted, proceed to step 8.

If the clutch is not properly adjusted, reposition the axis to the left-hand side hard stops.

E. Turn the adjustment knob the required direction (CCW if the torque setting is too high, and CW if it is too low).

F. Press motor starter M1’s manual override and observe the operation of the axis, motor, and clutch.

G. Repeat substeps C through F until the torque setting is correct.  8. Perform the following substeps to power down the station.

A. Turn the Main Power switch Off.

B. Perform a lockout/tagout on the system’s electrical power source.

S06-1

SKILL 6 DESIGN A PLC PROJECT THAT SEQUENCES A NON-SERVO ELECTRIC TRAVERSE AXIS

Procedure Overview

In this procedure, you will design a PLC project that sequences the non- servo electric traverse axis. This will familiarize you with the operation of the traverse axis and how to program its operation.

 1. Design a PLC program to sequence a non-servo traverse axis given the following information.

 The general sequence, I/O diagram, and power diagrams are as follows:  General Sequence

1) Pressing the start pushbutton causes motor starter M1 to energize, which extends the traverse toward the EOT position.

2) Once the traverse is fully extended, LS2 on, motor starter M1 is de-energized, turning off the motor. The part is then manually removed from the carriage.

3) Pressing the Start pushbutton again causes motor starter M2 to energize. The carriage should move toward the BOT position.

4) When the carriage is fully retracted, LS1 on, motor starter M2 is de-energized, turning the motor off.

S06-2

SKILL 6 DESIGN A PLC PROJECT THAT SEQUENCES A NON-SERVO ELECTRIC TRAVERSE AXIS

Figure 6-1. I/O Diagram

Figure 6-2. Power Diagram

I0.0

Q5.0 I1.6

TRAVERSE RETRACTED

I1.7

I/O DIAGRAMINPUTS OUTPUTS

LS2

LS1

START INPUT

TRAVERSE EXTENDED

Q5.1 M2

FORWARD MOTOR STARTER

REVERSE MOTOR STARTER

Q4.0 ACTIVE LAMP

REVERSE

FORWARD

CARRIAGE

LIMIT SWITCH

REV FWD

LS1 LS2

LIMIT SWITCH

CLUTCH

24 VDC

GND

S06-3

SKILL 6 DESIGN A PLC PROJECT THAT SEQUENCES A NON-SERVO ELECTRIC TRAVERSE AXIS

NON-SERVO ELECTRIC TRAVERSE AXIS SEQUENCE

Step Input Action Output Action

INPUTS OUTPUTS

S ta

rt P

B (

I0 .0

)

S to

p P

B (

I0 .1

)

L S

2 (

I1 .6

)

L S

1 (

I1 .7

)

M 1

( Q

5 .0

)

M 2

( Q

5 .1

)

0 Start Condition 0 1 0 1 0 0

1 Receive Start Input Extend Traverse 1/0 1

2 Traverse Extended Motor Stop 1 0 0

3 Receive Input Retract Traverse 1/0 1

4 Traverse Retracted Cycle Ends 0 1 0

End Condition 0 1 0 1 0 0

Figure 6-3. Sequence Diagram

 2. Perform the following substeps to open the PLC programming software.

A. Make sure that the interface from the personal computer to the PLC is connected.

B. Power up the PC and monitor.

C. Start the SIMATIC Manager.  3. Perform the following substeps to create a project.

A. Create a Project named L4S6XXX where XXX represents your initials.

B. Create an S7 Station object for the station and confi gure its hardware.

C. Open Organizational Block OB1.

D. Enter the program that you developed in Step 1 into Organizational Block OB1.

E. Save OB1.  4. Locate the 87-MS2 Gauging station.  5. If the 87-MS2 Gauging station is connected to another 87-MS station,

separate the stations. If the 87-MS2 Gauging station is already disconnected, continue to Step 6.

S06-4

SKILL 6 DESIGN A PLC PROJECT THAT SEQUENCES A NON-SERVO ELECTRIC TRAVERSE AXIS

 6. Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 6-4. Mechatronics Safety Check

 7. Plug the station’s power cable into a wall outlet.  8. Perform the following substeps to power up the 87-MS2 Gauging station.

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electrical power source.

C. Turn the station’s Main Power Switch to the On position.  9. Perform the following substeps to download the project to the PLC.

A. Reset the PLC.

B. Download the SIMATIC 300 Station object to the PLC.

Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart.

C. Click Yes on the dialog to complete a warm restart.  10. Go online with the processor and monitor the OB1 Block.  11. Press the Output Power pushbutton to enable the PLC’s outputs.

S06-5

SKILL 6 DESIGN A PLC PROJECT THAT SEQUENCES A NON-SERVO ELECTRIC TRAVERSE AXIS

 12. Perform the following substeps to test the operation of the program.

A. Manually operate the motor starter manual overrides to position the traverse axis carriage at the BOT position.

B. Manually place a valve body in the recess provided.

Make sure that the valve is oriented as shown in fi gure 6-5.

Figure 6-5. Valve Body in Place

C. Press and release the Start pushbutton.

The following sequence should occur: • Motor starter M1 should energize. • The carriage should move toward the EOT position until it strikes the hard stop and activates limit switch LS2. • Motor starter M1 should de-energize, the motor should stop. • The Start button lamp should be on during operation and turn off when the sequence is complete.

D. Manually remove the part from the traverse axis.

E. Press and release the Start pushbutton.

The following sequence should occur: • The Start pushbutton lamp should turn on solid during operation. • Motor starter M2 should energize. • The carriage should move toward the BOT position until it strikes the hard stop and activates limit switch LS1. • Motor starter M2 should de-energize and the motor should stop. • The Start pushbutton lamp should turn off.

F. Repeat substeps B through E until you are familiar with the operation of the traverse axis.

 13. Print out a copy of the ladder logic program and place it in your portfolio. It will be used in your assessment.

 14. Perform the following substeps to shut down the 87-MS2 Gauging station.

A. Close the LAD/STL/FBD Program Editor.

B. Close the SIMATIC Manager.

C. Turn off the PC and monitor.

D. Turn the 87-MS2’s Main Power switch to Off.

E. Perform a lockout/tagout on the system’s electrical power source.

S07-1

SKILL 7 DESIGN A PLC PROJECT THAT SEQUENCES A PART REJECT MODULE

Procedure Overview

In this procedure, you will design a PLC project that sequences a part reject module. This will familiarize you with the operation and programming of a part reject module.

 1. Design a PLC project to control a part reject module given the following information.

 The general sequence, I/O diagram, power diagrams as follows:  General Sequence

1) Pressing the Start pushbutton causes the Lift cylinder to extend, lifting a valve body off of the carriage. It also causes a 500 ms timer to start.

2) After the Lift cylinder has extended, indicated by the timer timing out, the Reject cylinder should extend to push the valve body into the bin.

3) After the Reject cylinder has extended (MR2 on), the valve body should be pushed into a bin and the cylinder should be retracted.

4) After the Reject cylinder has retracted (MR1 on), the Lift cylinder should start to retract and a 500 ms timer should start.

5) After the Lift cylinder has been retracted, which is indicated by the completion of the timer, the part reject module is in its home position.

 Special Conditions • The traverse axis should be manually positioned at the EOT position using the motor starter manual overrides. • A valve body should be manually placed in the recess on the carriage.

Figure 7-1. I/O Diagram

I0.0

Q4.5I1.2

REJECT CYLINDER RETRACTED

I1.3

I/O DIAGRAMINPUTS OUTPUTS

REJECT CYLINDER (SOL1)

MR1

MR2

START INPUT

REJECT CYLINDER EXTENDED Q5.6

LIFT CYLINDER (SOL3)

Q4.0 ACTIVE LAMP

S07-2

SKILL 7 DESIGN A PLC PROJECT THAT SEQUENCES A PART REJECT MODULE

Figure 7-2. Power Diagram

PART REJECT MODULE SEQUENCE

Step Input Action Output Action

INPUTS OUTPUTS S

ta rt

P B

( I0

.0 )

S to

p P

B (

I0 .1

)

M R

1 (

I1 .2

)

M R

2 (

I1 .3

)

S O

L 1 (

Q 4 .5

)

S O

L 3 (

Q 5 .6

)

0 Start Condition 0 1 1 0 0 0

1 Receive Start Input Extend Lift Cylinder 1/0 1

2 Lift Cylinder Extended Extend Reject Cylinder 1

3 Reject Cylinder Extended Retract Reject Cylinder 0 1 0

4 Reject Cylinder Retracted Retract Lift Cylinder 1 0 0

5 Lift Cylinder Retracted Cycle Ends

End Condition 0 1 1 0 0 0

Figure 7-3. Sequence Diagram

 2. Perform the following substeps to open the PLC programming software.

A. Make sure that the interface from the personal computer to the PLC is connected.

B. Power up the PC and monitor.

C. Start the SIMATIC Manager.  3. Perform the following substeps to create a project.

A. Create a Project named L4S7XXX where XXX represents your initials.

B. Create an S7 Station object for the station and confi gure its hardware.

C. Open Organizational Block OB1.

REJECT CYLINDER

LIFT CYLINDER

CYLINDER RETRACTED

MR1

CYLINDER EXTENDED

MR2

QUICK EXHAUST

FROM SOURCE

S07-3

SKILL 7 DESIGN A PLC PROJECT THAT SEQUENCES A PART REJECT MODULE

D. Enter the program that you developed in Step 1 into Organizational Block OB1.

E. Save OB1.  4. Locate the 87-MS2 Gauging station.  5. If the 87-MS2 Gauging station is connected to another 87-MS station,

separate the stations. If the 87-MS2 Gauging station is already disconnected, continue to Step 6.

 6. Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 7-4. Mechatronics Safety Check

 7. Connect an air supply line to the station’s air manifold quick connect.  8. Plug the station’s power cable into a wall outlet.  9. Perform the following substeps to power up the 87-MS2 Gauging Station.

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electrical power source.

C. Remove the lockout/tagout device from the pneumatic power source.

D. Turn on the air to the station by shifting the lever on the lockout valve.

E. Set the station’s air supply regulator to 50 psi/345 kPa.

F. Turn the station’s Main Power Switch to the On position.  10. Perform the following substeps to download the project to the PLC.

A. Reset the PLC.

B. Download the SIMATIC 300 Station object to the PLC.

Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart.

C. Click Yes on the dialog to complete a warm restart.  11. Go online with the processor and monitor the OB1 Block.  12. Press the Output Power pushbutton to enable the PLC’s outputs.

S07-4

SKILL 7 DESIGN A PLC PROJECT THAT SEQUENCES A PART REJECT MODULE

 13. Perform the following substeps to test the operation of the program.

A. Use the motor starter manual overrides to place the traverse axis at the EOT position.

Limit switch LS2 should be activated and the carriage should be against the hard stops, as shown in fi gure 7-5.

B. Make sure a reject bin is in place, as shown in fi gure 7-5.

C. Manually place a valve body in the recess provided on the carriage, as shown in fi gure 7-5.

Figure 7-5. Carriage, Reject Bin, and Valve Body in Place

REJECT BIN

CARRIAGE

VALVE BODY

REJECT CYLINDER

S07-5

SKILL 7 DESIGN A PLC PROJECT THAT SEQUENCES A PART REJECT MODULE

D. Press and release the Start pushbutton.

The following sequence should occur: • The lift cylinder should raise the part. • After the lift cylinder has fully extended the reject cylinder should extend, pushing the part into the reject bin. • After the reject cylinder has fully extended, both the reject cylinder and lift cylinder should retract. • This successfully completes one cycle of the part reject module.

E. Manually place a valve body in the recess provided on the carriage.

F. Press and release the Start pushbutton.

The cycle should repeat.

G. Repeat substeps D through F until you are familiar with the operation of the part reject module.

 14. Print out a copy of the ladder logic program and place it in your portfolio. It will be used in your assessment.

 15. Perform the following substeps to shut down the 87-MS2 Gauging station.

A. Close the LAD/STL/FBD Editor.

B. Close the SIMATIC Manager.

C. Turn off the PC and monitor.

D. Turn the 87-MS2’s Main Power switch to Off.

E. Perform a lockout/tagout on the system’s electrical power source.

F. Perform a lockout/tagout on the system’s pneumatic power source.

S08-1

SKILL 8 DESIGN A PLC PROJECT THAT SEQUENCES A GO/NO-GO GAUGING STATION

Procedure Overview

In this procedure, you will design a PLC project to sequence the Go/No-Go Gauging station. This will familiarize you with the operation and programming of a Go/No-Go Gauging station.

 1. Design a PLC project that sequences a Go/No-Go Gauging Station given the following information.

 The general sequence, I/O diagram, power diagram, and sequence diagram are as follows:

 General Sequence

1) When a part is placed on the carriage, the photoelectric sensor, PE1 either detects the presence of right most hole on the side with two holes, in which it does not activate its input, or it does not see the hole, in which case it does activate its input. If the input is high, then the part is bad (No-Go). Pressing the Start pushbutton causes motor starter M1 to energize. The carriage should move toward the EOT position. When the carriage activates inductive sensor IND1, the valve body is under the ultrasonic sensor. The ultrasonic sensor measures the valve body’s height as it passes underneath. If US1’s input does not go high, the part is bad (No-Go). If PE1 does not go high but US1 does, the part is good (Go). The carriage continues on to the EOT position.

2) The carriage actuates LS2 when it reaches the EOT position. The PLC de-energizes motor starter M1 to turn off the motor.

3) After the motor has stopped, the Lift cylinder extends, lifting the valve body off of the carriage. A 500 ms timer is used to give the cylinder time to extend.

4) After the Lift cylinder has extended, either the Reject (No Go) or Transfer (Go) cylinder should extend to push the valve body into a bin.

5) After the Reject or Transfer cylinder has extended, it should be retracted.

6) After the Reject or Transfer cylinder is retracted, the Lift cylinder should retract, again using a 500 ms timer to give the cylinder time to retract.

7) After all cylinders have retracted, motor starter M2 energizes. The carriage should move toward the BOT position.

8) The carriage reaches the BOT position, activating limit switch LS1. Motor starter M2 is de-energized, turning off the motor.

S08-2

SKILL 8 DESIGN A PLC PROJECT THAT SEQUENCES A GO/NO-GO GAUGING STATION

 Special Conditions • The traverse axis should be manually positioned at the BOT position using the motor starter manual overrides. • A valve body should be manually placed in the recess on the carriage. • Pressing the Stop pushbutton at any time should cause the sequence to stop (or halt) at the end of its current step. Pressing the Start pushbutton should resume the sequence. • The cycle should repeat when a new part is placed onto the traverse axis and the Start pushbutton is pressed. • The Start pushbutton should be on solid during operation and should turn off after the cycle ends.

Figure 8-1. I/O Diagram

I/O DIAGRAM

I0.0 Q4.0

Q4.5

Q4.6

Q4.7

Q5.0

Q5.1

I0.1

START

I1.7

LS1

ACTIVE LAMP

PART REJECT EXTEND (SOL1)

PART TRANSFER EXTEND (SOL2A)

PART TRANSFER RETRACT (SOL2B)

TRAVERSE FORWARD CONTACTOR

TRAVERSE REVERSE CONTACTOR

PB1

PB2

I1.6

LS2

I1.2

MR1

I1.3

MR2

I1.4

MR3

I1.5

MR4

TRAVERSE AXIS BOT

TRAVERSE AXIS EOT

REJECT CYLINDER RETRACTED

REJECT CYLINDER EXTENDED

TRANSFER CYLINDER RETRACTED

TRANSFER CYLINDER EXTENDED

I2.4

PE1 PORT NOT DETECTED

Q5.6

PART LIFT EXTEND (SOL3)

STOP

I2.2

IND1 PART HEIGHT

READING

I2.3

US1 PART HEIGHT

MEASUREMENT

S08-3

SKILL 8 DESIGN A PLC PROJECT THAT SEQUENCES A GO/NO-GO GAUGING STATION

Figure 8-2. Power Diagram

SOL2A

TRANSFER CYLINDER

SOL3

LIFT CYLINDER

CYLINDER RETRACTED

MR3

CYLINDER EXTENDED

MR4

QUICK EXHAUST

SOL1

REJECT CYLINDER

CYLINDER RETRACTED

MR1

CYLINDER EXTENDED

MR2

REVERSE

FORWARD

US1

CARRIAGE

LIMIT SWITCH

REV FWD

PE1

LS1 LS2

LIMIT SWITCH

CLUTCH

24 VDC

GND

SOL2B

FROM SOURCE

IND1

S08-4

SKILL 8 DESIGN A PLC PROJECT THAT SEQUENCES A GO/NO-GO GAUGING STATION

GO/NO-GO GAUGING STATION SEQUENCE- GOOD PART

Step Input Action Output Action

INPUTS OUTPUTS

S ta

rt P

B (

I0 .0

)

S to

p P

B (

I0 .1

)

M R

1 (

1 .2

)

M R

2 (

1 .3

)

M R

3 (

1 .4

)

M R

4 (

1 .5

)

L S

2 (

1 .6

)

L S

1 (

1 .7

)

IN D

1 (

I2 .2

)

U S

1 (

I2 .3

)

P E

1 (

I2 .4

)

S O

L 1

( Q

4 .5

)

S O

L 2

A (

Q 4

.6 )

S O

L 2

B (

Q 4

.7 )

S O

L 3

( Q

5 .6

)

M 1

( Q

5 .0

)

M 2

( Q

5 .1

)

0 Start Condition 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0

1 Receive Start Input Extend Traverse 1/0 1 1 1

2 Traverse Extended Motor Stop/Extend Lift Cylinder 1 0 0 1 0

3 Lift Cylinder Extended Extend Transfer Cylinder 1

4 Transfer Cylinder Extended Retract Transfer Cylinder 0 1 0 1

5 Transfer Cylinder Retracted Retract Lift Cylinder 1 0 0 0

6 Lift Cylinder Retracted Retract Traverse 1

7 Traverse Retracted Motor Off/Cycle Ends 0 1 0

End Condition 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0

GO/NO-GO GAUGING STATION SEQUENCE- BAD PART

Step Input Action Output Action

INPUTS OUTPUTS S

ta rt

P B

( I0

.0 )

S to

p P

B (

I0 .1

)

M R

1 (

1 .2

)

M R

2 (

1 .3

)

M R

3 (

1 .4

)

M R

4 (

1 .5

)

L S

2 (

1 .6

)

L S

1 (

1 .7

)

IN D

1 (

I2 .2

)

U S

1 (

I2 .3

)

P E

1 (

I2 .4

)

S O

L 1 (

Q 4 .5

)

S O

L 2 A

( Q

4 .6

)

S O

L 2 B

( Q

4 .7

)

S O

L 3 (

Q 5 .6

)

M 1 (

Q 5 .0

)

M 2 (

Q 5 .1

)

0 Start Condition 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0

1 Receive Start Input Extend Traverse 1/0 1 0 1 1

2 Traverse Extended Motor Stop/Extend Lift Cylinder 1 0 0 0 1 0

3 Lift Cylinder Extended Extend Reject Cylinder 1

4 Reject Cylinder Extended Retract Reject Cylinder 0 1 0

5 Reject Cylinder Retracted Retract Lift Cylinder 1 0 0

6 Lift Cylinder Retracted Retract Traverse 1

7 Traverse Retracted Motor Off/Cycle Ends 0 1 0

End Condition 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0

Figure 8-3. Sequence Diagram

 2. Perform the following substeps to open the PLC programming software.

A. Make sure that the interface from the personal computer to the PLC is connected.

B. Power up the PC and monitor.

C. Start the SIMATIC Manager.  3. Perform the following substeps to create a project.

A. Create a Project named L4S8XXX where XXX represents your initials.

B. Create an S7 Station object for the station and confi gure its hardware.

C. Open Organizational Block OB1.

D. Enter the program that you developed in step 1 into Organizational Block OB1.

E. Save OB1.

S08-5

SKILL 8 DESIGN A PLC PROJECT THAT SEQUENCES A GO/NO-GO GAUGING STATION

 4. Locate the 87-MS2 Gauging station.  5. If the 87-MS2 Gauging station is connected to another 87-MS station,

separate the stations. If the 87-MS2 Gauging station is already disconnected, continue to step 6.

 6. Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 8-4. Mechatronics Safety Check

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electric lockout.

C. Remove the lockout/tagout device from the pneumatic lockout.

D. Turn on the air to the station by shifting the lever on the lockout valve.

E. Set the station’s air supply regulator to 50 psi/345 kPa.

F. Turn the station’s Main Power Switch to the On position.  10. Perform the following substeps to download the project to the PLC.

A. Reset the PLC.

B. Download the SIMATIC 300 Station object to the PLC.

Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart.

C. Click Yes on the dialog to complete a warm restart.  11. Go online with the processor and monitor the OB1 Block.  12. Press the Output Power pushbutton to enable the PLC’s outputs.

S08-6

SKILL 8 DESIGN A PLC PROJECT THAT SEQUENCES A GO/NO-GO GAUGING STATION

 13. Perform the following substeps to test the operation of the program.  You will need good and bad valve bodies to test the operation of the program.

Ask your instructor to provide you with the parts.

A. Use the motor starter manual overrides to place the traverse axis at the BOT position. Limit switch LS1 should be activated.

B. Make sure a bin is in place for both the reject and transfer sequences.

C. Manually place a good valve body in the recess provided on the carriage in the orientation in fi gure 8-5.

Figure 8-5. Valve Body in Place

S08-7

SKILL 8 DESIGN A PLC PROJECT THAT SEQUENCES A GO/NO-GO GAUGING STATION

D. Press and release the Start pushbutton. • The following sequence should occur: • The photoelectric sensor should check for the port and determine the part is a go. • The traverse axis should move toward the EOT position. • The ultrasonic sensor should make a measurement on the part as it passes under the sensor and the PLC logic should determine that the part is a go. • After the traverse axis reaches the EOT position, the motor should stop. • After the motor has stopped, the Lift cylinder should extend • After the Lift cylinder has extended, the Transfer cylinder should extend • The Transfer cylinder should retract • The Lift cylinder should retract • Motor starter M2 should energize and the carriage should move toward the BOT position. • When the carriage reaches the BOT position, LS1 should energize and the motor should turn off.

E. Manually place a bad valve body in the recess provided on the carriage in the orientation shown in fi gure 8-5. For this skill, use a bad valve body with ports.

A bad valve body is shorter than a good valve body and may not have ports.

F. Press and release the Start pushbutton.

The following sequence should occur: • The photoelectric sensor should check for the port and determine the part is a go. • The traverse axis should move toward the EOT position. • The ultrasonic sensor should make a measurement on the part as it passes under the sensor and the PLC logic should determine that the part is a no-go. • After the traverse axis reaches the EOT position, the motor should stop. • After the motor has stopped, the Lift cylinder should extend • After the Lift cylinder has extended, the Reject cylinder should extend • The Reject cylinder should retract. • The Lift cylinder should retract. • Motor starter M2 should energize and the carriage should move toward the BOT position. • When the carriage reaches the BOT position, LS1 should energize and the motor should turn off.

G. Manually place a good valve body in the recess provided on the traverse carriage, but this time turn the valve body so the side with two holes faces away from PE1.

S08-8

SKILL 8 DESIGN A PLC PROJECT THAT SEQUENCES A GO/NO-GO GAUGING STATION

H. Press and release the Start pushbutton.

The following sequence should occur: • The photoelectric sensor should check for the port and determine the part is a no-go. • The traverse axis should move toward the EOT position. • The ultrasonic sensor should make a measurement on the part as it passes under the sensor and the PLC logic should determine that the part is a go. • After the traverse axis reaches the EOT position, the motor should stop. • After the motor has stopped, the Lift cylinder should extend • After the Lift cylinder has extended, the Reject cylinder should extend • The Reject cylinder should retract. • The Lift cylinder should retract. • Motor starter M2 should energize and the carriage should move toward the BOT position. • When the carriage reaches the BOT position, LS1 should energize and the motor should turn off.

 14. Manually place a good valve body in the recess provided on the traverse carriage in the correct orientation.

 15. Press and release the Start pushbutton.  16. Once the sequence begins, press the Stop pushbutton to stop (or halt) the

station after its current step.  Once the movement is complete, the station should stop.  17. Press the Start pushbutton.  The station should resume operation from its current step.  18. Print out a copy of the ladder logic program and place it in your portfolio. It

will be used in your assessment.  19. Perform the following substeps to shut down the 87-MS2 Gauging station.

A. Close the LAD/STL/FBD Editor.

B. Close the SIMATIC Manager.

C. Turn off the PC and monitor.

D. Turn the 87-MS2’s Main Power switch to Off.

E. Perform a lockout/tagout on the system’s electrical power source.

F. Perform a lockout/tagout on the system’s pneumatic power source.

S09-1

SKILL 9 DESIGN A PLC PROJECT THAT PROVIDES MANUAL/AUTO/RESET FUNCTIONS FOR A GO/NO-GO GAUGING STATION

Procedure Overview

In this procedure, you will design a PLC project that provides manual, automatic, and reset functions for the Go/No-Go gauging station. This will require you to modify the project that you developed in a previous skill. This will familiarize you with programming manual, auto, and reset functions.

 1. Design a PLC project that provides Manual/Auto/Reset functions for a Go/ No-Go Gauging station given the following information.

 The general sequence, I/O diagram, power diagram, and sequence diagram are as follows:

 General Sequence

1) In automatic mode, the program should work as it did in the previous skill.

2) When manual mode is selected, pressing the Start pushbutton causes the station to perform the next step of its sequence and stop. Each press of the Start pushbutton causes the next step to be performed until the cycle is complete.

3) When reset is selected: • The lift cylinder should retract using a 500-ms timer to verify it has had time to retract. • After it has retracted, the reject cylinder and transfer cylinder should retract at the same time. • When all of the cylinders have retracted, the traverse axis should move to the BOT position. • When all of the pneumatic actuators are retracted, and the traverse axis is in the BOT position, the lamp on the start pushbutton should turn off.

S09-2

SKILL 9 DESIGN A PLC PROJECT THAT PROVIDES MANUAL/AUTO/RESET FUNCTIONS FOR A GO/NO-GO GAUGING STATION

Figure 9-1. I/O Diagram

I/O DIAGRAM

I0.0 Q4.0

Q4.5

Q4.6

Q4.7

Q5.0

Q5.1

I0.1

START

I1.0

I1.1

I1.7

LS1

ACTIVE LAMP

PART REJECT EXTEND (SOL1)

PART TRANSFER EXTEND (SOL2A)

PART TRANSFER RETRACT (SOL2B)

TRAVERSE FORWARD CONTACTOR

TRAVERSE REVERSE CONTACTOR

PB1

PB2

I1.6

LS2

I1.2

MR1

I1.3

MR2

I1.4

MR3

I1.5

MR4

TRAVERSE AXIS BOT

TRAVERSE AXIS EOT

REJECT CYLINDER RETRACTED

REJECT CYLINDER EXTENDED

TRANSFER CYLINDER RETRACTED

TRANSFER CYLINDER EXTENDED

I2.4

PE1 PORT NOT DETECTED

Q5.6

PART LIFT EXTEND (SOL3)

STOP

RESET

AUTO

I2.2

IND1 PART HEIGHT

READING

I2.3

US1 PART HEIGHT

MEASUREMENT

S09-3

SKILL 9 DESIGN A PLC PROJECT THAT PROVIDES MANUAL/AUTO/RESET FUNCTIONS FOR A GO/NO-GO GAUGING STATION

Figure 9-2. Power Diagram

SOL2A

TRANSFER CYLINDER

SOL3

LIFT CYLINDER

CYLINDER RETRACTED

MR3

CYLINDER EXTENDED

MR4

QUICK EXHAUST

SOL1

REJECT CYLINDER

CYLINDER RETRACTED

MR1

CYLINDER EXTENDED

MR2

REVERSE

FORWARD

US1

CARRIAGE

LIMIT SWITCH

REV FWD

PE1

LS1 LS2

LIMIT SWITCH

CLUTCH

24 VDC

GND

SOL2B

FROM SOURCE

IND1

S09-4

SKILL 9 DESIGN A PLC PROJECT THAT PROVIDES MANUAL/AUTO/RESET FUNCTIONS FOR A GO/NO-GO GAUGING STATION

GO/NO-GO GAUGING STATION SEQUENCE- GOOD PART

Step Input Action Output Action

INPUTS OUTPUTS

S ta

rt P

B (

I0 .0

)

S to

p P

B (

I0 .1

)

M R

1 (

1 .2

)

M R

2 (

1 .3

)

M R

3 (

1 .4

)

M R

4 (

1 .5

)

L S

2 (

1 .6

)

L S

1 (

1 .7

)

IN D

1 (

I2 .2

)

U S

1 (

I2 .3

)

P E

1 (

I2 .4

)

S O

L 1

( Q

4 .5

)

S O

L 2

A (

Q 4

.6 )

S O

L 2

B (

Q 4

.7 )

S O

L 3

( Q

5 .6

)

M 1

( Q

5 .0

)

M 2

( Q

5 .1

)

0 Start Condition 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0

1 Receive Start Input Extend Traverse 1/0 1 1 1

2 Traverse Extended Motor Stop/Extend Lift Cylinder 1 0 0 1 0

3 Lift Cylinder Extended Extend Transfer Cylinder 1

4 Transfer Cylinder Extended Retract Transfer Cylinder 0 1 0 1

5 Transfer Cylinder Retracted Retract Lift Cylinder 1 0 0 0

6 Lift Cylinder Retracted Retract Traverse 1

7 Traverse Retracted Motor Off/Cycle Ends 0 1 0

End Condition 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0

GO/NO-GO GAUGING STATION SEQUENCE- BAD PART

Step Input Action Output Action

INPUTS OUTPUTS S

ta rt

P B

( I0

.0 )

S to

p P

B (

I0 .1

)

M R

1 (

1 .2

)

M R

2 (

1 .3

)

M R

3 (

1 .4

)

M R

4 (

1 .5

)

L S

2 (

1 .6

)

L S

1 (

1 .7

)

IN D

1 (

I2 .2

)

U S

1 (

I2 .3

)

P E

1 (

I2 .4

)

S O

L 1 (

Q 4 .5

)

S O

L 2 A

( Q

4 .6

)

S O

L 2 B

( Q

4 .7

)

S O

L 3 (

Q 5 .6

)

M 1 (

Q 5 .0

)

M 2 (

Q 5 .1

)

0 Start Condition 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0

1 Receive Start Input Extend Traverse 1/0 1 0 1 1

2 Traverse Extended Motor Stop/Extend Lift Cylinder 1 0 0 0 1 0

3 Lift Cylinder Extended Extend Reject Cylinder 1

4 Reject Cylinder Extended Retract Reject Cylinder 0 1 0

5 Reject Cylinder Retracted Retract Lift Cylinder 1 0 0

6 Lift Cylinder Retracted Retract Traverse 1

7 Traverse Retracted Motor Off/Cycle Ends 0 1 0

End Condition 0 1 1 0 1 0 0 1 0 0 0 0 0 0 0 0 0

Figure 9-3. Sequence Diagram

 2. Perform the following substeps to open the PLC programming software.

A. Make sure that the interface from the personal computer to the PLC is connected.

B. Power up the PC and monitor.

C. Start the SIMATIC Manager.  3. Perform the following substeps to create a project.

A. Open Project L4S8XXX that was created in a previous skill.

B. Click the Save As button on the toolbar to save the project with a new name.

The Save As dialog should open.

C. Enter the name L4S9XXX where XXX represents your initials.

D. Click OK on the dialog to create the project.

S09-5

SKILL 9 DESIGN A PLC PROJECT THAT PROVIDES MANUAL/AUTO/RESET FUNCTIONS FOR A GO/NO-GO GAUGING STATION

E. Fully expand the project tree.

F. Select the Blocks folder so that its contents are displayed in the right-hand side project window.

G. Open Organizational Block OB1 by double-clicking its icon.

H. Modify OB1 with the logic that you developed in Step1.

I. Save OB1.  4. Locate the 87-MS2 Gauging station.  5. If the 87-MS2 Gauging station is connected to another 87-MS station,

separate the stations. If the 87-MS2 Gauging station is already disconnected, continue to step 6.

 6. Perform the following safety check before you begin working on the station. Make sure that you can answer yes to each item before proceeding.

YES/NO SAFETY CHECKOUT

Remove all obstructions from the work area

Check for signs of damage to the equipment

Wear tight fi tting clothing, roll up long sleeves, remove ties, scarves, jewelry, etc.

Tie up long hair

Remove any robot teach pendants from the work area

Locate the emergency stop button

Ensure that safety glasses are worn by people in area

Ensure that all people are outside any work envelopes

Figure 9-4. Mechatronics Safety Check

A. Place the Mode Selector switch in the Manual position.

B. Remove the lockout/tagout device from the electrical power source.

C. Remove the lockout/tagout device from the pneumatic power source.

D. Turn on the air to the station by shifting the lever on the lockout valve.

E. Set the station’s air supply regulator to 50 psi/345 kPa.

F. Turn the station’s Main Power Switch to the On position.  10. Perform the following substeps to download the project to the PLC.

A. Reset the PLC.

B. Download the SIMATIC 300 Station object to the PLC.

Several dialogs will appear during the download. Click the appropriate response to continue downloading the program. The last dialog should ask if you wish to perform a complete (Warm) restart.

C. Click Yes on the dialog to complete a warm restart.

S09-6

SKILL 9 DESIGN A PLC PROJECT THAT PROVIDES MANUAL/AUTO/RESET FUNCTIONS FOR A GO/NO-GO GAUGING STATION

 11. Go online with the processor and monitor the OB1 Block.  12. Press the Output Power pushbutton to enable the PLC’s outputs.  13. Perform the following substeps to test the operation of the program in the

automatic mode.

A. Make sure a reject bin is in place.

B. Use the motor starter manual override to place the traverse axis at the BOT position. Limit switch LS1 should be activated and the carriage should be against the hard stops.

C. Manually place a good valve body in the recess provided on the traverse axis in the correct orientation.

D. Set the Mode Selector switch to Auto.

E. Press and release the Start pushbutton.

The following sequence should occur: • The photoelectric sensor should check for the port and determine the part is a go. • The traverse axis should move toward the EOT position. The ultrasonic sensor should make a measurement on the part as it passes under the sensor and the PLC logic should determine that the part is a go. • After the traverse axis reaches the EOT position, the motor should stop. • After the motor has stopped, the Lift cylinder should extend • After the Lift cylinder has extended, the Transfer cylinder should extend • The Transfer cylinder should retract • The Lift cylinder should retract • Motor starter M2 should energize and the carriage should move toward the BOT position. • When the carriage reaches the BOT position, LS1 should energize and the motor should turn off.

 14. Perform the following substeps to test the operation of the program in the manual mode.

A. Manually place a good valve body in the recess provided on the traverse axis.

B. Place the Mode Selector in the Manual position.

C. Press and release the Start pushbutton.

The traverse axis should move toward the EOT position. The photoelectric and ultrasonic sensors should check the part as it passes and the PLC logic should determine that the part is a go. When the carriage reaches the EOT position, limit switch LS2 should energize and the motor should turn off.

D. Press and release the Start pushbutton.

The Lift cylinder should extend, raising the valve body from the recess.

E. Press and release the Start pushbutton.

The Transfer cylinder should extend, pushing the part into the bin.

F. Press and release the Start pushbutton.

The Transfer cylinder should retract.

S09-7

SKILL 9 DESIGN A PLC PROJECT THAT PROVIDES MANUAL/AUTO/RESET FUNCTIONS FOR A GO/NO-GO GAUGING STATION

G. Press and release the Start pushbutton.

The Lift cylinder should retract.

H. Press and release the Start pushbutton.

The traverse axis should return to the BOT position. When the carriage reaches the BOT position, LS1 should energize and the motor should turn off.

 15. Perform the following substeps to test the reset portion of the program.  The Mode Selector should still be in the manual position.

A. Use the motor starter manual overrides to position the traverse axis at the EOT position.

B. Use the pneumatic valve manual overrides to extend the lift cylinder.

C. Use the pneumatic valve manual overrides to extend the transfer cylinder.

D. Use the pneumatic valve manual overrides to extend the reject cylinder.

E. Place the Mode Selector switch in the Reset position.

The following sequence should occur: • The lift cylinder should retract. • After it has retracted, the reject cylinder and transfer cylinder should retract at the same time. • When all of the cylinders have retracted, the traverse axis should move to the BOT position. • When all of the pneumatic actuators are retracted, and the traverse axis is in the BOT position, the lamp on the start pushbutton should be off.

 16. Print out a copy of the ladder logic program and place it in your portfolio. It will be used in your assessment.

 17. Perform the following substeps to shut down the 87-MS2 Gauging station.

A. Close the LAD/STL/FBD Program Editor.

B. Close the SIMATIC Manager.

C. Turn off the PC and monitor.

D. Turn the 87-MS2’s Main Power switch to Off.

E. Perform a lockout/tagout on the system’s electrical power source.

F. Perform a lockout/tagout on the system’s pneumatic power source.