FESTO MODULAR

PRODUCTION SYSTEM
INTRODUCTION TO PLC STATIONS

EE ELECTIVES II (LAB)

Members:
Abarca, Andrie
Avila, Renfred Jay R.
Baconawa, Adrian B.
Bagui, Yuan D.
De La Paz, Arvie R.
De Vega, John Nathaniel N.

January 2025
 I. INTRODUCTION

Programmable Logic Controllers (PLCs) are essential to modern industrial automation,

enabling efficient control of processes such as packaging, extrusion, sorting, and material handling.
Their versatility and reliability have made them indispensable in automating complex production
lines across industries. With manufacturers like Siemens, Allen Bradley, Mitsubishi, Schneider
Electric, and Omron offering a variety of PLC modules, these systems can adapt to meet specific
industrial requirements.

In this laboratory module, students will work with industrial station models developed by
FESTO, a leading provider of automation and technical training systems. These modular stations
replicate real-world industrial processes, integrating tasks like sorting, handling, and transferring
components to create a cohesive automated workflow. Each station is equipped with Siemens
SIMATIC S7-300 PLCs, known for their powerful functionality and flexibility in industrial
applications.

Through programming the SIMATIC S7-300 PLCs using the SIMATIC Step 7 software,
students will gain hands-on experience with the practical applications of PLCs in controlling
industrial systems. This module is designed to provide students with an in-depth understanding of
how automated processes are designed, implemented, and optimized in modern industrial
environments.

II. OBJECTIVES

The main objectives of this modules are:

• Gain an understanding of the primary components of a PLC.

• Become familiar with commonly used industrial input devices.
• Develop familiarity with commonly used industrial output devices.
• Analyze a process station to determine and map the addresses of input and output
devices.
 III. THEORETICAL BACKGROUND

Programmable Logic Controllers (PLCs) are one of the most important components of
industrial automation systems used universally in many applications to elevate flexibility,
precision, and durability. This kind of controllers is vital when it comes to regulation of identified
automated operations in the various superior sectors including the packaging as well as extrusion,
sorting as well as handling of various materials. Due to their flexibility and relatively complex
functions, they are becoming extremely useful when it comes to getting involved into automation
of manufacturing and production lines.

Some of the most famous worldwide companies, producing PLCs, presented in the table
below, offering a variety of modular designs suitable for differing industrial needs. Lead players
are Siemens, Allen Bradley, Mitsubishi, Schneider Electric and Omron. Originally and
independently, each company develops various features and programming environments to make
sure that their PLCs address the several aspects of industrial applications. Of these, Siemens PLCs
are perhaps the most commonly seen, and more user-friendly, especially for training purposes.

These modular stations are planned to function cooperatively and to mimic the actual
industrial procedures by combining several automated procedures into the one station. The stations
are governed by the Siemens SIMATIC S7-300 PLCs which is a strong and versatile development
for industrial applications. These PLCs will be programmed using the SIMATIC Step 7 software
with which you will get practical experience with one of the leading automation tools on the
market. The following practical exposure will help the readers or users of this module to have a
clearer understanding of what PLCs are and why they are essential in the current complex
industrial applications.
 IV. INTRODUCTION TO THE PLC

The Siemens SIMATIC S7-300 is one among the sturdy and comodule Programmable
Logic Controller (PLCs) suitable for a variety of industries. Like all PLCs, it consists of four main
components: a power supply, the usual processor card, input cards, as well as output cards. The
S7-300 is configured to run on a 24 V DC supply, comes with the CPU 313C-2DP control unit,
thus guaranteeing the effective control of processes. These are card 0 and card 1 within which there
are 16 input ports as well as 16 output ports are also present. These features make the S7-300 best
suited for efficient processing of enhanced automation tasks in manufacturing and industries.

Figure 4.1
Siemens SIMATIC S7-300 PLC

As described, the streams of inputs and outputs are divided between two I/O cards the
preferential ones of which are shown below. Card 0 interfaces with the inputs and outputs of the
station and at the same time, card 1 is connected to the control console consisting of start, stop,
and reset push button. These cards are interfaced with the PLC through I/O terminals in these
terminals, data can be fed to the PLC or collected from the PLC switching between them in a
systematic manner. The input and output signals are led through the wires soldered with screws to
the I/O socket as illustrated in Figure 1.3. The socket connected to a 24-pin I/O cable, in which 8
pins used for input operation, 8 pins used for output operation and the remaining pins used for
providing 0 V and 24 V for sensors and Actuators. On the other end of the I/O cable, there is a
connection with PLC I/O cards to enable smooth working between the station and the control
system.
 V. PROGRAMMING

In any given field of a Programmable Logic Controller (PLC), every input or output must
have a unique address referable to an input or output point on the station or the control console.
This addressing makes certain that the PLC is able to discover and interface with the several
instruments connected to it. Every input or output comes with a corresponding address that is
employed within the PLC program to perform operations on the basis of true-world input signals.

With inputs, the PLC program permits multiple uses of the same input either as a Normally
Open (NO) input or as a Normally Closed (NC) input. Program can also include other components
such as Relay Coils and different types of Timers in order to make the program as thorough as
possible. However, the output can be used only once in the program and they do not allow to use
the same result in the certain field. All these mean that should an output be called in more than one
place, then one gets unpredictable, or wrong behavior, that can lead to interference with operation
of the system.

Normally Open (NO) Contact Operation

Normally Open (NO) contacts are contacts that remain open (inactive) when the input
signal is not present or in its default state. When the input is activated, the NO contact closes
(becomes active), allowing current to flow and enabling the connected device or action in the PLC
program. NO contacts are commonly used to represent conditions where an action occurs only
when a specific input is received or when a device, such as a sensor or switch, is triggered. For
example, when a push button is pressed (activating the input), the NO contact closes, allowing the
PLC to process the logic and turn on an output, such as a motor.

Figure 5.1
Run Mode of Program, NO not Activated
 Figure 5.2
Run Mode of Program, NO Activated

Normally Close (NC) Contact Operation

`Normally Closed (NC) contacts, in contrast to NO contacts, are closed (active) by default,
meaning current can pass through them when the input signal is not present or when the device is
not activated. When the input is triggered or activated, the NC contact opens (becomes inactive),
breaking the current flow. NC contacts are useful for representing conditions where an action is
triggered by the absence of an input or when a safety feature requires an action to occur when a
device is not functioning as expected. For example, if a safety switch is turned off, the NC contact
would open, preventing the PLC from activating certain outputs, like machinery or equipment.

Figure 5.3
Run Mode of Program, NC not Activated

Figure 5.4
Run Mode of Program, NC Activated
Internal Relay Coils Operations

Internal relay coils in a PLC function as virtual relays, holding a binary state (ON or OFF)
based on the program's logic. These coils are used within the program to store intermediate states
or results that are not connected to physical hardware. When activated, an internal relay coil
represents an action or condition being met in the process, and it can control the flow of the
program or serve as an input for other logic blocks. Internal relay coils help streamline the
organization of control logic without relying on physical relay devices.

Figure 5.4
Sample Ladder Diagram Without Internal Relay
From the ladder diagram above, the stopping of the outputs is missing and cannot be cannot
be controlled once the input of I0.3 and I0.4 are activated. The outputs are uncontrollable both
from the beginning and end of the motion. So, from this condition, an internal relay can be used.
This circuit would result to the ladder diagram below.

Figure 5.5
Sample Ladder Diagram with Internal Relay
Set/Reset Coils Operations

Set/Reset coils are specialized relay coils used to control the binary state of a device in a
latched or retained manner. A Set coil sets the output to a "1" (ON) state, while a Reset coil clears
it to a "0" (OFF) state. These coils are typically used when there is a need for memory retention,
where an output remains in a specific state until an explicit Reset command is given. They are
often used for tasks such as maintaining the state of a motor or a valve after an initial condition
has been met, ensuring stable operation in automated processes.

Figure 5.6
(a) Ladder Symbol for Set Coil (B) Ladder Symbol for Reset Coil

For example, if "Start" push button is pressed and a work piece is available at the beginning
of the output, then the output will be actuated until "Reset" push button is pressed.

Figure 5.7
Simple Ladder diagram for Set/Reset Coil

From the figure that when "Start" or "I1.0" is pressed and a work piece is available ("I0.0"
is activated), current will flow (changing the state from LOW to High) through the set coil
addressed "Q0.1" which is the address of the output. This assigning of the address to the set coil
means: set the output coil addressed "Q0.1" to 1 (or HIGH). Now even if "Start" is released or the
piece is no longer available, the set coil addressed "Q0.1" will make sure that the output "Q0.1" is
still activated (at least until a reset signal occurs).
Timer Operations

Timers in PLCs are used to introduce time-based control into automation processes,
allowing certain actions or outputs to be delayed or held for specific durations. These timers are
essential for handling time-sensitive operations such as controlling motor startups, delaying
actions, or managing process cycles. Below is an explanation of the different types of timers, how
they operate, and how they are used in PLC programs:

Figure 5.8
Timer Block
Where:

• S = is the Set (Trigger) signal of the timer.

• TV = is the time value stored in the timer which must be in the form (S5T#tv). The
maximum time value for tv that you can enter is 9,990 seconds, or 2H_46M_30S.
• R = is the Reset signal of the timer.
• Q = is the output of the timer.
• BI = is the current time* in binary code.
• BCD = is the current time* in binary coded decimal code.
• Timer number = this can be in the form (T#), where # can be any number in the range (0-
255), since Siemens S7-300 PLC allows the use of 256 timers at max.

The following are examples on how to write the time tv in its correct form:

• S5TIME#4S = 4 seconds
• S5T#2h_15m = 2 hours and 15 minutes
• S5T#1H_12M_18S = 1 hour, 12 minutes, and 18 seconds
The following five sections will discuss each timer type individually

1. The Pulse Timer (S_PULSE)

S_PULSE (Pulse S5 Timer) generates a brief pulse after a set duration. This type of timer
is often used in applications where a short signal is required to trigger an event or action after a
specific time delay. For example, the Pulse Timer can be used to activate a solenoid valve for a
brief moment after a certain condition is met, such as turning on a conveyor belt or initiating a
process. The timer begins counting when the input condition is true, and after the pre-set time has
passed, it sends out a pulse to trigger the output. Once the pulse is sent, the timer resets, making it
ideal for one-time delays or triggering events that need to happen quickly.

Figure 5.8
S_PULSE Timer Block

2. The Pulse Extended Timer (S_PEXT)

The Pulse Extended Timer is similar to the Pulse Timer, but with more flexibility in terms
of the duration of the pulse. This timer allows for extended delays before sending out the pulse,
making it suitable for processes that require a longer or adjustable period to trigger an output. The
Pulse Extended Timer is useful when an action needs to occur after a longer waiting period, such
as controlling a heating element that should turn off after a specific time interval. The timer
operates in the same way as the Pulse Timer, but the duration of the pulse is more customizable to
meet specific process needs.

Figure 5.9
S_PEXT Timer Block
 3. The On Delay Timer (S_ODT)

The On Delay Timer is one of the most commonly used timers in PLC programming. It
delays the activation of an output for a preset amount of time after the input condition is met. This
type of timer is useful in applications where an action should only take place after a delay, such as
when a motor needs to be started after a brief waiting period once a start signal is received. When
the input condition becomes true, the timer begins counting. If the input stays true for the duration
of the preset time, the output is activated. If the input condition changes before the time have
elapsed, the timer resets, and no action is taken. This timer ensures that outputs are not triggered
immediately when the input is activated, preventing premature actions in the system.

Figure 5.10
S_ODT Timer Block

4. The ON Delay Retentive Timer (S_ODTS)

The On Delay Retentive Timer operates similarly to the standard On Delay Timer, with
one key difference: it retains the time accumulated even if the input condition goes false
temporarily. This type of timer is useful in situations where you want to ensure that the timer
continues counting from the point it left off once the input condition returns true. For example, if
a motor needs to run for a specified duration after a start signal is given but should continue running
even if a temporary interruption occurs, the On Delay Retentive Timer ensures the motor runs for
the correct total time, regardless of the input condition being interrupted. Once the input condition
returns true after an interruption, the timer continues counting from where it stopped, making it
ideal for systems that require continuity despite brief interruptions.

Figure 5.11
S_ODTS Timer Block
 5. The Off Delay Timer (S_OFFDT)

The Off Delay Timer is used to delay the deactivation of an output after the input condition
has been turned off. It keeps the output active for a preset time after the input goes false. This timer
is useful for applications where you need to maintain the output for a certain period even after the
triggering input is no longer active. For instance, a light might need to stay on for a few seconds
after a door is closed to ensure the area remains illuminated. When the input condition is true, the
output is active, but once the input condition goes false, the Off Delay Timer begins counting.
After the preset time elapses, the output is deactivated. If the input condition goes true again before
the timer completes, the timing is reset.

Figure 5.12
S_OFFDT Timer Block

Figure 5.13 summarizes the principle of operation of each SIMATIC S7 timer.

Figure 5.13
Timing Diagram
 VI. SAMPLE PROGRAMS

Sample programs are helpful elements in learning the functioning of PLCs, as well as
different capabilities of the control systems that can be programmed. These programs thus act as
basic working examples where even an operator, without perhaps having actual programming
knowledge, can understand how the inputs, outputs, timers and other entities in a PLC environment
work. Through analyzing the forms of the given sample programs, the students can understand the
structure and algorithm of PLC programming, and can learn how to debug, redesign and improve
the control processes. The next section will describe typical sample programs to illustrate the
requirements of typical industrial automation processes so that learners can gain practical
experience in learning through implementation.

To learn how to program the PLC, let's take practical examples on the sample station for
the Sample Programs. Addresses for the Buffering station are provided in Table 6.1

Table 6.1
Sample Station Address

Sample Program 1

If "Start" push button is pressed and a work piece is available at the beginning of the
conveyor belt, then the conveyor belt will be actuated until the piece reaches the end of the belt.

Solution:

The conditions for operating the conveyor belt (activating it) are the same as the pervious
example. On the other hand, the normally open push button "Reset" was replaced with the normally
closed sensor "I0.1". And as explained above, since the sensor is normally closed, we will use a
normally open contact from it that will maintain the current flowing through it until it is activated.
The ladder diagram needed to perform the operation described above is shown in Figure 6.1

Figure 6.1
Ladder Diagram for Sample Program 1

Sample Program 2

If "Start" push button is pressed and a work piece is available at the separating (buffering)
position, then the separator will extend until it reaches its full extent then will retract again.

Solution:

Here, the conveyor belt will be operated once "Start" or "I1.0" is pressed and a work piece
is at the buffering position. The buffering sensor "I0.1" is a normally closed sensor, then if we want
the sensor to conduct current once it is activated, we will use a normally closed contact from it.
The sensor that informs the system that the separator is fully extended is "I0.4" which is a normally
open sensor, so if we want it to conduct current until it is activated, we will use a normally closed
contact from it.

Figure 6.2
Ladder Diagram for Sample Program 2
Sample Program 3

If "Start" push button is pressed, the conveyor belt will be activated for 4 sec or till "Stop"
push button is pressed. It is obvious from the question that the conveyor belt will start immediately
once "Start" is pressed, which mean that there is no delay. Then the proper timer for this type of
question is S_PULSE or S_PEXT timers.

Solution (Using S_Pulse timer):

According to the timing diagram shown in Figure 5.13, S_PULSE timer needs the set signal
to be maintained for at least time equals tv if the time tv is to elapse completely, hence the need
for the latch. Once "Stop" is pressed or the 4 sec are over the timer will turn off so will the conveyor
belt.

Figure 6.3
Ladder Diagram for Sample Program 3 Using
Pulse Timer

Solution (Using S_PEXT timer):

According to the timing diagram shown in Figure 5.13, S_PULSE timer needs the set signal
to be maintained for at least time equals tv if the time tv is to elapse completely, hence the need
for the latch. Once "Stop" is pressed or the 4 sec are over the timer will turn off so will the conveyor
belt.

Figure 6.4
Ladder Diagram for Sample Program 3 Using
Extended Timer
Sample Program 4

If "Start" push button is pressed, the conveyor belt will wait 4sec then get activated
till "Stop" push button is pressed.

Solution:

The obvious from the question is that there is a delay time between the press of "Start" and
the operation of the conveyor belt. So obviously, an ON-delay timer is needed. But there are two
types of ON delay timers: S_ODT and S_ODTS.

Figure 6.5
Ladder Diagram for Sample Program 4 Using
On-Delay Timer

Figure 6.6
Ladder Diagram for Sample Program 4 Using
On-Delay Retentive Timer
 VII. PROGRAMMING PROCEDURE
The programming process is the essential part of using PLCs and it prescribes a certain
structure regarding the creation, uploading and testing of programs. This section will provide
students with installation and configuration procedure of the SIMATIC Step 7 software used in
creating and programming of PLC. In this case the process encompasses installation of the program
environment, generation of a new project and realization of the necessary commands that are
inherent in specific kinds of tasks. Therefore, the means of putting the program in the Siemens
SIMATIC S7-300 PLC will also be explained, in order to enable the student to move his or her
code from software in to the real hardware controller. This approach allows the students to have
the actual feel of programming and applying PLC by interfacing with the hardware.

A. Getting Started with SIMATIC S7 Software

This software is developed by Siemens Company, and this version specifically is designed
to program the SIMATIC S7-300 PLC. The first step through programming is to open a project
where the user can build the necessary ladder diagram for a certain operation of the station. The
followings steps are the procedure into opening the software to its main window and in ladder
programming window.

1. On the computer’s home screen, double click the SIMATIC S7 Software icon shown in
Figure 7.1.

Figure 7.1
SIMATIC S7 icon

2. Create new project using the software wizard. This is done by checking the box beside
"Display Wizard on starting SIMATIC Manager" as shown by Figure 2.3. Then click "
 Figure 7.2
Step 2 of Starting SIMATIC S7 Manager
3. Choose the CPU of the SIMATIC S7-300 PLC available in the lab which is CPU312C as
shown by Figure 2.4. Then click "Next".

Figure 7.3
Step 3 of Starting SIMATIC S7 Manager
4. Since we program using Ladder diagram, choose LAD from "Language for Selected
Blocks" as shown by Figure 2.5. Then Click "Next".

Figure 7.4
Step 4 of Starting SIMATIC S7 Manager
5. Name your program at "Project name" as shown in Figure 2.6 then click "Finish".

Figure 7.5
Step 5 of Starting SIMATIC S7 Manager

6. The figure window will appear. To create a new project with specified to the used PLC,
click “File” from the top right and “New”.

Figure 7.6
Step 6 of Starting SIMATIC S7 Manager
7. After, “New Project” window will appear. Insert the name of your Project and then click
“Ok”.

Figure 7.7
Step 7 of Starting SIMATIC S7 Manager

8. Once returned to the Main window, right click on the name of your project and click “Insert
New Object”, then “SIMATIC 300”.

Figure 7.8
Step 8 of Starting SIMATIC S7 Manager
9. Once clicked, a tab of SIMATIC 300 Station will pop up on the main window. Click it and
click “Hardware”

Figure 7.9
Step 9 of Starting SIMATIC S7 Manager

10. Once “Hardware” is clicked, an “HW Coding” Window will appear. This is the window to
edit the rack of the PLC, as well as the name of the address of the I/O terminals. From the
right side, a sub-window is present.

Figure 7.10
Step 10 of Starting SIMATIC S7 Manager
11. From the right-side window, click “SIMATIC 300”, then “RACK 300”, and then “Rail”.

Figure 7.11
Step 11 of Starting SIMATIC S7 Manager

12. Once clicked, 2 rail windows will appear. Click the second row of the rail.

Figure 7.12
Step 12 of Starting SIMATIC S7 Manager
13. Once the second rail is highlighted, go again on the right-side window from SIMATIC 300
and click “CPU-300”, then “CPU 314C-2 PN/DP”, then the folder below it, and lastly, click
“V3.3”. This is the specific PLC being used on the laboratory. However, this varies on what
PLC you are using. The specific details of the PLC being used can be seen on the equipment
itself.

Figure 7.13
Step 13 of Starting SIMATIC S7 Manager

14. Once “V3.3” is clicked, a Properties Window will appear. The IP address of the computer
is highlighted. If not specified, make sure to insert the address. Also click “Do not use
router” from gateway since I/O terminal will be used instead. Click “Ok”

Figure 7.14
Step 14 of Starting SIMATIC S7 Manager
15. Once clicked, the racks of the window will have the certain CPU details in including
MPI/DP, pins of I/O, ports and addresses. In this rack, click “D124/D016”.

Figure 7.15
Step 15 of Starting SIMATIC S7 Manager

16. After clicking, Properties window will appear. Click the “Addresses” tab. This will show
the addressing of input and output of the entire program. You can set what number will be
the main address of your input by disabling “System Default” and then setting the Start
Input to your desired address. For this instance, the address will be 0. Click “Ok”

Figure 7.16
Step 16 of Starting SIMATIC S7 Manager
17. Next, from the same rack, click “CPU 314C-2 PN/DP”. The properties window will appear.
Click the “Protection” tab and enable “1. Keyswitch setting”. This will disable the write-
protection that hinders the rack from saving and compiling. Click “Ok”

Figure 7.17
Step 17 of Starting SIMATIC S7 Manager

18. Once clicked, click the “Save and Compile” button and close the Hardware window.

Figure 7.18
Step 18 of Starting SIMATIC S7 Manager
19. Once returned to main window, right next to “Hardware”, click “CPU 314C-2 PN/DP”,
then click “S7 Program (1)”, “Sources”, “Blocks”, then “OB1”.

Figure 7.19
Step 19 of Starting SIMATIC S7 Manager

20. After clicking “OB1”, the properties window of the Organization Block will appear. Since
this laboratory requires us to use Ladder Diagrams, from “Created in Language”, click the
arrow down button and select “LAD”. Click “Ok”.

Figure 7.20
Step 20 of Starting SIMATIC S7 Manager
21. The programming window shown in Figure 2.8 will appear. In this window you will find
the rungs you will be building your ladder diagram at and the logic bits (inputs, outputs),
timers, counters, comparators and any other component provided by the PLC that you can
program with.

Figure 7.21
Step 21 of Starting SIMATIC S7 Manager

22. If addressing is chosen to be changed to the name separate to the program, it can be changed
on the symbol table. Click the “Options” tab then “Symbol Table”

Figure 7.22
Step 22 of Starting SIMATIC S7 Manager
B. Uploading a Program to the PLC
1. In order for the program to be uploaded, make sure that the computer is plugged to the PLC
with a LAN cable. The LAN cable port can be inserted from the first rack of the PLC.
2. From the same project that the program is in, go back to the main window. From there,
click “Options” then “Set PG/PC Interface”.

Figure 7.23
Step 2 of Uploading a Program in PLC

3. Another window will appear. In this, click the Interface Parameter that is currently
<Active>. This Active interface is commonly a Realtek Gaming GbE Family Controller.
Click this and click “Ok”

Figure 7.24
Step 3 of Uploading a Program in PLC
4. Go back to the main window then click “Hardware”. Once the Hardware window is opened,
click “Save and Compile” first before clicking the “Download” button.

Figure 7.25
Step 4 of Uploading a Program in PLC

5. A Select Target Module Window will open, click Ok if the right module is selected.

Figure 7.26
Step 5 of Uploading a Program in PLC

6. Once clicked, a Select Node Address window will appear. Click “View” to open the
currently connected PLC. Once the current accessible node of the PLC appeared, this will
show the details of the currently uploaded program inside the PLC. Click “Upload” to
upload the new program then click ok.
 Figure 7.27
Step 6 of Uploading a Program in PLC

7. Click “Save and Compile” once again before closing the Hardware window.

Figure 7.28
Step 7 of Uploading a Program in PLC
 8. Now, go back to your program to open the program window. Click “Save and Compile”
again to save the program that is finished. Then, click “Download” from the ribbon and
click the Glasses icon or the online monitoring to view the current state of the station.

Figure 7.29
Step 7 of Uploading a Program in PLC

9. Test the station if working and the Online Monitoring is following the Hardware.

VIII. CONCLUSION

This module provided an in-depth understanding of the fundamentals of PLC operation,

programming, and the step-by-step procedures involved in working with SIMATIC Step 7
software. Students developed practical skills in configuring the Siemens S7-300 PLC, creating and
simulating ladder logic programs, and successfully uploading these programs to the PLC for
execution. Additionally, the module emphasized the importance of logical organization and
addressing within the program to ensure precise and efficient system control. These competencies
form the foundation for effectively managing and troubleshooting industrial automation systems
in real-world applications.
 FESTO MODULAR
PRODUCTION SYSTEM
FESTO MPS (DISTRIBUTION SYSTEM)

EE ELECTIVES II (LAB)

Members:
Abarca, Andrie
Avila, Renfred Jay R.
Baconawa, Adrian B.
Bagui, Yuan D.
De La Paz, Arvie R.
De Vega, John Nathaniel N.

January 2025
 I. INTRODUCTION

The number of manufacturing cells integrated in a contemporary production line of

factories are dependent, and each cell focuses on the accomplishment of a particular process in the
manufacturing line. Such cells perform roles such as distributing, testing, processing, handling,
assembling, and storing which facilitates smooth production. FESTO MPS (Modular Production
System) consists of individual and especially adapted stations for various logistics demands within
production processes. These systems can be so designed as to have flexibility and hence, they are
very appropriate for training scenarios as well as for practical real-world automation routines.

The Distribution Station is one of the important links within the FESTO MPS that
undertakes tasks of the preliminary work in the material flow and preparation for being used on
the subsequent stages of the production channel. In particular, it effectively sorts and delivers
workpieces establishing correct orientation regarding further stages of manufacturing processes.
Endowed with modern sensors and actuators, the Distribution Station imitates actual industrial
processes making it possible to get a practical view of such systems.

In this experiment, students will let emphasis on the programming as well as the control of
the sequence of operation of the FESTO MPS Distribution System by means of the Siemens S7-
300 PLC. With the use of SIMATIC Step 7 software, important functions of the system will be
realized and controlled, giving useful information about the PLC programming as well as the
different concepts in industrial automation. This real-life simulation shall improve students’
knowledge on distribution procedures within modern production lines as well as their controls.

II. OBJECTIVES

This experiment is designed to:

• Provide an introduction to the distribution system and the principles of vacuum

technology.
• Demonstrate the use of pneumatic actuators, including linear and rotary drives.
• Enable the programming of the distribution system's operation using ladder logic
programming.
 III. STATION DESCRIPTION

The stack magazine consists of a magazine barrel that is designed to hold up to eight
workpieces to make the distribution process continuous. Through a through-beam sensor, the
filling level of the stack is observed and the magazine is signaled to be refilled when empty. A
double-acting cylinder is used to eject out the workpieces one after another so as to achieve a
proper separation.

Figure 3.1
FESTO MPS Distributing Station

After separation, the workpieces are manipulated by the changer module the latter uses
suction cup for pick and place operation on each workpiece safely. A vacuum system is useful
because it checks to make certain that workpiece has been correctly picked up by the robotic
system before proceeding. Therefore, integration of pneumatic and vacuum systems makes the
handling of materials to be smooth and efficient.

The transfer from one station to the downstream station is done by the transfer unit and
which is motorized by the rotary drive. The arm of the transfer unit swings round to align the
workpiece for transfer at the right point in order to fit it effectively into the next function in the
line. The Distribution Station shows how sensors, actuators, and vacuum technologies can be
implemented; the whole system closely mimics real industrial material handling systems.
 IV. MATERIALS

The FESTO MPS Distribution Station comprises several critical components that work
together to perform efficient and automated material handling operations. Each part plays a
specific role in the system, contributing to its functionality and precision. Understanding these
components is essential for grasping how the station operates and interacts with the PLC control
system.

Figure 4.1
FESTO MPS Distributing Station Main Parts

Stack Magazine Module

The stack magazine's barrel is designed to hold up to eight workpieces, which must be
inserted with their open sides facing upwards. A double-acting cylinder is used to eject the lowest
workpiece from the gravity-fed magazine to a mechanical stop, which serves as the transfer point
for the changer module. The availability of workpieces within the magazine is continuously
monitored using a through-beam sensor. The position of the ejecting cylinder is tracked
electronically via inductive sensors, ensuring precise operation. Additionally, the advancing and
retracting speeds of the ejecting cylinder can be adjusted using one-way flow control valves,
allowing for fine-tuning of the system's performance.

.
 Figure 4.2
FESTO MPS Distributing Station Stack magazine

Before describing the components, it is important to understand the basic definitions of

cylinders. In pneumatic systems, the working fluid is air, while in hydraulic systems, it is liquid.
However, in this case study, only pneumatic equipment is used, as the forces required are relatively
small, eliminating the need for hydraulic systems.

• A single-acting cylinder is a type of cylinder where the working fluid acts on only one
side of the piston. Retraction of the piston is achieved using an external force, such as a
spring or the load itself.

• A double-acting cylinder, on the other hand, is designed so the working fluid alternates
between acting on both sides of the piston. To connect the piston to an external mechanism,
such as a crankshaft, one end of the cylinder features an opening for the piston rod, which
is sealed with a gland or stuffing box to prevent fluid leakage. Double-acting cylinders are
used in situations where external retraction forces are unavailable or when high force is
required in both directions of the piston’s travel.
No. Part Name Description

1. Proximity Sensor End position sensing of the ejecting cylinder.

Optical Sensor. Monitor the availability of workpieces in the

2. Through Beam Sensor
magazine barrel
Pneumatic actuator, double acting, with magnet ring for position
3. Double Acting Cylinder detection. Pushes the workpiece out from the magazine barrel to the
transfer point for the changer module to pick up.
One-way Flow Control
4. Flow control valves to adjust the piston rod speed
Valve

Table 4.1
Stack Magazine Parts and Description

Rotary Drive Module

The rotary drive module is a pneumatic handling device designed to grip workpieces
ejected from the magazine using a vacuum-operated suction cup. A vacuum switch ensures that
the workpiece has been successfully picked up before proceeding. The transfer unit's arm, powered
by the rotary drive, moves the workpiece to the transfer point of the next station in the sequence.

The swiveling range of the rotary drive can be adjusted between 90 degrees and 270
degrees using mechanical end stops, providing flexibility in its operation. The end positions of the
rotary drive are detected and monitored through electrical limit switches, ensuring precise control
and positioning during the transfer process.

Figure 4.3
FESTO MPS Distributing Station Rotary Drive
No. Part Name Description
An electrical limit switch used to detect the end positions of the
1. Micro Switch
rotary drive for precise positioning.
A pneumatic actuator that enables controlled swiveling motion of
2. Semi-Rotary Drive the transfer unit's arm within an adjustable range of 90 to 270
degrees.
A pneumatic actuator that enables controlled swiveling motion of
3. Suction Cup the transfer unit's arm within an adjustable range of 90 to 270
degrees.
One-way Flow Control
4. Flow control valves to adjust the piston rod speed
Valve

Table 4.2
Rotary Module Parts and Description

Control Panel Module

The Control Panel module features seven push buttons with integrated indicator lights,
enabling the operator to control the distribution station's functions, such as starting, stopping, and
resetting operations. The indicator lights provide real-time status updates about the station or
controller program, including notifications of faults or an empty workpiece magazine.
Additionally, the panel includes an emergency stop button and a safety relay, allowing the operator
to immediately halt all station activities during emergencies for enhanced safety.

Figure 4.4
FESTO MPS Distributing Station Control Panel
No. Part Name Description
Allows the operator to start or stop the distribution station's
1. Start/Stop Push button
operation.

Enables the operator to reset the station to its initial state after a
2. Reset Button
fault or completion of a process.

Provide visual feedback on the station's status, such as faults or an

3. LED Indicator Lights
empty workpiece magazine.

Facilitate connections between the control panel and the station's

4. I/O Ports
input and output devices for seamless communication.

Table 4.3
Control Panel Parts and Description

Pneumatic Valves Subsystems

Pneumatic actuators and sensors operated on compressed air and the valve system acts as
the intermediate between the electrical and the mechanical dimension. It uses the electrical control
signal to actuate the solenoid valve, in terms of enabling/disabling the flow of compressed supply
air to the actuators/sensors.

Figure 4.5
FESTO MPS Distributing Station Pneumatic Valves
Systems
No. Part Name Description

1. 3/2-Way Solenoid Valve Connected to the Semi-rotary drive

2. Vacuum Switch Used to detect the partial vacuum at the vacuum suction cup.

3. 5/2 Way Solenoid Valve Connected to the pneumatic cylinder in the Stack Magazine module

Connected to the Suction cup attached on the head of the semi-

4. Vacuum Generator
rotary drive.

Table 4.4
Pneumatic Valve Subsystems Parts and Description

Automatic Operation

The schematic shows how the system is primed to a state where the state of all the
mechanical components is known. After touching the START button, the system operates
automatically, and if the workpiece is present in the magazine, it starts working on it. The cylinder
prolongs, the rotary drive travels to the left and once the suction is switched on, the rotary drive
shifts to the right. During this, the magazine cylinder 8 retracts and the rotary drive 3 is in the
proper position as shown in FIG. 2. After that, suction is turned off and the next workpiece is
already accepted and worked on by the system. In case the z magazine is empty, the process is
stopped and the operator has to load a new workpiece and then click on start. The automatic
operation when done, can be halted only by the stop button or the emergency button, after which,
it will need to be restarted.
 V. SKETCH

This section focuses on the schematic sketch of the distribution station, illustrating the
layout and interconnections of key components. The sketch provides a clear view of elements such
as the stack magazine, pneumatic actuators, control panel, and I/O ports, allowing students to
understand how these parts are organized and interact within the system. By studying the diagram,
students can better visualize the flow of operations and how the various components contribute to
the overall functionality of the distribution system.

Figure 5.1
FESTO MPS Distributing Station Labels

The image shows the schematic sketch of the distribution station, with key components
labeled, including the sensors and pneumatic valves. The sensors are strategically placed to
monitor critical aspects such as the filling level of the stack magazine and the activation of the
suction cup. Pneumatic valves are also highlighted, controlling the flow of air to the cylinders and
rotary drive, enabling precise movement and control of the system's components. The diagram
helps visualize the interconnections between these components, illustrating how the sensors and
valves play a crucial role in the operation of the distribution system.
Perspective Views of the Station

Figure 5.2
FESTO MPS
Distributing Station
Plan View

Figure 5.3
FESTO MPS Distributing
Station Right-Hand Side View

Figure 5.4
FESTO MPS
Distributing Station
Front View
 VI. WIRING

This section focuses on the wiring and connections involved in the pneumatic setup of
the distribution station. It covers the integration of electrical components with pneumatic actuators,
including the wiring of sensors, valves, and control circuits. Understanding the wiring process is
essential for ensuring the correct operation of pneumatic systems, as it directly influences the
performance of devices such as cylinders, rotary drives, and vacuum systems. Proper wiring
ensures reliable control, safety, and efficiency of the system's automated processes.

Figure 6.1
FESTO MPS Distributing Station Pneumatic
Schematic Diagram

Figure 6.1 presents the pneumatic diagram of the FESTO MPS distribution system, which
includes five key outputs: SOL_A and SOL_B control the movement of the cylinder, SOL_C and
SOL_D manage the movement of the pneumatic motor, and SOL_E regulates the suction operation
of the pneumatic system. The diagram also highlights the integration of limit switches and
proximity switches within the system, as well as a pressure switch that monitors whether an object
is securely attached to the suction cup. These components work together to ensure precise and
efficient operation of the system.
 Figure 6.2
FESTO MPS Distributing Station PLC Electrical
Schematic Diagram

The schematic diagram illustrates the digital input and output connections of the FESTO
MPS distribution station to the PLC. On the input side, signals from sensors like the pressure
switch, optical sensor, and limit switches (LS1, LS2) are fed into the PLC for real-time feedback
about the system's status. PS1 and PS2 likely correspond to additional sensors that monitor specific
points of the process. On the output side, the PLC controls the solenoid valves (SOL_A, SOL_B,
SOL_C, SOL_D, and SOL_E), which manage the operation of pneumatic components such as
cylinders and rotary drives. The diagram also shows the power supply (24V) and ground (0V)
connections, ensuring proper operation of all connected devices.
 VII. PROGRAM

Within this section, the program that governs the running of the distribution station is
discussed and illustrated by a ladder diagram of the system logic. The ladder diagram is divided
into separate networks which are used in the performance of a particular functions in the station.
These networks govern several activities including cylinder movement, rotary drive operation,
suction control and sensor monitoring. This way the students will learn how each of the networks
is involved in the program and how the control system brings s all the components in the automated
process seamlessly.

Table 7.1
FESTO MPS Distributing Station Input and Output Addresses

The input and output address table above maps the physical sensors and actuators to
specific addresses in the control program. Inputs, such as sensors for detecting workpieces or
cylinder positions, are assigned unique addresses, allowing the PLC to monitor their status.
Outputs, like solenoids controlling cylinders, pneumatic motors, and suction operations, are also
assigned addresses for precise control. This address table ensures that each component is correctly
referenced in the program, enabling accurate and reliable operation of the distribution station.
Ladder Diagram Procedure

1. The first network of the program must have a “Start” and “Stop” to have an official starting
line for the station. However, realistically, before a station starts, a delay must take care to
create indication of the process is about to start. Take a NO contact of Start and Stop
connected to 3 different outputs:
• A “Warning” indicator output to indicate that the machine is about to start after
the delay. Once the delay is finished, the indicator light must be deactivated. For
this, connect a “R8” NC contact for later.
• An On-Delay timer to simulate the delay. Set it 3-5 seconds and label “T1”.
• A “R6” relay coil for latching of the network. With that, latch a NO contact by
connecting it parallel to the “Start” contact.

Figure 7.1
Distributing Station Ladder Diagram: Start/Stop Network

2. For the next network, determine the sensor that will be activated once the station starts. For
this instance, it’s the Magnetic Proximity Sensor on the Vacuum, “S3”. Make the sensor in
NC contact and connect it series to “T1” so the station will start after the delay of the timer.
Also, connect another NC Relay contact series to the sensor “S3” for repetition of the cycle.
This relay contact will be the last relay contact to be used before the process repeat the
cycle. Connect this series to the following outputs:
• First relay coil for latching of the network and starting the station. Connect a relay
contact of this relay coil (NC) series to a station output “Y1” to extend the
cylinder. From this, the station officially starts its process. Connect a NO Contact
of this relay parallel to the first sensor “S3” for latching.
• The relay coil that is connected to the relay contact series to the “Warning”
indicator output so once the timer runs out, the indicator of “Warning”
deactivates.
• Another indicator light “Going” to indicate that the process is ongoing. As soon
as the stations starts the process, the “Going” Indicator light will give indication
for the said process is ongoing.

Figure 7.2
Distributing Station Ladder Diagram: 1st Process Network

Figure 7.3
Distributing Station Ladder Diagram: 1st Output Network
3. For the 1st Relay connected network, the network must be responsible for the next process
after the first step, which is gathering the object from the magazine position. From that, the
second output will be activated once the first output is done. Needless to say, the sensor
responsible for activating the 2nd output, “Y4” is the sensor if the magazine is in front
position, “S2”. Connect this sensor to a NO relay contact from the previous network, “R1”
and a new relay coil “R2”. Connect a NO Contact of this new relay coil parallel to “S2”
for latching purposes. This network shall move the swivel drive to the magazine, so in a
separate network, connect a NO contact to the “Y4” output.

Figure 7.4
Distributing Station Ladder Diagram: 2nd Process Network

Figure 7.5
Distributing Station Ladder Diagram: 2nd Output Network
4. For the 2nd Relay connected network, the network must be responsible for unextending the
cylinder since the swivel drive already positions in the magazine. So, the sensor responsible
for deactivating the extended cylinder is the sensor if the swivel drive is in “Gather”
position, “S4”. Connect this sensor to a NO relay contact from the previous network “R2”
and a new relay coil “R3”. Connect a NO contact of this new relay coil parallel to “S4” for
latching purposes. This network shall unextend the cylinder in the magazine, so in a
separate network, connect a NC contact to the “Y1” output on Figure 6.3.

Figure 7.6
Distributing Station Ladder Diagram: 3rd Process Network
5. For the 3rd Relay connected network, the network must be responsible for turning on the
vacuum to suck the object while simultaneously turning off the output that switches off the
vacuum. So, the sensor responsible for turning on the vacuum is the sensor if the cylinder
is at back position, “S1”. Connect this sensor to a NO relay contact from the previous
network “R3” and a new relay coil “R4”. Connect a NO contact of this new relay coil
parallel to “S1” for latching purposes. This network shall turn on the vacuum and turn off
the output that turns off the vacuum, so in a separate network, connect a NO relay contact
of “R4” series to “Y2” and NC relay contact series to “Y3”.

Figure 7.7
Distributing Station Ladder Diagram: 4th Process Network

Figure 7.8
Distributing Station Ladder Diagram: 4th Output Network
6. For the 4th Relay connected network, the network must be responsible for moving the
swivel drive to the next station. So, the sensor responsible for this is if the vacuum securely
sucked the work piece, “S3”. Connect this sensor to a NO relay contact from the previous
network “R4” and a new relay coil “R5”. Connect a NO contact of this new relay coil
parallel to “S3” for latching purposes. This network shall move the swivel drive to the next
station, so in a separate network, connect a NO relay contact of “R5” series to “Y5” and
NC relay contact series to “Y4” turn off the output that moves the swivel drive to the
magazine.

Figure 7.9
Distributing Station Ladder Diagram: 5th Process Network

Figure 7.10
Distributing Station Ladder Diagram: 5th Output Network
7. For the last relay connected network, the network must be responsible for turning on the
Turn-Off vacuum output to remove the work piece from being sucked while turn off the
Turn-On Vacuum output. So, the sensor responsible for this is if the swivel drive is in the
position of the next station, “S5”. Connect this sensor to a NO relay contact from the
previous network “R5” and a new relay coil “R7”. Connect a NO contact of this new relay
coil parallel to “S5” for latching purposes. This network shall move remove the workpiece
from being sucked, so in a separate network, connect a NO relay contact of “R5” series to
“Y3” and NC relay contact series to “Y2” turn off vacuum. Since this is the last relay
network, label the relay contact form the 2nd network “R7” to repeat the process of the
ladder diagram.

Figure 7.11
Distributing Station Ladder Diagram: Last Process Network

Figure 7.12
Distributing Station Ladder Diagram: Last Output Network
Ladder Diagram and Symbol Table

Figure 7.13
Distributing Station Ladder Diagram
 Figure 7.14
Distributing Station Symbol Table of the Program

VIII. CONCLUSION
The distribution station offered a valuable demonstration of how pneumatic and electronic
systems work together in an automated industrial environment. Through this module, students
explored the operation of critical components, including stack magazines, double-acting cylinders,
rotary drives, and suction systems, and their synchronization using sensors and solenoid valves.
By programming the PLC to control these elements, students learned the importance of sequence-
dependent operations, sensor feedback, and efficient resource management in automated
processes. This hands-on experience highlighted the significance of precision and adaptability in
designing and managing modern industrial automation systems.
SIMATIC dc\ 01/28/2025 10:15:24 AM
SIMATIC 300(1)\CPU 314C-2 PN/DP\...\OB1 - <offline>

OB1 - <offline>
""
Name: Family:
Author: Version: 0.1
Block version: 2
Time stamp Code: 01/14/2025 11:06:04 AM
Interface: 02/15/1996 04:51:12 PM
Lengths (block/logic/data): 00320 00186 00022

Name Data Type Address Comment

TEMP 0.0
OB1_EV_CLASS Byte 0.0 Bits 0-3 = 1 (Coming event), Bits 4-7 = 1 (Event class 1)
OB1_SCAN_1 Byte 1.0 1 (Cold restart scan 1 of OB 1), 3 (Scan 2-n of OB 1)
OB1_PRIORITY Byte 2.0 Priority of OB Execution
OB1_OB_NUMBR Byte 3.0 1 (Organization block 1, OB1)
OB1_RESERVED_1 Byte 4.0 Reserved for system
OB1_RESERVED_2 Byte 5.0 Reserved for system
OB1_PREV_CYCLE Int 6.0 Cycle time of previous OB1 scan (milliseconds)
OB1_MIN_CYCLE Int 8.0 Minimum cycle time of OB1 (milliseconds)
OB1_MAX_CYCLE Int 10.0 Maximum cycle time of OB1 (milliseconds)
OB1_DATE_TIME Date_And_Time 12.0 Date and time OB1 started

Block: OB1 "Main Program Sweep (Cycle)"

Network: 1

I136.3 M136.6 M136.0

"S3" "R7" T1 "R1"

M136.0 M136.7
"R1" "R8"

Q137.4
"GOING"

Network: 2

I137.0 I137.1 M136.7 Q137.2

"START" "STOP" "R8" "WARNING"

M136.5 M136.5
"R6" "R6"

T1
S_ODT
S Q

S5T#3S TV BI

R BCD

Page 1 of 3
SIMATIC dc\ 01/28/2025 10:15:24 AM
SIMATIC 300(1)\CPU 314C-2 PN/DP\...\OB1 - <offline>

Network: 3

I136.2 M136.0 M136.1

"S2" "R1" "R2"

M136.1
"R2"

Network: 4

I136.4 M136.1 M136.2

"S4" "R2" "R3"

M136.2
"R3"

Network: 5

I136.1 M136.2 M136.3

"S1" "R3" "R4"

M136.3
"R4"

Network: 6

I136.3 M136.3 M136.4

"S3" "R4" "R5"

M136.4
"R5"

Network: 7

I136.5 M136.4 M136.6

"S5" "R5" "R7"

M136.6
"R7"

Page 2 of 3
SIMATIC dc\ 01/28/2025 10:15:24 AM
SIMATIC 300(1)\CPU 314C-2 PN/DP\...\OB1 - <offline>

Network: 8

M136.0 M136.2 Q136.0

"R1" "R3" "Y1"

Network: 9

M136.1 M136.4 Q136.3

"R2" "R5" "Y4"

Network: 10

M136.3 M136.6 Q136.1

"R4" "R7" "Y2"

Network: 11

M136.4 Q136.4
"R5" "Y5"

Network: 12

M136.6 Q136.2
"R7" "Y3"

M136.3
"R4"

Page 3 of 3
THE TESTING STATION

Problem Description

According to VDI 2860, testing, in the same way as measuring, forms part of the
handling function of checking. Information acquisition (ACTUAL) and the comparison of
specified characteristics (REQUIRED) and the resulting decision of “Workpiece
acceptable/ rejected” i.e. “Yes/No”, represent important component parts of testing. An
important component part of measuring is the comparison of characteristics (ACTUAL
values with specified reference values (REQUIRED values).

Typical testing characteristics are:

 Availability checking
 Identity checking
  Contour checking
 Size checking
 Color checking
 Weight checking
 Checking the availability of a workpiece

In automated production, in contrast with manual production testing assumes a key role.
In manual production, reject parts can be immediately rejected, whereas in automated
product, reject parts can lead to malfunction of the production process or a halt in
production. Moreover, this laboratory covers the typical testing focusing on “Size
Checking.”

The function of the Testing station is to:

 Determine the material characteristics of a workpiece
 Check the workpiece height
 Either reject a workpiece or make it available to a subsequent station

Components

Station (ready
mounted on profile
plate)
Air Compressor
Control console with
membrane keyboard

PLC Board

MPS ® trolley with

locking castors
 Components (Materials)

Component Symbol Function Illustration

1 Control Console The control
console allows
simple operation
of the MPS®
station. It has a
membrane
keypad and is
connected to a
controller via
SysLink. The
control console
allows up to 16
operating inputs
and 16 operating
outputs to be
connected. The
signals from
pushbuttons,
switches, signal
laMPS®, free
inputs, and free
outputs are
available at
additional
terminals.
2 Terminal Block XMA2 The terminal block
connects the PLC
cable to individual
functions on the
station.

3 Filter/Pressure The filter regulator

Regulator cleans the air and
controls the
pressure.

4 Lifting Module The Lifting module

is used to lift
workpieces from
the Recognition
module to the
Measuring
module.

5 Actuator/Ejecting The actuators

Cylinder used are a rodless
lifting cylinder and
an ejecting
cylinder. The
moving
compressed air
tubing and
 electrical cables
are routed via the
cable guide.
6 Valve Manifolds The valve
manifold controls
the flow of air in
response to
electrical signals.

7 Air-Cushioned The Slide module

Slide Module with air cushioning
is used to
transport
workpieces. Five
workpieces can
be
accommodated
on the air
cushioned slide if
the mechanical
stopper is fitted.
The cushioning
minimizes friction
between the
workpieces and
slide surface. The
inclination angle
of the slide is
infinitely
adjustable.
8 Measuring R1 The linear
Module (Linear displacement
Displacement sensor is used for
Sensor) measuring the
height of a
workpiece. The
Measuring
module measures
the height of
workpieces with
an analog sensor.
The operational
principle is based
on a linear
potential meter
with a voltage
divider tapping.
An attached shock
absorber
cushions the end
position approach
of the lifting
cylinder.
9 Analog B5 The analog
Comparator measured value
can be digitalized
via a comparator
with adjustable
threshold values
(0/1 signal). The
analogue signal
can be supplied to
a PLC using
 analogue signal
processing via the
connection block.
10 Optical Proximity B2 It uses infrared
Sensor/Diffuse light to detect the
Sensor light reflected by
the workpiece
Different surfaces
or color
changes the
amount of
reflected light.
This is used for
color detection. It
detects silver and
red workpieces.
Color
identification is
carried out by
means of the
proximity sensors
with digital output.
11 Capacitive PART The capacitive
Proximity Sensor _AV proximity sensor
is used for
detection of
workpieces. The
workpiece
changes the
capacity of a
capacitor build in
the sensor head.
Workpieces are
detected
independent of
color. and
material. The
capacitive
proximity sensor
detects silver, red
and black
workpieces.
12 Retro-reflective B4 The retro-
Sensor reflective sensor
is used for
monitoring the
working space of
the Lifting module.
If the working
space is occupied,
it is not possible to
move the lifting
cylinder. A retro-
reflective sensor
consists of
transmitter and
receiver in the
same housing.
The retroreflective
sensor emits
visible red light.
The light is
reflected by an
external reflector.
If the light beam is
interrupted by an
object, the
switching status of
the retro-reflective
sensor changes.
13 Proximity Sensor 1B2 A proximity sensor
are used for end
positioning
sensing of the
cylinders. They
are sensitive to a
permanent
magnet mounted
on the piston of
the cylinder. This
activated when
the cylinder is
back on the
original position
which indicates
“Lifting Cylinder is
Down.”
14 Proximity Sensor 1B1 A proximity sensor
are used for end
positioning
sensing of the
cylinders. They
are sensitive to a
permanent
magnet mounted
on the piston of
the cylinder. This
activated when
the cylinder is
reaching the
height of ejecting
the accepted
workpiece which
 indicates that
“Lifting Cylinder is
Up.”
15 Light Barrier IP_FI Light barrier to the
Receiver/Input following station

16 Light Barrier IP_N_FO Infrared sender to

Sender/Output the previous
station,maximum
range 6000 mm
Light barrier to the
following station
 Positional Sketch

1B1 R1

Pressure
Air-Cushioned
Lifting Module Regulator
Part_AV Slide Module

B2
1B2

Cylinder

B4

XMA2
IP_N_FO

B5
Valve
Manifold

IP_FI
VIEWS

Top/Plain View

Front View

Side View
Wiring

Control Console Wiring

 Testing Station Electrical Wiring/Circuit Diagram

24V 0V
Testing Station (PLC)
Start 0V 0V
Stop 24V 24V

0 0
I 1.0 Q 1.0
S0 C0

1 1
I 1.1 Q 1.1
S1 C1

S3 I 1.3
2 2 Q 1.2
C2

S4 I 1.4
3 CPU 3 Q 1.3
C3

S5 I 1.5
4 4
5 5
6 6
7 7
24V 24V
0V 0V

24V 0V
Control Panel
0V 0V
24V 24V
Start
0 0
Stop
1 1
CPU
2
3

24V 24V
0V 0V
Program of the Testing Station

A programmable logic controller (PLC) is a specialized computer used to connect input

field devices to output field devices through logic implemented in software. For example,
a drill press that needs to turn on only when there is a part in the press and the operator
has one hand on each of the two start switches. The logic functions to make sure that all
such conditions are met before starting the press can be implemented using a PLC.

Inputs of the Station

Symbol Address Comment

Part_AV I1.0 Workpiece available inside the clamping
B2 I1.1 Check if workpiece is black – 0 = black
R4 I1.2 Safety light barrier
R1 I1.3 Check the height of the workpiece – 1 = ok
1B1 I1.4 Lifting cylinder is up
1B2 I1.5 Lifting cylinder is down
Push_ba I1.6 Pushing cylinder is in back position
Follow I1.7 Light barrier to the following station

Inputs of the Control Panel

Symbol Address Comment

START I2.0 Start button
STOP I2.1 Stop button
AUTOMAN I2.2 Switch automatic and manual cycle
RESET I2.3 Reset button
EMERGEN I2.5 Emergency stop switch-reset with Quit-button

Inputs of the Communication

Symbol Address Comment

CI1_Prev I2.4 Input communication from Q1.6 previous station
CI1_Foll I2.6 Input communication from Q1.4 following station
CI2_Foll I2.7 Input communication from Q1.5 following station
Outputs of the Station

Symbol Address Comment

Liftdown Q1.0 Solenoid of the lifting cylinder down
Liftup Q1.1 Solenoid of the lifting cylinder up
Matpush Q1.2 Solenoid of the pushing cylinder
Slide Q1.3 Solenoid of the air-slide
Previous Q1.7 Light barrier to previous station

Outputs of the Control Panel

Symbol Address Comment

L_START Q2.0 Light inside the Start button
L_RESET Q2.1 Light inside the Reset button
L_SPEC1 Q2.2 Light no. 1 special function
L_SPEC2 Q2.3 Light no. 2 special function

Outputs of the Communication

Symbol Address Comment

CQ1_Prev Q2.4 Communication output to I1.6 previous station
CQ2_Prev Q2.5 Communication output to I1.7 previous station
CQ1_Foll Q2.6 Communication output to I1.4 following station

Program of the Testing Station

Upon identifying the inputs and outputs address of the station as well as the
Programmable Logic Controller (PLC), it has a maximum of 8 characters from 0 to 7.
Moreover, the student were able to design a program through a series of trial of program
and progressively succeeding to acquire this provided program that will be shown below
as follows:
Symbol Table
Conclusion

The completion of this module has provided a robust foundation for understanding
and applying Programmable Logic Controllers (PLCs) using STEP 7 and SIMATIC
software. The experience gained addresses each of the stated objectives, ensuring both
theoretical knowledge and practical skills essential for modern industrial automation
systems.

This study effectively delivered basic knowledge of PLC functions, enabling us to

become proficient in navigating and utilizing the STEP 7 and SIMATIC interface. By
familiarizing ourselves with the programming languages and tools, we enhanced our
ability to implement functional control systems. Through hands-on practice, we solidified
our understanding of programming logics where the distinction between input and output
modules were learned, and the systematic assignment of PLC addresses.

Furthermore, the exploration of the Testing Station introduced us to its various

components and their roles within a working cycle. We successfully prepared the Testing
Station for operation by commissioning power supplies, configuring pneumatic and
electrical systems, and executing its operation. Additionally, interpreting ISO drawings (or
the ladder diagram) allowed us to comprehend the broader design and functionality of the
system that ties together the theoretical concepts with real-world applications.

In conclusion, this module underscores the significance of combining theoretical

knowledge with hands-on experience in mastering PLC programming and Testing Station
operations. The competencies developed through this laboratory course provide a solid
foundation for further exploration and application in the field of industrial automation and
electrical engineering.
 Republic of the Philippines
SOUTHERN LUZON STATE UNIVERSITY
Department of Electrical Engineering
Lucban, Quezon

Name: CABALLAS, JAN ASHLEY J.

CASTILLO, ERICA MAE I.

ELIPONEO, CRYSTAL KAYE V.

ENGUERO, JHON CARLO

GAMBA, GIA JANE R.

HERNANDEZ, REZALYN A.

Section: BSEE IV- GJ

Date: JANUARY , 2025

ENGR. MELLER GONZALES

Instructor
I. INTRODUCTION

A Programmable Logic Controller (PLC) operates by managing and automating

a system's processes through a set of instructions programmed into it. PLCs are widely
used in controlling industrial machinery like conveyors, robotic cells, temperature
systems, and more. They enable efficient communication, monitoring, and control of
complex automation tasks. PLCs are also capable of triggering alarms in case of
malfunctions, recording operational data (such as productivity levels), and
automatically managing processes by starting or stopping them. These controllers are
appreciated for being user-friendly, cost-effective, and reliable, which contributes to
their widespread use in various industries.

The Festo Modular Production Systems (MPS) consists of several stations, each
designed to perform specific functions within a simulated production line. These
stations include the handling station, distributing station, processing station, and testing
station. Each station is essential for conducting practical experiments in the lab,
allowing for the exploration of different technologies and automation principles.

In this module, it will focus on the MPS Processing Station, providing an in-depth
look at its components, functions, wiring, and programming. A detailed description of
the station will be presented, along with a diagram of the machine and its associated
ladder diagram. The aim is to thoroughly examine how the processing station works
and its role in the overall modular production system.

The Festo MPS Processing Station provides hands-on experience with automation
and control systems. It simulates a real production line where students work with
motors, sensors, and conveyors, all controlled by a PLC. In the lab, students design,
program, and troubleshoot automated processes, learning how electrical and
mechanical systems work together. They gain practical skills in PLC programming,
sensor integration, and motor control by working on tasks like sorting, assembly, and
testing.

Overall, the MPS Processing Station is an essential educational tool that helps
Electrical Engineering college students apply theoretical concepts to real-world
scenarios, develop critical skills, and gain the practical knowledge needed for success
in the engineering industry and field.
A. Sample Program
B. Step-By-Step Process

Setting up the Program:

1. First, Download and Install Siemens Simatic Manager (Step 7) software in laptop.
2. Open the Simatic Manager.
3. Select File>New, and create new project, and name it based on name what you want.
4. Next step, Right-Click the new Project, Insert New Object>Simatic 300 station.
5. Double-Click the Simatic 300, then you can see the Hardware click it.
6. After clicking the Simatic 300, you kind of go to the many tables part of the software,
where expand the Simatic 300 to the side. Click RACK-300, then Rail.
7. Then you fill the table add CPU and Power Supply according to the designation on the
equipment used.
8. When done to that, Click File>Save the most important is you have ti click COMPILE.
You can see this on the upper part of the software.
9. Afte that, you have to go back to the first part, where you click the Hardware part. Now
Click CPU name you are assigned>Blocks>OB1.
10. Then the software will go to the Ladder Program part.
After setting up the first stage, now it’s time to make a ladder program part:
11. Create a Program for a Station the group assigned (Processing).
12. Use Programming Elements, such as Relays, Timers, NO and NC. Then label it.
13. After that, you have to create a Symbol Table. Go to Options>Symbol Table.
14. Assigned names to all addresses, make sure it is equal to the ladder label that you
make.
Now for the last stage, where you can upload the program:
15. In uploading the program, Click the Option, then click the PG/PC Interface.
16. Check and click the assigned part where you can if the device is Realtek.... (Active)
then OK.
17. Go to Hardware check everything first, then click another file>save, then COMPILE.
18. Then you can Download the Module.
19. Download now the Ladder Program, which is in the Upper part of the Software.
Blocks>OB1.
20. Select the CPU and you have to check if there is the name of the previous station, to
make sure if it will RUN.
21. After that Click RUN. Monitor if it’s working.
22. The sequence should be like this: Test and stamp the object, Rotate the rotary
indexing table, Clamp the object, Drill the object, Eject the object to the next station,
Repeat the cycle.
23. Then you’re DONE.
II. ANALYSIS

A. Problem Description Processing Station

The Processing Station (MPS) is a machine designed to perform specific tasks in a
step-by-step manner. The MPS Processing follows a sequence of operations to
complete tasks like processing, inspection, and transfer of materials.
STEP 1: Starting the Machine
▪ The first step is turning on the MPS and ensuring all components are ready.
▪ Sensors, motors, and other parts are checked to confirm they are functioning properly.
STEP 2: Loading Materials
▪ Materials are placed into the machine by through hand.
▪ The MPS ensures the material is in the correct starting position before moving on.
STEP 3: Processing the Material
▪ The machine carries out its task, such as inspecting, drilling, or transferring.
▪ This is the most important step, where the materials are transformed or worked on as
required.
STEP 4: Checking the Work
▪ Sensors under the moving plate and in attached equipment inspect the workpiece to
detect any mistakes in the load or to the parts malfunction.
STEP 5: Moving the Material
▪ Once the material is processed and checked, it is moved to the next stage or removed
from the system.
STEP 6: Resetting the Machine
▪ After finishing the cycle, the MPS Processing resets itself to prepare for the next task.
▪ This includes the clearing the moving plate and returning to the starting position.

Problems Might Occur in the Step-by-Step Process

While the Processing Station (MPS) is designed to work efficiently, certain problems
can occur during its operation. Below are the potential issues that might arises in each
step of the process:
STEP 1: Starting the Machine
▪ Sensors or motors might not initialize correctly.
▪ There could be a power issue, preventing the system from starting.
▪ Faulty wiring or a damaged component might cause errors during the initial check.
STEP 2: Loading Materials
▪ Materials may not be placed correctly, leading to misalignment in the following steps.
▪ Automated loading systems might malfunction or fail to detect the material.
STEP 3: Processing the Material
▪ The machine might not perform the task accurately due to tool wear or calibration.
▪ Mechanical failure, such as jams or misfires, can disrupt the process.
 STEP 4: Checking the Work
▪ Sensors might fail to detect defects due to misalignment.
▪ Software errors in the inspection system can rout in inaccurate checks.
STEP 5: Moving the Material
▪ Materials might get stuck or fall during transfer, causing delays.
▪ Processed materials might collide with new ones if timing is not synchronized.
STEP 6: Resetting the Machine
▪ The system might not reset completely, leaving parts in the wrong position.
▪ Errors in programming could cause the machine to skip or malfunction the components,
also can fail to prepare for the next cycle.
Regular maintenance, proper calibration, and thorough checks can help reduce the
chances of these issues occurring
COMPONENTS AND FUNCTIONS OF THE FESTO PROCESSING MACHINE

COMPONENTS NAME SYMBOL DESCRIPTION

The drilling assembly moves up and down
to drill holes. The downward movement
Drilling Assembly
M1 lowers the drill to cut into the material,
(UP & DOWN)
while the upward movement lifts it back
up after drilling.
It uses an actuator to control the
Drilling Module with Vertical
M3 movement, ensuring precise and efficient
Axis
drilling.
It removes the finished parts from the
Ejector Module (Transfer) M6
workstation.
It checks if the parts are correct such as
Proofing Workpiece M5 ensuring the size, color, or position is right
before moving to the next step.
It rotates the table to move parts to
Motor for the Rotary
M2 different stations as it ensures smooth and
Indexing Table
precise movement for accurate processing.
It detects the tables position also helping to
Sensor for the Rotary
B3 ensure accurate movement and proper
Indexing Table
alignment of the workpiece.
It checks if the workpiece is in the correct
Unit Orientation Checking
B1 position. It also helps ensure proper
Sensor
alignment before the next process.
Checker Module (Sensor) PART_AV Sense object availability
 It holds the workpiece in place during
Clamping Module M4 processing as ensuring the stability and
accuracy while working on the part.
It detects the position of the drill, ensuring
Sensor for Drilling Module
B2 the drill is in the correct place before
with Vertical Axis
starting the operation.

B. Materials

➢ Festo MPS Processing Station

➢ Programmable Logic Controller (PLC)
➢ Laptop

C. Table

D. Machine Sketch
E. Wiring (Ladder Diagram)
III. CONCLUSION
The Festo Modular Production System (MPS) Processing Station is an important
learning tool that connects theoretical knowledge with practical application in
automation and control systems. It allows students to simulate real-world industrial
scenarios by providing hands-on experience with components such as rotary indexing
tables, drilling modules, and PLC programming. This module teaches the fundamental
principles of automation but also equips students with the skills to design, program,
and troubleshoot complex systems.

Through step-by-step guidance on programming PLCs, students become proficient

in software such as Siemens Simatic Manager, learning to create ladder diagrams,
configure hardware, and implement logic for automated processes. The structured
workflow—from setup to execution—demonstrates the integration of electrical,
mechanical, and control systems in an efficient production line.

The key takeaway from this capability is that the MPS Processing Station enables
the development of the Electrical Engineering student in respect to reasoning, technical
skills, and the hands-on solving of problems. All these skills are crucial in performing
their duties within the service sector of the engineering world, preparing them for
success as innovative solutions in modern automated systems.
 SOUTHERN LUZON STATE UNIVERSITY

LUCBAN QUEZON

COLLEGE OF ENGINEERING

FESTO

HANDLING STATION MANUAL

ALMACEN, BRYANT KERVINA.

ARSOLACIA, ANN GELYANNE Z.
BRIONES, KENT OWEN
CALUCIN, MARK REAVIN C.
CUERDO, ROMMEL
ESPERANZA, JAYMARK
BSEE IV GJ

Engr. Meller Gonzales

Instructor

1|Page
 Table of Contents

I. INTRODUCTION __________________________________________________ 3

II. HANDLING STATION ______________________________________________ 3

III. FUNCTION ______________________________________________________ 4

IV. DIAGRAM_______________________________________________________ 5

V. PARTS__________________________________________________________ 6

VI. SEQUENCE ______________________________________________________ 9

VII. INPUT AND OUTPUT ______________________________________________ 10

VIII. LADDER DIAGRAM________________________________________________ 11

IX. STEP BY STEP OPERATION 13

REFERENCES ____________________________________________________ 20

2|Page
 I. INTRODUCTION

FESTO is a globally recognized leader in industrial automation and pneumatic

technologies, with a history dating back to its founding in Germany in 1925. The company
specializes in innovative solutions for factory and process automation as well as vocational
training in automation and control technology. FESTO’s extensive product portfolio includes
pneumatic and electric drive systems, valves, sensors, and control systems, catering to industries
such as automotive, electronics, and food processing.

With a strong emphasis on research and development, FESTO is committed to advancing

technology and consistently delivers cutting-edge innovations that enhance industrial efficiency
and productivity. The company is equally dedicated to environmental sustainability, integrating
eco-friendly practices into its manufacturing processes and product designs.

Known for the precision and reliability of its products, FESTO’s solutions are utilized
worldwide, significantly improving manufacturing and production systems across various sectors.
Beyond its industrial contributions, the company is deeply invested in education, equipping
professionals with essential automation skills through training programs and learning resources.

FESTO’s extensive global presence, supported by subsidiaries and distribution partners,

ensures easy access to its wide array of products and services. Guided by a customer-focused
approach, FESTO continues to play a vital role in shaping the future of industrial automation.

3|Page
 II. HANDLING STATION

A Handling Station is an advanced automated system designed to enhance material

handling processes in industrial settings. By incorporating cutting-edge technologies such as
robotics, control systems, and sensors, it optimizes tasks like picking, placing, sorting, and
moving objects with precision and efficiency. Handling Stations are widely utilized across
industries like manufacturing, logistics, and distribution, where they play a critical role in
automating complex operations and boosting overall productivity.

Companies like FESTO, known for their leadership in industrial automation, offer
innovative Handling Station solutions as part of their diverse product portfolio. FESTO's
Handling Stations exemplify their commitment to transforming material handling processes
through state-of-the-art automation. These systems integrate robotics, control technologies, and
sensors seamlessly, underscoring FESTO's dedication to providing advanced and holistic
automation solutions tailored to modern industrial needs.

III. FUNCTION

A Handling Station is an advanced automated system meticulously engineered to enhance

material handling operations in industrial environments. It is designed to optimize processes such
as picking, placing, sorting, and transporting objects within sectors like manufacturing, logistics,
and distribution. By integrating state-of-the-art technologies—including robotic arms, conveyor
systems, sensors, and centralized control units—the Handling Station achieves remarkable
efficiency and precision.

Robotic arms serve as the cornerstone of the system, performing controlled and precise
movements to ensure the safe and accurate handling of materials. A key component, the optical
reflex light sensor, detects the presence of workpieces and differentiates between materials, such
as black and non-black (e.g., red or metallic), enabling the system to sort workpieces effectively.
The pneumatic gripper further enhances the process by securely transferring workpieces from the
receptacle module to designated locations, such as a slide.

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 Sensors play a vital role in providing real-time feedback, enhancing both the accuracy
and safety of operations, while conveyor systems facilitate seamless material transportation,
boosting overall efficiency. Centralized control systems act as the brain of the operation,
coordinating the activities of all components to ensure synchronized and efficient performance.

Additionally, Handling Stations often feature user-friendly programming interfaces,

allowing operators to customize and adapt the system to specific operational needs. These
stations significantly reduce the reliance on manual labor for repetitive and labor-intensive tasks,
improving the speed, accuracy, and efficiency of material handling processes. Their primary
objective is to streamline operations, minimize errors, and maximize productivity in industrial
workflows.

IV. DIAGRAM

The diagram presented highlights the key components that constitute a handling station. The
system primarily consists of the following elements:

1. Receptacle Module – Serves as the starting point for workpieces, where materials are initially placed
and prepared for handling.
2. PicAlfa Module – Facilitates the controlled picking and manipulation of workpieces, integrating
advanced robotic mechanisms for precision.
3. Slide Module – Provides a smooth and efficient path for transferring workpieces to their designated
locations.
4. Profile Plate – Acts as the structural base, ensuring stability and alignment for all mounted components.
5. Trolley – Offers mobility and flexibility, enabling the station to be easily repositioned within the
workspace as needed.
6. Control Console – Houses the user interface and control mechanisms, allowing operators to program
and monitor the station’s operations.

5|Page
 7. PLC Board – Functions as the central processing unit, orchestrating and coordinating the activities of the
various modules for seamless operation.

These integrated components work collectively to deliver a cohesive and efficient material handling
solution, showcasing the sophistication and functionality of the handling station.

PicAlfa module
Recording module

Profile plate Slide module

Control panel Cart

PLC board

Figure 1. Parts of Handling Station

6|Page
 V. PARTS

Recording module
Workpieces are inserted into the module by hand or by a

Previous station inserted. The workpieces are held in a holder

detected by an optical reflex light sensor.

PicAlfa module
The PicAlfa pneumatic module, which is exclusively
equipped with pneumatic drives, uses industrial
handling components. Via a linear axis with flexible
end position adjustment and damping, it is
positioned quickly - even on Intermediate positions.
A linear flat cylinder serves as the lifting cylinder for
the Z axis with end position query. There is a
pneumatic gripper on the lifting cylinder. The one
integrated into the gripper jaw optical proximity
switch detects the workpieces.

The PicAlfa module is extremely flexible: stroke length, inclination of the axes, The arrangement
of the end position sensors and the mounting position can be adjusted. This means that the
module can be used for a wide variety of handling tasks without additional Elements can be
adjusted.

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Slide module

The slide module is used to

transport and store workpieces.
The Chute can hold 5 workpieces.
The angle of inclination of the
slide can be adjusted
continuously. In t h e handling
station, the slide module is used twice.

Assembly of profile plate and control panel

1) profile plate
2) hammer nuts M6-32 (4x)
3) cars
4) cylinder screw M6x10 (4x)
5) sheet metal screw 3.5x9
(2x)
6) control panel

8|Page
TABLE 1. MODULES AND OTHER PARTS

PARTS FUNCTION

Receptacle A component responsible for holding and precisely positioning workpieces

module during the handling process.

PicAlfa The complete handling station itself which is made of different

module components. It is a versatile and educational tool for experimenting with
basic handling tasks in a simulated factory environment

Slide module A component used to transport and gather workpieces. It can hold five
workpieces and the angle of inclination of the slide is adjustable.
Pneumatic A component used for grasping and manipulating workpieces during
Gripper handling tasks.
Profile plate This forms the base structure of the PicAlfa module. It's typically made of
anodized aluminum extrusions, providing a sturdy and lightweight
platform for mounting other components.
Trolley It is a movable carriage that travels along the X-axis of the PicAlfa module.
It houses the gripper assembly and is responsible for manipulating
workpieces within the designated area.
Control
console The user interface for operating the PicAlfa module. It consists of buttons,
switches, and LEDs.
The brain of the PicAlfa module, which is responsible for executing
PLC board program instructions, controlling, and communicating with external
devices.

9|Page
TABLE 2. SENSORS

Sensor Function

Diffuse sensor (Receptacle) A sensor used for detection of the workpieces.

Diffuse sensor (Gripper) A sensor used for color distinction of the workpieces.
Proximity sensor (PicAlfa) A sensor used for end position sensing of the linear axis.
Proximity sensor (PicAlfa) A sensor used for end position sensing of the cylinder.

VI. SEQUENCE

1. Examine the receptacle for the presence of a workpiece; if identified, initiate the forward
movement of the actuator cylinder.
2. Upon advancement, securely grasp the identified workpiece.

3. Following the grip, elevate the cylinder along with the workpiece.

4. Progress the actuator cylinder to the designated position as needed.

5. Lower the actuator cylinder while concurrently releasing the gripper to place the workpiece
onto the slide.
6. Elevate the cylinder subsequent to the deposition of the workpiece.

7. Restore the actuator cylinder to its initial position by moving it to the left.

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 VII. INPUT AND OUTPUT

Input Module Input Signal Output (down) Output Signal

Receptacle Module Workpiece Detected (I4.4) Grip Actuator Cylinder

(Move Down)
PicAlfa Module(2B1) Activate Gripper (I4.0) Up Gripper Engage

PicAlfa Module(2B1) Activate after (I4.5) Right Actuator Cylinder (Move

Gripping Workpiece Up)
PicAlfa Module(2B2) Activate after (I4.2) Down Actuator Motor (Advance
Cylinder Move Up and Ungrip Right)
Slide Module(2B1) Deposition (I4.4) Up Actuator Cylinder
Command (Deposit Move Down & Gripper
Workpiece on Slide) Release
PicAlfa Module(2B1) Post-Deposition (I4.5) Left Actuator Cylinder (Move
Adjustment Up)
PicAlfa Module(2B2) Reset Command (I4.1) Actuator Motor (Move
(Returning to Initial Left)
Position)

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 VIII. LADDER DIAGRAM (HANDLING STATION)

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SYMBOL TABLE

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 IX. STEPS HOW TO CREATE PROGRAM

1. Create a file
File /New project/ Name / ok

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2. Insert SIMATIC 300 Station
- right click/insert new object/Simatic 300 station/double click to replace

3. Attach the V3.3 to create Program

- Hardware /Simatic 300/ RACK 300/RAIL /SELECT THE TABLE/CPU 300/ CPU314C-2 PN-
DP/6ES7 314-6EH04/V3.3/ok/save

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4. Open S7 Program
-CPU 314C-2 PN-DP/ S7 Program/ blocks/OB1

5. Set a Protection
- double click the CPU 314C-2 PN-DP/ Protection/select number 1/ok

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6. Address the D124/DO16
- Double Click the D124-DO16/select addresses/put your group number into start/ ok

7. Select Ladder Program

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STEPS HOW TO UPLOAD

1. Set into PG/PC Interface

-Options/Set PG-PC Interface

2. Set to Realtek RTL8821C 802.11ac PCIe Adapter. TCPIP

- Double click the Realtek RTL8821C 802.11ac PCIe Adapter. TCPIP/Ok

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 3. Select Target Module
-hardware/save and compile/ download module/ok

4. Select Node Address

- hardware/save and compile/ download module/ok/view/update/ok

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 5. Run the Program
-back to ladder diagram/download/Monitor (ON-OFF)_

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REFERENCES

[Link]
n_Handling_C_H5.pdf
[Link]

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