Technical Specification ŠKODA AUTO a.s. Part II-MO-03 ...

Developed: Car Production Planning (PPF) 20190531_TZ SKODA AUTO_II-MO-03-Elektricka cast vyr. zarizeni_en Part II-MO-03

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Technical Specification ŠKODA AUTO a.s.

Part II-MO-03 – Electrical Part of Production Equipment for Final Assembly

Part II-MO-03 (KELH II) was developed in cooperation between ŠKODA AUTO (PPF / 1) and VW AG (for processors see

below). The supplier is obliged to observe the following technical specifications.

Processors: Brendel, Uwe VW

Milichovský, Miloš Škoda PPF/1 Tel.: +420 731 296 612

Šťastný, Michal Škoda PPF-K/6 Tel.: +420 732 294 438

Pyszny, Rafael VW-NF NP-P/E1 Tel.: 0151-74635873

Hafner, Niklas VW-NF NP-P/E2 Tel.: 0152-64305

Hurtado Velasco, Jesus SEAT SEA/PP-6

Paredes Cervera, Alberto SEAT SEA/PP Tel.: +34 93 773 1254

Nietsch, Christoph MAN PTPIT2-M

Blaschke, Franz MAN PTPIT2-M

History of Changes

Status Datum Describing

1.0 30.11.2019 New edition. Rework and adaptation of KELH (concern spec.) of Final assembly.

Structure of Technical Specification - Electrical Part of Equipment

tel:+420731296612;ms-skip-rnl=True




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Technical specification - The electrical part of the equipment consists of three parts and regulates only the scope of supply of

the electrical part (machines and machinery):

TZ_I-09 Electrical part of equipment - General requirements

Information on regulations, directives, procedures, etc. that are relevant for the implementation of the project at the

Volkswagen Group (outside the NAR).

TZ_II-X-03 Electrical part of equipment - Requirements specified by the department

This requirement define here standard specifications, supplementary and special requirements of production units. Deviations

and supplements described herein take precedence over Part I.

TZ_III-X-03-<Project Name>_<Plant>_ Electrical part of equipment - Project-specific requirements

Here you will find all the entries valid for the current project (only the first vehicle type is the project name) and for the

location. Deviations and supplements described herein take precedence over Part I and Part II as well as Co-Applicable

Documents of Part IV.

x = production unit (see Part I - 00 Structure of the Specifications)


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Content:

1 General .................................................................................................................................................................................. 7 1.1 Contracting authority project contact partner ................................................................................................................ 7 1.2 Supplier personnel ......................................................................................................................................................... 7 1.3 Communication ............................................................................................................................................................. 7 1.4 Regulations and related documents ............................................................................................................................... 7

1.4.1 Enter the software version ................................................................................................................................. 7 1.5 Milestones ..................................................................................................................................................................... 8 1.6 Environmental conditions ............................................................................................................................................. 9

1.6.1 Fire protection ................................................................................................................................................... 9 1.6.2 Explosion Protection ......................................................................................................................................... 9 1.6.3 Wet Areas .......................................................................................................................................................... 9

1.7 UPS ............................................................................................................................................................................... 9 1.8 Energy Efficiency and Management ........................................................................................................................... 10 1.9 Material Release List ................................................................................................................................................... 10 1.10 Reuse ........................................................................................................................................................................... 10 1.11 Integration into existing Production Equipment .......................................................................................................... 10 1.12 Provision ..................................................................................................................................................................... 10 1.13 Update konstrukčních zadání, software a firmware .................................................................................................... 11 1.14 Construction Site ......................................................................................................................................................... 11

2 Quoting ............................................................................................................................................................................... 11 2.1 Investment ................................................................................................................................................................... 11

2.1.1 Planning, Designing, Documentation .............................................................................................................. 11 2.1.2 Distribution Boxes, Purchased Parts ............................................................................................................... 11 2.1.3 Installation and Assembly ............................................................................................................................... 11 2.1.4 Commissioning / Robot Programming / Training ........................................................................................... 12

3 Control Concept .................................................................................................................................................................. 12 3.1 Control Equipment ...................................................................................................................................................... 12

3.1.1 Small Controls ................................................................................................................................................. 12 3.2 Operation Modes ......................................................................................................................................................... 13

3.2.1 Předvolby ........................................................................................................................................................ 13 3.2.1.1 With / without Central Control Unit (CSM / local) ........................................................................... 13 3.2.1.2 Deselection of Functions / Stations ................................................................................................... 14 3.2.1.3 Select / Remove Interface .................................................................................................................. 14 3.2.1.4 Stop at the End of the Cycle or Pause Switch ................................................................................... 14 3.2.1.5 Run System Empty ............................................................................................................................ 14 3.2.1.6 Production witout Part (PWP resp. Ghost Run) ............................................................................... 14 3.2.1.7 Run in Home Position ....................................................................................................................... 14 3.2.1.8 Cleaning, Maintenance, Lubrication, Calibration, Reference Point .................................................. 14 3.2.1.9 Přemostění strojní bezpečnosti ...................................................... Chyba! Záložka není definována.

3.3 Personnel Safety .......................................................................................................................................................... 14 3.3.1 Emergency Stop .............................................................................................................................................. 15 3.3.2 Movable Covers .............................................................................................................................................. 15 3.3.3 Safery Barrier Doors ....................................................................................................................................... 15 3.3.4 Running Boards, Mats and Safety Edge .......................................................................................................... 15 3.3.5 Swinging Flaps ................................................................................................................................................ 15 3.3.6 Skanner and Light Barriers for Personal Safety (CPD) ................................................................................... 15 3.3.7 Bridging of Personal Security ......................................................................................................................... 15 3.3.8 Jam Indicator ................................................................................................................................................... 15

3.4 Type Control ............................................................................................................................................................... 16 3.4.1 RFID ................................................................................................................................................................ 16 3.4.2 Barcode records ............................................................................................................................................... 16 3.4.3 Baptism / Allocation of Production Data (Car RFID) ..................................................................................... 16 3.4.4 Sequence Comparison ..................................................................................................................................... 16


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3.5 Networking Concept ................................................................................................................................................... 16 3.6 Connection of Control Center ..................................................................................................................................... 20

4 Specification of Technology ............................................................................................................................................... 20 4.1 Conveyer Technology ................................................................................................................................................. 20

4.1.1 Control of Conveyor Technology .................................................................................................................... 21 4.1.2 Path Detection ................................................................................................................................................. 21 4.1.3 Integration of Process Devices ........................................................................................................................ 21 4.1.4 Busbar Systems ............................................................................................................................................... 22 4.1.5 Car Control ...................................................................................................................................................... 22 4.1.6 Electric Overhead Trolleys .............................................................................................................................. 22 4.1.7 Sliding Platforms ............................................................................................................................................. 23 4.1.8 Inspection Camera ........................................................................................................................................... 23 4.1.9 Diagnostic Route, Repair / Maintenance Area ................................................................................................ 23

4.2 Robot ........................................................................................................................................................................... 24 4.3 Process Technology .................................................................................................................................................... 24

4.3.1 Screwdriving Technology ............................................................................................................................... 24 4.3.2 Test and measurement technology .................................................................................................................. 24

4.4 Application Technology .............................................................................................................................................. 24 4.5 Process Technology .................................................................................................................................................... 24 4.6 Technology for the Area ............................................................................................................................................. 24

4.6.1 Image processing ............................................................................................................................................. 24 4.7 PC Systems ................................................................................................................................................................. 25

5 Design ................................................................................................................................................................................. 25 5.1 Workshops .................................................................................................................................................................. 25 5.2 Checklists .................................................................................................................................................................... 25 5.3 Concepts ...................................................................................................................................................................... 25 5.4 Functional safety ......................................................................................................................................................... 25 5.5 Construction Hardware ............................................................................................................................................... 25

5.5.1 Signal Sensor ................................................................................................................................................... 25 5.6 Software Design .......................................................................................................................................................... 26

5.6.1 Process Control ............................................................................................................................................... 26 5.6.1.1 Step Chains ........................................................................................................................................ 26 5.6.1.2 Linkage controls ................................................................................................................................ 26

5.6.2 Fault Reporting Concept ................................................................................................................................. 27 5.6.3 Time Synchronization ..................................................................................................................................... 28

5.7 HMI/Visualisiation ...................................................................................................................................................... 28 5.7.1 Signal Lights ................................................................................................................................................... 28

5.8 Technika pohonu ..................................................................................................... Chyba! Záložka není definována. 5.8.1 Engines ............................................................................................................................................................ 29 5.8.2 Sensors ............................................................................................................................................................ 30 5.8.3 Interface ........................................................................................................................................................... 30 5.8.4 Safety of Machines .......................................................................................................................................... 30

5.9 Interface ...................................................................................................................................................................... 30 5.9.1 Security interface ............................................................................................................................................. 32 5.9.2 ML Switch-Off of Movable Assembly Devices / manipulators ...................................................................... 32 In the case of assembly devices or manipulators within the assembly line, a belt limit switch with three roller lever

switches must be implemented and put into operation. The execution must be carried out according to the

illustration. A profile isolator (see also chapter 5.9.3) and a confirmation button must also be provided. ................. 32 5.9.3 Profile freedom from assembly devices .......................................................................................................... 33

6 Virtual Commissioning ....................................................................................................................................................... 33 6.1 Explanantions .............................................................................................................................................................. 33 6.2 Describtion of Performances ....................................................................................................................................... 33

6.2.1 Simulation Station ........................................................................................................................................... 34 6.2.2 Simulation Model ............................................................................................................................................ 34

7 Infeed and Infrastructure ..................................................................................................................................................... 34 7.1 Power Supply Concept ................................................................................................................................................ 34 7.2 Compensation .............................................................................................................................................................. 35


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7.3 Lightening ................................................................................................................................................................... 35 7.4 Maintenance Sockets ................................................................................................................................................... 35

8 Switch cabinet ..................................................................................................................................................................... 35 8.1 Control cabinet concept ............................................................................................................................................... 36

8.1.1 Cabinet Moduls ............................................................................................................................................... 36 8.1.2 Air conditioning of the switch cabinet ............................................................................................................ 37

9 Montage und Installation..................................................................................................................................................... 37 9.1 Wiring Concept for Electric and Media ...................................................................................................................... 38 9.2 Installation Execution .................................................................................................................................................. 39 9.3 Fieldbus Connection .................................................................................................................................................... 39 9.4 Mechanical Design ...................................................................................................................................................... 39 9.5 Marking ....................................................................................................................................................................... 40 9.6 Equipotential bonding / EMC...................................................................................................................................... 40

9.6.1 Protection Potential Compensation ................................................................................................................. 41 9.6.2 Function Potential Compensation .................................................................................................................... 41

10 Commissioning ................................................................................................................................................................... 41 10.1 On-Site Data Backup ................................................................................................................................................... 42 10.2 Substitute Material On-Site ......................................................................................................................................... 42

11 Robot Programming ............................................................................................................................................................ 42 12 Documentation .................................................................................................................................................................... 42 13 Acceptance .......................................................................................................................................................................... 42

13.1 Preconditions ............................................................................................................................................................... 42 13.2 Safety Check ............................................................................................................................................................... 42 13.3 Acceptance Procedure (Start-Up Management) .......................................................................................................... 43

14 Training and instruction ...................................................................................................................................................... 43 14.1 Definitions ................................................................................................................................................................... 43 14.2 Minimum scope of training and instruction ................................................................................................................ 43


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Abbreviations

Basic Concepts for the Whole Part II of the Technical Assignment of ŠKODA AUTO a.s.

ATEX ATmospères EXplosibles / EXplosive ATmospheres

BGV Regulation of professional cooperative (Berufsgenossenschaftliche Vorschrift)

EKS Electronic-Key-System

FIS Production Information System

FKN Car identification number (Fahrzeug-Kennummer)

HIP Platform installation hall (Halleninstallationsplattform)

ISSO Information systems security organization (Informationssysteme-Sicherheitsorganisation)

IT Information technology (Informationstechnik/-technologie)

KELH Concern-wide specifications (Konzerneinheitliches Lastenheft)

LAN Local Area Network

PN PROFINET

RIP Robot installation platform (Roboterinstallationsplattform)

UPS/USV Uninterruptible Power Supply/Source (Unterbrechungsfreie StromVersorgung)

VVS Volkswagen cabling standard (Volkswagen Verkabelungs-Standard)

Elaborated: Assembly Planning (PPF-M) 20190531_TZ SKODA AUTO_II-MO-03-Elektricka cast vyr. zarizeni_en Part II-MO-03

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1 General

Part II of Technical Specification MO-II-03 corresponds fully to KELH II-B05-03: Electrical Equipment for Assembly

KELH (Concern unified specification) Part III The plant's electrical system is integrated in the project-specific part of the

overall technical specification or is connected to a tender.

1.1 Contracting authority project contact partner

1.2 Supplier personnel

After the contract is awarded, the project management is appointed, except for all electricity volumes. Qualification for

electrical engineering and automation is expected. During the realization, it is necessary to ensure the presence on the

construction site.

For the volume described in the technical specification, it is necessary to count on the supplier's own personnel for

commissioning, shift and production, and to specify it. It is not allowed to multiple the personnel disposition. This includes,

but is not limited to:

projects running in the same way (e.g. when submitting project packages)

different tasks (e.g. the person commissioning is also the site coordinator)

The project realization also includes the coordination of all subcontractors with the professional staff of the supplier, resp.

after approval by the contracting authority, one of the subcontractors for the entire duration of the project. The supplier is

obliged to make available to all subcontractors all documents of the tender. Subcontractors must be committed to and verified

by the contracting entity's standards.

It is the responsibility of the contractor to let train all designers, commissioners and programmers involved or intending to be

involved in this project in the current standards of the contracting authority.

1.3 Communication

1.4 Regulations and related documents

Please take into account following regulations and directives serve as a calculation aid when delivering procedures:

Material release list

Reference resp. model plans for EPLAN P8

Reference projects resp. PLC software standards

Project-specific regulations for installation, programming, bus system, safety technology, I / O occupancy (on / off),

measurement and interface

Checklists

Generally, it is necessary to obtain the data through a competent electrical department.

1.4.1 Enter the software version

In addition to KUS (KELH) part I-B09 please perform hardware and software constructions with version states as follows:

CAE-System EPLAN P8

SPS-Logic TIA-Portal STEP 7 incl. safety

HMI TIA-Portal WinCC Advanced, CIMPLICITY

The final version of the software is determined during the technical meeting.


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1.5 Milestones

At least take into account the following milestones during the course of the project:

planning meetings

Comparison of the quantity structure, coordination of the schedule etc.

Hardware Workshop

Software Workshop

Presentation and handover of the project-specific implementation guidelines as well as the updated material

approval list•

System concept discussion (layout)

Electrical design - presentation hardware

Electrical design - presentation software

Technical execution (control concept, component list, circuit diagrams, software etc.)

Allocation of system identification, drawing number for circuit documents

Approvement of functional safety and the safety matrix

Releasing the design

Testing of EPLAN, software, visualization (structure, compliance with the specifications)

Technical inspection (parts list, operating modes, safety circuits, etc.)

Shipping approval from the supplier

Examination according to KELH, system specification and workshop; pattern structures, control cabinet inspection

and assembly controls; checking the installation of subcomponent

System in jog mode

System in automatic mode

Preliminary acceptance

Delivery of the complete documentation 4 weeks before pre-acceptance

Presentation of the completely processed and completed checklists 4 weeks before acceptance

Testing the execution according to KELH

Checking for the processing of the construction control defects

Checking according to checklist

Checking of cabinet control

Hand-over in operation (system acceptance / transfer of risk)

The assembly, installation and commissioning of the system is complete.

Safety-related and functional (A and B) defects are no longer present.

Training and instruction of the operating and maintenance personnel has been carried o.

CE conformity and country-specific declarations are available.

Safety check has been carried out.

When operations has been handed over, all faults and messages must be completed and classified

Final acceptance

All defects from the list of defects have been rectified.

Proof of availability provided.

The customer received the final documentation.

Description of Specifications

In addition, a performance description must be drawn up during the planning and design discussions (comparable to a

specification for project management after the contract has been awarded by the contractor). In the description of

performances, details from design discussions and any deviations from the specifications are documented in detail. Only

after confirmation by the planning of automation technology may the contractor implement it.

The service description is part of the documentation.


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Please, consider following minimum content in the performance description:

Layout of the entire system including all correct station, control panel, protective circuit, emergency stop circuit

breakdowns and their names, including material supply and material flow

Location of the control cabinets, system and process technologies in the system layout (power distribution, BMS,

control panels, drive technology, network technology, robots, gluing, screws, etc.)

Division of control areas

Functional sequence of the entire and partial systems

Functional sequence of tool components

Emergency strategies e.g. in the event of failure of system components

1.6 Environmental conditions

1.6.1 Fire protection

The interface to the fire alarm centre or to fire protection controls can be implemented via potential-free I / Os. If a fire alarm

triggered, the system must be positioned immediately so that the gate areas are free and the fire protection gates can be closed

completely. At the latest after 30 seconds, the gates close regardless of the system status. Then all components must be shut

down in a controlled manner. At the latest after another 15 seconds, all energies must be switched off.

In systems with a CO2 extinguishing system (e.g. roller test benches, fuel supply systems, etc.), the entire media supply and

control technology must be switched off when the extinguishing system is triggered. Supply and exhaust air systems must be

shut down immediately. The air inlets and outlets must be closed. After the CO2 flooding has taken place, the exhaust air

systems must be able to be restarted individually by hand.

1.6.2 Explosion Protection

In explosion-protected zones, the intrinsic safety of the signal lines must be ensured by suitable I / O modules. Only ATEX-

certified switching devices must be provided within the zones. Equipment may only be installed in the Ex area after

consultation with the responsible electrical department.

1.6.3 Wet Areas

The complete electrical installation inside cabins with permanent wet areas must be carried out at least in the

protection class IP 66 and additionally covered to be shifted to the outside.

Stainless steel ducts must be used near acids, alkalis and in wet areas. They must be covered and have drainage

facilities. The cable ducts must be laid in such a way that they are accessible without being in the immediate area

of the splash water. Encapsulated initiators (with fixed connection) must be provided in the wet area. The cabling

must be carried out with a protective hose and screwed tightly when entering the cable ducts and on the

protective housing of the initiator. Motors must always be installed outside of the wet area. If this is not possible

for technical reasons, use protection class IP 66 with additional surface protection OS2. When installing, ensure

that the sealing surfaces are properly seated and clean.

1.7 UPS

To avoid system downtime due to short-term voltage drops, in some production areas are installed central UPSs. If a UPS

connection is required, it is necessary to prepare the power supply according to specifications (reference or sample plans) for

connection to the external UPS power supply. For the UPS power supply, the same agreement as for normal power supply

applies with respect to delivery specification.


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1.8 Energy Efficiency and Management

In view of the choice of components and control technology, the design, construction and commissioning laid down measures,

which allow the operator to use the equipment in an energy-efficient way:

Reduce standby consumption during unproductive times and breaks (e.g. using PRO-FIenergy, disconnecting

pneumatic power, etc.

Control panel darkening

Design of drive technology

Energy consumption (electrical, pneumatic, etc.) is measured on ARG / PLC using measuring instruments. The measured

values are processed in the operating equipment control, visualized and sent to the control room. The measured area of the

energy meter must be dimensioned for the entire working area. The return power supply must also be recorded.

1.9 Material Release List

All PROFINET devices used must meet at least the open PROFI-NET standards and the specifications in accordance with IEC

61158 and IEC 61784 must be certified by accredited testing laboratories.

The same components are handed over to the final acceptance with a uniform state of hardware, software and firmware.

1.10 Reuse

This paragraph applies exclusively to remodeling measures.

The reuse of devices, components and materials already in use is not allowed for new equipment.

Disassembled materials as spare parts must be provided on request for maintenance.

If mechanical parts are reused, they must be fitted and installed with new electrical parts.

1.11 Integration into existing Production Equipment

Equipment modifications cannot assume that there will be a reserve in terminal boxes, gears, conventional boxes, control

panels, etc. For reasons of space and overview, completely new terminal boxes, conventional expansion boxes and parallel

control panels cannot be used for each extension. For these reasons, work such as replacing a smaller control panel with a

larger one, or extending the operating equipment to the supplier's delivery volume.

If disassembly is required, the control panels must be rearranged according to the plant structure. The remaining transfers

between the cabinet and control panels, terminal boxes and other peripherals need to be re-aligned.

Removing the mechanical parts may make it necessary to restore the remaining wiring.

Reserves should be used first during conversion work. If new junction boxes and terminal boxes are required, they must be

dimensioned with a 20% reserve.

Fieldbus systems must be checked for their damping and shielding values and replaced if necessary.

All bulbs in the conventional detector and display and data indicator lights are replaced with LEDs.

1.12 Provision

The customer reserves the right to provide hardware and control components, HMI components and licenses. Reductions are

deducted using the quantitative structure.


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1.13 Update of Design Specifications, Software and Firmware

For the calculation it is necessary to evaluate three updates on the technology. Upon approval of the planned hardware, software

and firmware, the customer enters the appropriate available version number. It should be done according to the written

designation of the planned components by the supplier.

1.14 Construction Site

2 Quoting

For the sake of comparability of quotations, the contractor shall fill in the list of services entered by the customer and return

it in the original format.

2.1 Investment

2.1.1 Planning, Designing, Documentation

This includes elaboration of electronic layouts for the overall equipment, control concepts and elaboration of the overall wiring

bases for electrical equipment such as current flow diagram, connection and construction with CAE EPLAN. In addition, the

design of the control logic and the visualization and general descriptions, operating manuals, etc. are evaluated.

2.1.2 Distribution Boxes, Purchased Parts

This item reports the cost of purchased parts (e.g. master / slave control stations, PC, software, etc.), junction boxes including

automation devices and fieldbus components located in the junction box, network box and compact network box including

switches and patch-panels and switchboard construction.

Equipment lighting components, maintenance sockets and cable ducts are not detailed in the quantity structure. For this

purpose, the supplier determines and evaluates the required quantities, taking into account the specifications in the technical

specifications and in the layout.

2.1.3 Installation and Assembly

This item includes the cost of materials and installation for power supply, equipment lighting and maintenance sockets,

junction boxes for high-voltage buses, sub-switchboards and their supply and transmission. Small material such as screws,

handcuffs, Velcro fastener etc. doesn´t need to be listed separately, but please take it into account in the calculation.

Installation of Operating Means

The installation includes all connecting lines of operating means from valve islands, position switches, motors, etc.

The costs of valves, islets, position switches, motors, frequency converter, adhesive control, etc. must be reported in the

mechanics offer.

Transfers

Transfers are all wiring connections between the terminal box in the junction box and the terminals of the slave control stations,

the terminal boxes and the modular boxes of the equipment installation, the robots, the screw and other process devices, and

all devices connected directly to the junction box terminal box.

Furthermore, these are the wiring connections between the slave stations, terminal and modular boxes and the wiring as the

connection of the distribution boxes to each other and the network wiring and the connection sockets.


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2.1.4 Commissioning / Robot Programming / Training

In this position, the costs for commissioning the overall equipment, putting the screw data management system (SDMS),

programming the robot and training for production and maintenance stuff are reported.

3 Control Concept

A system is divided into control / load voltage, manual / automatic areas and stations / function groups. The number and

division must be determined according to functional and spatial conditions and to be coordinated with the responsible electrical

department before implementation.

Separate control / load voltage areas must always be provided for conveyor areas that run through systems with their own

controls.

An HMI is used in the control cabinet to display the messages and to visualize the control / load voltage ranges and operating

modes. An HMI is also built into the control panels, which enables operation of the individual system areas in addition to the

visualization.

The connection to the control centre and, if necessary, to the higher-level system for vehicle control is established via an

Ethernet interface.

Before submitting an offer, the contractor is obliged to check the performance of the specified control concept. If it is not

possible to implement the system with this concept for performance reasons, this must be communicated to the client and

alternative solutions offered.

3.1 Control Equipment

When selecting the CPU, taken into account that the following limit values must not be exceeded:

Cycle time: max. 40ms

Memory allocation: max. 70%

Number of network connections: max. 70%

Address space allocation: max. 80%

If the specified values cannot be adhered to with the CPUs mentioned, the system must be divided into several working groups

after consultation with the responsible electrical department.

In the user logic, the cycle values for minimum, maximum and current cycle times must be recorded in data blocks.

The program must be stored on a retentive memory plugged into the PLC.

After a power failure and loss of start or load voltage, the system must be restarted from the same position after actuating the

"Start". It is assumed that the personal and machine safety conditions (start requirements) are fulfilled and faults have been

remedied and acknowledged.

Manipulations on the material flow as well as an intervention by means of a programming device in the control of the system

are not permitted as "starting aid" for the start-up.

3.1.1 Small Controls

Each electro-pneumatic micro or handheld device gets an individual control with a switch box.


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The control box contains the automation device, I / O-modules for switching on, personal security and internal control, fuse

elements and terminal blocks.

All peripheral devices are connected as decentralized units in the field via Profinet.

Automati-

sierungs-

gerät

40

0V

~/2

4V

=

Touchpanel

Sicherungen

DE/ DA

Klemmen

600mm

80

0m

m

Fig. 1 Control cabinet with PLC for very small or hand tools

Use touch panels according to the approval list for operation. The conventional 22.5mm control elements for emergency stop,

E7 lock, are located in the control box door. In addition to partial checks and basic or working cylinder position, the number

of pieces and cycle time are also displayed on the touch panel.

3.2 Operation Modes

Operating modes preselection manual / automatic

The manual / automatic operating modes can be implemented via soft buttons in the visualization. These can be selected both

centrally for the entire system and in some areas and changed accordingly.

Detector Check

Each movement must be checked in its end positions with position switches or proximity switches. The switching states must

be displayed on the control panel. If there is an error, e.g. if both statements queue at the same time, an error message is

generated on the control panel and the process is interrupted in the cycle concerned. Once the error has been remedied, the

message check must be acknowledged manually.

Running Time Control

The running times of movements have to be monitored. The position change of an actuator must take place within a defined

time. If this time window is exceeded, an error message must be generated and the sequence interrupted in the cycle concerned.

3.2.1 Presets

Each pre-selection must be visualized on the HMI and reported to the control room (central system monitoring - CSM).

The following area codes are to be implemented:


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3.2.1.1 With / without Central Control Unit (CSM / local)

If the central control unit is preselected, all parameters, pauses, lights etc. can be set and controlled from there. If the central

control unit is not preselected, the same operations can be carried out on site.

3.2.1.2 Deselection of Functions / Stations

A function or station in your own system is deselected with this preselection. The system continues to operate automatically

without the selected function / station.

If possible, axes and lower-level equipment must be individually cancellable. If necessary, the actuators can be moved profile-

free into a parking position or in the basic position. This measure is intended to maintain operation of the remaining

components in the event of a failure.

Explosion protection, fire protection, personnel and mechanical security (collision interlocks) must not be influenced.

3.2.1.3 Select / Remove Interface

For each interface (such as identification systems, worker guidance, component documentation, Poka-Yoke, screw-driving

technology, UPS or process devices) a selection / deselection must be implemented.

The system continues to operate automatically without the interface partner concerned.

Explosion protection, fire protection, personnel and mechanical security (collision interlocks) must not be influenced.

3.2.1.4 Stop at the End of the Cycle or Pause Switch

This preselection is used to stop the system in accordance with the system. This function is also carried out with the pause

signal. As soon as a defined starting position is reached, the control system stops all parts of the system successively. The

starting position must be selected for all system parts so that an automatic restart from this position is possible at any time. In

the case of transport devices, the possibility of filling the buffer must be given by stopping with a time delay.

3.2.1.5 Run System Empty

With the preselection "Run system empty", the system is automatically run empty. If the system has run empty, it remains in

a defined position. The empty transport means are driving through the stations without processing. The process devices do not

receive any signals via the interface for the empty funding.

3.2.1.6 Production witout Part (PWP resp. Ghost Run)

This preselection activates a complete process simulation without part in automatic mode. Parts controls must be simulated

programmatically in this preselection, component receptacles and deliveries are deactivated.

3.2.1.7 Run in Home Position

The selection 'home position run' must automatically set the system to a defined start state from every situation.

3.2.1.8 Cleaning, Maintenance, Lubrication, Calibration, Reference Point

These presets allow partial processes that are necessary for repair and commissioning. Interlocks, machine and personnel

security are still active. Movements take place only as long as a button is pressed. For safety reasons, the partial sequence

stops after an additional maximum actuation time.

3.2.1.9 Bridging Machinery Safety

The E7 bypass is implemented with a key switch and displayed on the HMI. The E7 bypass is implemented with a key

switch and displayed on the HMI. The key may only be removable in the off position.

3.3 Personnel Safety

The triggering of a safety device must be indicated with a signal tower at the immediate location and on the control panel.


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After leaving a danger zone, reactivation may only take place after additional acknowledgment by means of an illuminated

push button.

3.3.1 Emergency Stop

All emergency stop switches must be reported individually to the system visualization.

In general, emergency stop buttons must be provided at the following locations:

• at every control station

• at every loading area

• on every container change system

• at every entry and exit station

• on every door light barrier

• at conveyor systems with cycle time shifted workplaces

• Left and right at transitions and passages. The passages must be protected by light barriers or shut-off bars.

3.3.2 Movable Covers

Movable covers must be equipped with non-contact safety switches.

3.3.3 Safety Barrier Doors

An access requirement must be implemented on all safety barrier doors. When selected, all ongoing movements are

completed until the next stop and then the access authorization is signalled to the operating personnel. A key combination

with illuminated pushbuttons must be provided for the access request and the acknowledgment.

3.3.4 Running Boards, Mats and Safety Edge

Are only permitted after consultation with the responsible electrical department.

3.3.5 Swinging Flaps

Swinging flaps must be designed with non-contact safety switches.

3.3.6 Scanner and Light Barriers for Personal Safety (CPD)

The design of contactless protective devices (CPD) must be coordinated with the responsible electrical department. In the fact,

a vibration-free attachment is important. Please avoid impairment caused by external light. BWS must be exchangeable without

mechanical readjustment.

3.3.7 Bridging of Personal Security

To bridge the safety device, install an E2 key switch with indicator light and a connector for an enabling button according to

the reference document. Provide an enabling button with an integrated start button for each system.

3.3.8 Jam Indicator

If 5/2-way impulse valves with end position control are used, a jamming indicator is required. Please follow to following

requirements:


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Install a separate white signal light as a jamming indicator for each electrically secured protective door.

Indicate the jammed movement by the end position indicator flashing on the HMI and on the signal lamp.

Highlight the names of the jammed movements in yellow in the HMI.

3.4 Type Control

The equipment control must ensure that it is known at all times which component is in which station (position, type, etc.).

Visualize information on the plant side at the HMI. The BMS reads an identification code from the data carrier via a reading

point. With the help of the identification code, a central data provider requests the information required for type control.

3.4.1 RFID

The contractor must provide read / write units for this. Each individual writing / reading point must be cancellable. A trigger

signal must activate each read / write unit. It is not permitted to detect it automatically (e.g. Autodetect).

Writing operations are generally only to be carried out when the funding is in a standing state. The data carrier is also checked

at the next reading point.

If the type control malfunctions, the type must be preselected manually on the HMI. The system operator must enter a PIN

and / or select a program. For this purpose, a suitable input option (e.g. scanner, input on the HMI / PC) must be created.

Authorization must be provided if necessary.

3.4.2 Barcode Records

Stationary and mobile barcode scanners are connected via PROFINET. It can be used different codes. Please connect readers

in an adjustable manner according to the agreed code position. Display reading result directly on the scanner or on the display

aid belonging to the reading device. The contractor must guarantee constant printing and application quality for devices for

creating barcode labels. Follow the alignment of the code exactly. The module width must not be less than 0,5 mm due to the

process reliability.

All barcode identification points must be equipped with a manual emergency strategy. Provide additional manual entries,

which enable the barcode to be entered in plain text on the control panel or on a separate entry station with monitor and

keyboard. The customer requires manual input by the personnel via an optical and acoustic signal. Check manual entries for

the check digit, number of digits and plausibility. The location of the manual input terminals is determined in the construction

phase.

3.4.3 Baptism / Allocation of Production Data (Car RFID)

With the so called baptism, the vehicle data is assigned to the funding at the first read / write point. If the read / write point

of baptism is deselected, the subsequent read / write point must be able to take over this function.

3.4.4 Sequence Comparison

Provide a sequence comparison on handovers or when components are brought together.

It is used to compare target data sets with the actual data sets, or to compare two actual data sets from pre-assembly and main

assembly (e.g. pre-run data from FIS with PIN present; PIN from drive set with PIN in the EMS). The sequence adjustment

must be cancellable.

3.5 Networking Concept

Please implement the network concept in accordance with the Volkswagen AG cabling standard (VVS). Select the network

cables according to the environmental conditions, according to the specifications of the client (e.g. VVS, site cabling

regulations SCR, material approval list).


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Inductive or capacitive interference cannot be ruled out and must not impair the function of the network. Fluctuations in the

operating parameters due to aging, temperature fluctuations, contamination, damping drift etc. must not affect the functionality.

When planning the network, a connection reserve of 20% must be maintained for future changes. Please agree details with the

client (concept).

Network Safety

If partitioning in accordance with CUS (KELH) (VW concern uniform specifications) Part I-B09 does not exist

or cannot be implemented (e.g. integration projects), the contractor must install partitioning through decentralized

firewalls in consultation with the client.

Protect all existing interfaces (web interface, SSH etc.) of all switches and routers in all areas with passwords in

accordance with the Volkswagen complexity requirements. Please give over the passwords to the responsible

maintenance.

Profinet Segment

Coordinate the topology of the network with the responsible specialist planner or implement the topology concepts specified

by the client.

For this create a network overview (not E-plan) according to the presentation specifications of the customers.

Take following premises into account for the calculation:

Keep free an RJ45 port for monitoring (mirroring) the ports as a reserve on each switch. This does not apply to PN

conformance Class-C switches

Set up a switch cascade of a maximum of 40 in succession. There are participants, in stitches that branch off, which

are not taken into account here.

If there are more than 40 participants, another switch cascade must be set up.

Use only Conformance Class-C (Siemens IRT) switches for network sections with Profinet protocols.

Connect the participants in stitches of max. X10 participants to the switch cascade.

Closing the network or stitches to a ring form.

Asynchronous services and participants with high bus load such as Thin client solutions, main / secondary control

stations must be connected separately. A switch cascade as the main line rank for integration must be set up within

the system.

Integrate PROFINET participants that do not meet conformance class C into the PROFINET topology using a separate

stitch in the field (switch).

Always connect the main control station must to a switch in the equipment cabinet.

The network cabling in the field must be carried out using ProfiNET-specified copper cables (connection is assigned

according to EIA / TIA 568B).

Adjust the bus cycle time according to the specifications of the customer.

Connectivity

All network cables to and from control cabinets must always be routed via outlets, patch fields, DIN rail distributors or DIN

rail-compatible couplings.

Decentralized module boxes are not sold with outlets or similar fitted. Here, the installation is carried out using field-assembled

plugs on approved cables.

Connection to the Network Cabinet of the Customer


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Connect the system redundantly to two locally separated network cabinets via two Fast-Ethernet-compatible (100 Mbit / s)

Uplink ports with glass fibre (fibre optic cable with 4 assembled fibres).

Route the cables from the system to the network cabinets in separate cable carrier systems (routes, conductors, etc.) installed

exclusively for the network. These must be clearly identified (see VVS in current version) and belong to the scope of delivery

of the contractor.

Fig. 2 representation of interfaces

Interfaces Connectivity technology

1, 2, 3 DIN rail distributor

Network and Participant Documentation

The documentation must be submitted electronically (original open files and as a PDF) and in paper form. Drawings are with

MS Visio; Create lists with MS Excel. The documentation includes a complete list of participants with installation location

(work group / control cabinet / field in hall etc.), module name, module type, module manufacturer, IP parameters (address,

subnet, gateway), MAC address, host name and additional information ( E.g. function, redundancy manager, etc.).

Fig. 3 Examples of a tabular list of participants

Please document clients, panel PCs or similar systems in a table.


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Here must be named information such as operating system (OS), functions (e.g. web server, database server, HMI or similar),

releases (files, folders), installed hardware & software (CPU, RAM, HDD, antivirus, EndPoint Security etc.) the

communication ports and protocols used, as well as installed service packs and patches at the time of delivery. State special

information on software requiring a license and access to operating manuals and instructions in the documentation.

To clarify communication relationships, make a drawing that describes the ports and protocols used in the different field levels.

Fig. 4 Example for documentation of communication relations

The drawing should include all active network participants (e.g. PLC, PC etc.) as well as the ports and patch points used.

Please find her information such as IP data, MAC, installation location & cable ID.

All measurement reports including a complete overview of certified cables also belong in the documentation.

Documentation / Acceptance of PROFINET systems

The measurements in PROFINET based systems are according to the “Guidelines for using the AIT PROFINETanalyzer”

from the Volkswagen brand planning.

Documentation includes Uplink cables and a transfer switches. Note here that the UpLink cables to the higher-level system

network must not be generally captured by PROFINET acceptance software. This information must appear separately from

the documentation.

Drawn up a complete acceptance report. This results in compliance with the naming conventions applicable at the location,

compliance with limit values for fiber-optic cables in relation to the attenuation reserve (not ≤2.5dB) and cable length (see

PNO PROFINET planning guideline No.8061), port statistics / diagnostic data (utilization, CRC Errors etc.) of the built-in L2

switches as well as the firmware and / or software versions used. Furthermore, the acceptance protocol shows compliance with

the prescribed update times.

WLAN

If WLAN is used, please document both the configurations of the devices that use WLAN, the topological arrangement in the

field and the ducts used for the access points (APs). Carry out all measurements and documented in the 2.4GHz and 5GHz

bands. In particular in the 5 GHz band, the radar frequencies 5,690 - 5,710 GHz must not be used


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SSID MAC address Frequency duct (v

GHz) Duct

Logistics 00-0b-0e-9e-fb-07 5,3 60

Production 00-0b-0e-9e-fb-01 5,3 60

FTS-WLAN-1 00-0e-8c-99-c5-50 5,22 44

FTS-WLAN-2 00-0f-a3-d7-7a-76 5,24 48

Fig. 5 Example for spreadsheet documentation of Access Points

Measure the entire installation with a site survey program that maps the attenuation of the individual APs and the entire

installation. Create the documentation on a hall layout, which depicts the installed system, and shows the measuring points

used.

Measure the use of frequencies and the ducts used with suitable spectrum analysis software.

When using an RCoax leaky wave conductor or a slotted waveguide, carry out an electromagnetic field strength measurement.

Ensure that the permissible range of 60 to 80 dBµV / m is not exceeded at a distance of 2 meters.

If devices have to change the AP, document the roaming behaviour and function. For this, generate a list from which the

application switchover time and show the ducts used.

Consider all data traffic on the air interface. In any case, observe a retransmission value of a maximum of 33%.

Documentation of Security Zones

If using security zones (firewalls, IPS etc.) in the area of production resp. in the control area of systems, document these.

Above all, describe the rules used (approvals, prohibitions) with regard to communication ports, partners and protocols.

Describe the security zone concept used and functions (e.g. NAT, VPN).

3.6 Connection of Control Center

All production and fault data (e. g. fault messages, target values, actual values, buffer levels, IDs, energy consumption values,

etc.) must be recorded in the PLC and made available to a higher-level system via LAN.

The control centre system is ordered separately and is not a part of this specification. An interface coordination takes place

after the order is issued in the control centre system. In the case of existing control centre systems, the interface must be learned

and integrated by the contractor.

4 Specification of Technology

4.1 Conveyer Technology

The manual control of work piece carriers can be recognized and reported by the system control and must not lead to a

malfunction. Plant areas behind a fault location or block location must continue to run. Feeding controls have to take into

account the remaining buffers up to the point of the fault and must be stopped sensibly.

Provide plausibility checks and runtime reports for each segment.

When using decentralized frequency inverters, connect initiators and partial checks of the funding segments to the inputs of

the frequency inverters.

It is not permitted to use of trailing cables for horizontal conveyor elements with a travel distance longer than 15 meters. The

energy is transferred via bus bars or inductively, the data is transferred via data light barriers or Profinet iWLAN.


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If there is a risk of damage to the conveyed goods during transport (e.g. caused by parts hanging out of containers, the position

of moving parts, etc.), a contour check must be carried out in front of the danger point. Indicate a contour violation on site

using a signal tower. Further transport may only take place after the contour violation has been remedied and manually

acknowledged by an illuminated pushbutton. In areas of rotary tables, lifters, shuttles, etc., as well as at all transfer / transfer

stations in the system, gap controls must be provided to ensure that the object to be conveyed is securely positioned on the

direction-changing conveyor unit and that no parts protrude into adjacent movement areas. The media used, such as belts,

chains, belts, etc. must be monitored with a break check.

4.1.1 Control of Conveyor Technology

The drives are controlled via the bus system. The drive receives its drive command (forward, reverse) and the set points for

ramp and speed from the PLC.

For positioning drives, the driving behaviour (ramps) must be stored in the converter. Due to the variable routes, the device is

currently calculating the values. Approach the specifications from the control are for the positioning drives in addition to start

/ stop, speeds and the position. The positioning is done with absolute encoders or inductive sensors.

Target values (belt speed, working time models and quantities) must be parameterized via the visualization or the control

system.

Save these target values in the PLC in data block areas. It is not permitted to save the target values in the visualization software.

Present the speeds and control ranges to the client for approval as part of the construction work.

4.1.2 Path Detection

Conveyor technology elements in the field of flow production must be equipped with a position measuring system. To e.g.

supply reading points, process devices or higher-level systems with trigger signals, the path detection must be prepared in the

software. Provide speed and position for synchronous systems.

4.1.3 Integration of Process Devices

In order to integrate process devices (screwing systems, assembly stations, handling devices, etc.), an interface (I / O signal

exchange, safety interface) to the process device must be installed and commissioned by the contractor of the system controller.

Provide following information for signal exchange:

Parts entry (beginning of the work area)

Vehicle identification number

2/3 message (pre-warning)

Part discontinuation (end of the work area)

The signals supplied by the process device must be integrated into the system control and evaluated, e.g.:

Line stop

Status signals

Emergency stop

Integrate the signal transmitters required for the integration of process devices (e.g. parking position, profile freedom, belt

stop, etc.) into the system control and put into operation.

Ensure the profile freedom of devices for all process devices (e.g. manipulators, application systems) that intervene in the

conveyor line via profile isolators. Stop the conveyor movement when you leave the profile switch.


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Switch off the conveyor technology before the mechanical end position of process devices along reaching the production line.

The contractor of the system control must assess in his risk assessment whether the shutdown should be machine-safe or

personal-safe. Display conveyer stops caused by process devices (missing parking position or freedom of profile, conveyer

shutdown) on site using signal towers.

The scope of delivery of the contractor of the process device includes:

Coordination for the constructive integration of the signal generator with the respective system supplier

Specification of the labelling of the signal transmitter

Cables and cable routes

Mechanical and electrical installation of the signalling device including labelling

The scope of delivery of the contractor of the system control includes:

Coordination for the constructive integration of the signal transmitter with the respective process device supplier

Signal tower including labelling boards

Signal tower including labelling boards

Mechanical and electrical installation of the signal tower including labelling plates

necessary I / O modules or PN / PN coupler and the necessary terminal box

Complete commissioning

Safety concept and risk assessment for the entire system

4.1.4 Bus Bar Systems

Always connect the feed lines to a bus bar system via rail connection boxes. Document rail cuts in a system layout.

Prevent spread of tension across the carbon brushes. So that there are no dangerous situations in neighbouring load voltage

circuits or in neighbouring systems, install isolating blocks in a person-safe design on the corresponding rail junctions.

4.1.5 Car Control

Realize different speeds, lift heights or tact distances depending on the position of the car along the driving route and the type

of car. The HMI must be able to be parameterized the corresponding data and transmitted them to the vehicle control. In the

plant control, separate data modules manage these parameters. In order to enable the contracting authority to compare data

modules online using existing archiving systems, no dynamic data shall be included.

To capture the lift height, take into account the absolute travel distance measurement-system and capture the track-

measurement-system-barcode or the magnetic measurement system must be along the travel path.

If the car is serviceable or diagnosed via remote control (radio or infrared), two remote controls are included in the delivery.

It must be possible to replace the entire steering box including the current collectors immediately and without any auxiliary

tools. It must be possible to operate the main switch from the outside. In case of poor accessibility of the main switch, it is

necessary to calculate additionally the switch of the drive on the car or the hitch within the reach of the operator. The operating

and fault indicators must be clearly visible on the control cabinet.

4.1.6 Electric Overhead Trolleys

In general, use double pantographs. Two protective conductor pantographs - current collectors must be attached to each vehicle.

The pantographs must be suitable for reversible operation in both directions.

The routes are divided into several driving zones. These must be safely switched off in the event of an emergency stop.

Recognize the manual shifting of the vehicles and reported by the resource control. It must not lead to malfunction.


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After selection, loaded vehicles must also be able to be driven over the empty routes and empty vehicles also over the full

routes.

Decision points (e.g. switches, jacks, pick-up points, etc.) must be secured through component checks. These must also be

taken into account in special procedures.

Install a collision protection sensor on the chassis to ensure a distance from the vehicle ahead.

For gentle handling of the vehicles, the cars must be slowly accelerated, resp. braked.

The moving parts on the hinges must be connected to equipotential bonding.

4.1.7 Sliding Platforms

The control accessibility under the platform must be made through the inspection opening. Ensure that the control system is

accessible through this opening when the platform is loaded. In order to ensure that all traffic and fault status data is visible,

fit the flat-vision panes to the platform.

4.1.8 Inspection Camera

For overhead electric railways and sliding platforms, a mobile inspection camera is included for each lane. It shall be mountable

by means of a suitable attachment to any wagon. Use the camera to inspect the track (e.g. rail system, bar code strip, etc.)

during operation.

Technical requirements for the camera system:

Secure fixing no the vehicle

Adjustability via a swivel joint

compact camera housing with mounting option (e.g. threaded bush)

resistant to vibrations while driving

Possibility to record fast movements ("action cam")

Ease of use

Wide angle lens (min. 100 °)

Integrated display for subject control or camera orientation

Recording of the video sequence in Full HD quality with min. 30 frames / sec.

Save the video sequence on an SD card (min. 64GB, Class 10)

Stored video sequences must be playable directly on a PC without additional software

Battery life min. 6 hours

4.1.9 Diagnostic Route, Repair / Maintenance Area

A diagnostic route must be set up in the empty area of a driving circuit. All vehicle functions are automatically checked on

this route. These include:

Brake Test

Check driving speed

Check collision protection sensor

grinding carbon test

PE exam

differential current measurement

Each function to be tested must be individually selectable and cancellable via the HMI of the maintenance area. If an error is

found, the vehicle must be automatically returned to the maintenance area. The reason for the removal must be indicated for

each vehicle in the maintenance area on the HMI.

By entering the vehicle number, it must be possible to select a vehicle to be removed. For this purpose, an input option for up

to four vehicle numbers must be implemented on all HMIs in a circuit. If a vehicle is removed based on the vehicle number,

the number must be automatically removed from the list. If a circuit extends over several system controls, this list must be

kept in sync across all system controls.


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For automatic removal of the next available vehicle, a selection must also be made on the HMI of the maintenance area.

If a vehicle is declared to be removed and the maintenance area is fully occupied, a message must be displayed on the HMI

and forwarded to the control centre. After a waiting period, the vehicle continues in the normal flow of funding. This function

can be implemented by selecting / deselecting the HMI.

The maintenance area must be able to be completely de-energized using a maintenance switch.

The rail area that can be switched off must be separated from the adjacent areas in a person-safe manner by separating blocks

and must be color-coded.

Lowering rails in the maintenance area are to be integrated into the system control. The power rails on the lowering rail must

have a separate maintenance switch in order to be able to switch them completely free of voltage. The lowering rail must not

be lifted or lowered as long as the bus bar or the locking of the end positions are active.

4.2 Robot

If using a PROFINET fieldbus cable in the internally routed hose package, a diagnostic isolating point must be provided on

axes 1, 2 and possibly in front of axis 7 on the bulkhead plate. The repeaters are also included in the scope of delivery when

ordering the robot or the cable package.

A robot installation platform (RIP) must be provided for process devices on the robot with compressed air feed. The RIP

consists of a ball valve, filter unit and pressure switch, which can be used to interrupt the compressed air during maintenance

work. The installation takes place in the immediate vicinity at the foot of the robot.

4.3 Process Technology

4.3.1 Screwdriving Technology

The use of screwdriving technology is specified in the "Technical part" of the mechanics. The basis for the screwdriving

technology is the Volkswagen group standard "VW 01110" and the "Group specification 31". The execution of the screw data

management system (worker guidance and documentation) must be carried out in accordance with the SDMS guidelines for

planning automation technology.

The command exchange must be coordinated with the automation technology planning. The "master PC concept" is used.

4.3.2 Test and measurement technology

The universal test system (Universelles Prüfsystem - UPS) takes over all communication with vehicle control units centrally

and solely. It is the master regarding data exchange between participating test systems, test benches and subsystems. Implement

the interface to the plant technology via Ethernet IEEE 802.3.

Carry out the data exchange within the test process via the UPS. The system coordinates the entire test sequence, supplies the

subsystems with target specifications and accepts the result data. Name identically across all systems the variables, measured

values and transfer parameters and generally coordinated with the responsible test engineering planning department.

Take into account a providing of calibrations on testing and measuring equipment. Offer separately in the quotation any

necessary calibration device. The control of calibration values must be designed in such a way that the system operator can

carry it out independently and reliably, without overwriting existing calibration values. It must be ensured that existing

calibration values can only be overwritten by authorized personnel. The calibration cycle must be reported to the operator and

logged.


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4.4 Application Technology

4.5 Process Technology

4.6 Technology for the Area

4.6.1 Image Processing

The camera system communicates with the system control via TCP / IP or PROFINET. When planning, it must be taken into

account that the lighting can greatly deviate due to the effects of daylight (early, noon, evening), seasons (summer, winter)

and pollution. Avoid an influences by sunlight on image processing system used and workplace lighting with up to 1300 lux.

The basic requirements are optimal lighting and clear reference points on the object. If a contrast medium is required, a laser

system is preferred.

The use of image processing systems must be coordinated with the responsible electrical engineering department. The concept

presented by the contractor requires the written approval of the client.

The video image must be displayed on the image processing device for diagnostic purposes. A monitor or touch panel may

need to be provided for monitoring and operation. If the data is pre-processed in the camera, this data must also be visualized

for diagnostic purposes. This must also be possible during the measurement process.

Production-related correction data for the optical sensors must be saved and processed in the device itself. Mount adjustable

lenses and shutters so as to be vibration-proof. Provide either reference marks or a calibration device to verify image

processing.

Design cameras as selectable and cancellable individually. Camera systems must be equipped with a manual emergency

strategy. Provide additional manual entries, via which the preselection on the control panel is possible. A required manual

input by the personnel is requested via an optical signal.

4.7 PC Systems

Observe related documents (Co-Applicable Documents-I-B09-2) "PC based Windows systems" when using computer-aided

systems in the assembly area.

The PC systems used may not take on any control tasks. Control actuators are only by the PLC.

5 Design

5.1 Workshops

The duration of each workshop is one day. The relevant contractors of the contractor must take part in the workshops.

The contractor and the client agree the location.

5.2 Checklists

5.3 Concepts

5.4 Functional safety

When using security software, are the following points to observe:

A competent person describes the safety functions / the safety concept

Another expert person realizes the safety functions in the PLC

A third expert (IBN) has to check these safety functions


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5.5 Construction Hardware

5.5.1 Signal Sensor

Design the function of the electrical signal transmitter in hardware and software in such a way that incorrect operation does

not lead to incorrect counts, incorrect entries in tables and inadmissible movements. The signal transmitters may have to be

implemented twice. Appropriate measures such as plausibility checks, double set-up of parts checks, linking with functional

processes, runtime monitoring, detection of manipulations etc. must be used to reliably record, process and report the material

flow. In general, plausibility checks must be carried out for functions in order to monitor the functionality of the installed

devices (e.g. for pressure monitoring of fans and pumps, etc.).

Type scanning are only permitted in justified exceptional cases and after consultation with the responsible electrical department

with optical sensors.

Series connection of signal transmitters is generally not permitted.

Command and signalling devices must be pluggable (preferably M12) and have at least one LED to indicate the switching

status. This must be visible to maintenance personnel without tools.

Movements need to be be recorded absolutely. Indirect cylinder polling is not permitted.

A label must be attached to the row positioning switches, on which the position of the actuators is clearly labelled.

When combining several light barriers, make sure that there is no mutual interference.

The switching states must be directly checked and processed.

5.6 Software Design

Use symbolic addresses for all inputs / outputs, flags, times etc. When the CPU is restarted (reset) in the basic position of the

system, errors must not occur in the process. Retain clock controls and process flags.

Basically, structured modular programming corresponding to the system is required. In the standard software, a distinction is

made between structure blocks and module blocks:

Use structure blocks to structure the user program. Use these blocks to program the releases and interlocks as well as to call

up the individual module blocks. Programme structure blocks in the ladder diagram. Simple load and transfer commands, e.g.

In order to enter data in data structures, it can also be programmed in the instruction list. Neither complex functions nor jumps

are permitted in structure blocks.

The control and monitoring of the individual actuators or modules as well as more complex functions such as calculations or

type evaluations are programmed in module modules. These blocks are structured internally and can be programmed in the

instruction list (or SCL for TIA Portal). Access to absolute operands such as inputs, outputs and flags is not permitted. The

data transfer to module blocks takes place via parameters or data fields.

The customer provides libraries with module components for controlling actuators or process devices as well as complete

program packages for various tasks (e.g. identification systems, central control technology, etc.). Function blocks of the

software libraries provided must not be changed.

It cannot be assumed that library blocks are available for all components of the system. Functions and modules that cannot be

covered by the library provided are to be created by the contractor in agreement with the responsible electrical department for

the client. Transfer all created source files unencrypted and unprotected. Base the implementation on the programming method

of the library blocks taking into account the specified guidelines for the creation of module blocks. Before the start of

commissioning, submit the current state of the software to the responsible electrical department to be confirmed.

Software controllers must be used for all control tasks and parameterized using the PID Control software from Siemens. Upper

and lower limit values must be provided for all target values.


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Configure plant extensions with the software versions with which the application software was created. The contractor must

procure and use the required software versions for his project planning devices. If the software versions are no longer suitable

due to hardware expansions, the contractor must obtain the current versions and update all affected devices.

The GSDML files used are included in the scope of delivery.

5.6.1 Process Control

Control decisions are made exclusively by the control of operating means.

5.6.1.1 Step Chains

Step chains may only be used after technical justification by the contractor and a written approval by the client.

Use step chains for the automatic process. Use the step flags formed in the sequencers to control the actuators via module FBs.

The module FBs are called from the structure FBs. Since all monitoring takes place in the module and structure FBs, no fault

detection and no temporal monitoring of the steps is required within the sequencers.´

The ease of servicing compared must not be reduced to conventional logic control.

5.6.1.2 Linkage Controls

Program generally the scope of delivery Linkage controls in the ladder diagram in connection with the library blocks available.

The software packages required for programming, parameterization, maintenance and diagnostics, the firmware of the supplied

components including the possibly existing operating system in its current version, the device manuals as well as the required

programming cables and interface modules are part of the scope of delivery. The software packages must correspond to the

current status. All connecting cables required for programming must be supplied once for each production system. The

contractor must procure the software packages and tools required for project planning, including the necessary licenses and

hand over them to the client at no cost.

5.6.2 Fault Reporting Concept

Integrate production and fault data recording into the systems. Make it available at the start of commissioning in order to

enable weaknesses to be identified in the start-up phase. Record and evaluate the data in the PLC.

Faults are events that interrupt the automatic process. Faults that can damage the machine must only be acknowledgeable on

site.

Messages are events that do not immediately interrupt the automatic process. These acknowledge themselves after the

triggering event has been eliminated.

Record all operating states that lead to a plant standstill or are necessary for central plant monitoring. Record at least the

following faults / messages for each component:

Electrical interference

Motor overload, fuse failure, power failure, process monitoring, detector controls, initiator and limit switch

monitoring (pair monitoring), failure and passivation of fieldbus components as well as all available fault and

monitoring signals of the modules and PCs used

Mechanical malfunctions

Addressing approach bars, flaps, contact strips, overload protection at tensioning stations, torque supports, jamming

indicators

General surveillance

Response of compressed air monitors, flow monitors, temperature monitors, lack of lubricant, etc.

General malfunctions

Emergency stop, driving and call switches, personal protection devices,

Run time monitoring

Interlocks to adjacent systems

e.g. profile-free, staking out, basic positions

Trend reports


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about states of conveyor technology, e.g. meter readings, buffer readings, traffic jam or gap messages, cycle time

monitoring

about irregular consumption values, e.g. water, electricity, air

about increasing pollution or wear

Other organizational and system-related messages

e.g. system in manual mode, control voltage / load voltage range "X" switched off, selection and deselection of

systems or system components etc.

Associated Values

means of transport numbers, identification numbers or fault numbers of subordinate systems (overhead conveyor

controls)

Archive fault messages in a message archive after they have been rectified and acknowledged. Design the fault report archive

and set up it as a circulation buffer (FIFO). Export the fault texts from the software project and made available according to

the specifications of the responsible electrical department. For the fault evaluation of the system, divide all messages into the

corresponding types of fault, types of message, classes and priorities. The contractor must optimize the system or software

based on the reporting system data until the system is accepted. When using ANDON boards, the preparation of the display

data is included in the scope of delivery.

Display all faults and messages on all HMIs in the system. In addition, display a collective fault via a signal tower.

5.6.3 Time Synchronization

Synchronize the clocks of all controls with the control centre. Synchronize the time in the control panels with the time of the

associated BMS and displayed.

If no control centre is available, synchronize the time via an existing FIS connection. If no connection to higher-level systems

is possible, use a BMS as the time master.

5.7 HMI/Visualisiation

The assignment and number of control panels depends on the type and size of the system. As a minimum, it can be assumed

that the consoles must be separated according to lines or production stations. Only those system elements that are in the visible

area of this desk may be controllable in the respective desk. If the system is distributed over several levels (e.g. lifters), each

level will have its own desk. If functions of several consoles can be controlled, they must be locked against each other.

For reasons of ergonomics, when attaching the control panels on site, make sure that the center of the screen is at a country-

specific ergonomic height.

Display each fault message with the following information: consecutive number, date / time, location, message text as well as

a message class and priority.

5.7.1 Signal Lights

Separate signal towers must be provided for all protective devices, process devices, driving and call switch functions as well

as for every workstation with operator approval. Install a corresponding label next to the display elements.

5.8 Drive Technology

Select the thermal overcurrent releases so that the rated motor current is in the lower part of the setting range. Each drive must

be able to be moved forwards and backwards in the "manual" operating mode.

In the event of an emergency stop or protection circuit interruption, bring the drives to a controlled standstill at least after

Category 1 stop. In the reference documents, you can see the corresponding wiring.

Design linear actuators with a frequency converter, position measuring system and a drive with encoder feedback. With

eccentric lifting tables, a position query via initiators is permitted. Design all movements of conveyor elements for two

directions and at variable speeds.

When the maximum loads (e.g. EMS vehicles, lifts, etc.) are reached, the drives, converters, etc. must have a reserve of 20%.


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If replacement drives are installed on system parts, it must be ensured that these, including the encoders, can be activated

without having to re-clamp. The contractor must omission replacement inverters and / or replacement drives installed in

systems and test them over a coordinated period to ensure proper functioning. It makes sense to make the changeover together

with the responsible maintenance staff during system training.

Fig. 6 Schematic representation of a replacement drive concept

A maintenance switch must generally be provided.

When using maintenance switches, the following information label must be clearly visible on every switch and attached in the

local language:

Soft starters must be installed for pumps with a capacity of 45 kW and above and 20 kW for fans.

In principle, provide a separate frequency converter for each drive. Design the frequency converter and drive should preferably

so that they operate permanently with a PWM frequency of 16 kHz in order to avoid high-frequency whistling noises in the

production area. This PWM frequency must be set on all frequency converters.

In order to be able to diagnose the stiffness of the motors, corresponding current windows in the frequency inverters must be

defined, evaluated and reported to the higher-level control system.

The frequency inverters must have a storage medium on which the parameter settings are saved and can be loaded onto the

replacement device when replacing a frequency inverter without the need for a PC. The braking resistors must be implemented

with integrated thermostatic switches.

When using frequency-controlled drives, the contractor is obliged to have the wiring, the setting of the operating modes and

the parameterization of the system checked by a competent person. The complete drive train (converter, motor, gearbox,

associated system cables, etc.) can be obtained from the same manufacturer.

After the commissioning of the drive system, carry out a recording of several measured variables in accordance with the related

documents (Co-Applicable Documents) for manufacturer-specific drive technology. Created and document the actual values

of the individual travel profiles for each drive in the control sequence, including an emergency stop profile.

Caution!

Maintenance switch may only be switched off at a

standstill of the drive"


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Decentralized Technology

With decentralized technology, install the frequency converter and drive separately.

Central technology

The power supply of each drive cabinet comes from the central power distribution cabinet via its own cable.

Provided at least one control unit in each drive cabinet.

5.8.1 Engines

Design drives for continuous operation and generally equipped with temperature monitoring (cold conductors).

Drives with a power up to and including 22kW must be pluggable. Up to 15 kW use for drives an integrated plug connection.

Implement the star or triangle bridges in the connector insert of the supply line (exception: modular connector).

After commissioning each drive system, create and document a record of the individual travel profiles including an emergency

stop profile with the oscilloscope function.

5.8.2 Sensors

5.8.3 Interface

5.8.4 Safety of Machines

Hardware end positions e.g. lifters must be implemented by safety limit switches (positive opening) or by mechanical

precautions. These end positions are not approached in the normal functional sequence. If an incorrectly functioning software

limit switch is run over in the event of an error, a safe shutdown of the movement must be ensured without damage to the

machine and the material being conveyed. Generate an error message in the resource control. Moving out of the mechanical

safety limit switches (in the opposite direction) is only possible in the "Manual" operating mode via the E7 lock.

5.9 Interface

The signal exchange of digital I / Os between two systems basically takes place via a PROFI-NET coupler. If this is not

possible for technical reasons, the signals are transmitted potential-free via I / O modules. The signal-receiving control unit

provides the voltage supply for the output module of the signal-sending control unit.

Install the PROFINET coupler in the conveyor system or process device that partially delivers the material flow and it is

included in the scope of delivery of the respective contractor. The required interface cables (PROFINET and power supply)

including cable routes are part of the scope of delivery of the coupling partner.


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Fig. 7 Schematic representation of interfaces with Profinet coupler

Use only static states based on the acknowledgment principle (no impulses) for signal exchange. Display the status of all link

signals from and to other systems on the HMI. At the separation points between the systems, control the adjacent elements so

that simple operation is possible in manual mode. Implement the program and the interface signals in such a way that in the

manual mode of a function group, the neighbouring function group runs correctly in the automatic mode.

The necessary interface signals must be coordinated with the materials handling equipment suppliers during the construction

phase under the responsibility of the contractor, and be submitted to the planning automation technology for approval.

All process-relevant information (e.g. entry approval, exit approval, profile-free, station in emergency stop, station fault etc.)

including the necessary type information (vehicle type and identification number) must be exchanged via the interface. Signals

received via the interface must be verified with their own sensors for crash protection (for example, a screwing system sends

the "Release exit" signal. However, the exit is only started after the profile freedom of the screwing system has been detected

by own sensors from conveyor technology).

Interfaces to fire and smoke protection systems must be provided for cross-fire systems.

If changes to the air balance of the assembly hall must be expected from the operation of systems, an interface to the technical

building equipment (TGA) must be implemented.


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5.9.1 Security interface

A safety interface from and to adjacent systems must be provided for safe shutdown in the event of an emergency stop,

protective circuit, etc. Carry out all safety-relevant signals in a person-safe manner and transmit them via a PROFINET coupler

(PROFINET with PROFIsafe coupling). Transmit the transmission from and to systems without PROFINET interface by

double-duct, potential-free via safety contacts. Emergency stop signals may also need to be potential-free via separate contacts

attached to the emergency stop switch, so that the function of the switch is guaranteed even when the system is switched off.

Emergency stop circuits and protective circuits must always be set up separately and taken into account separately in the

interfaces, as these may have to affect different areas. A division into separate protection circles is necessary if there are several

safety devices that also have to act on different areas.

5.9.2 ML Switch-Off of Movable Assembly Devices / manipulators

In the case of assembly devices or manipulators within the assembly line, implement a belt limit switch with three roller

lever switches and put it into operation. Carry out the execution according to the illustration. Provide also a profile isolator

(see also chapter 5.9.3) and a confirmation button.

Fig. 8 Concept of ML switching-off

Function of the roller lever switch::

Switch 1 reports that the end of the cycle has been reached. To be displayed via a yellow warning light

Switch 2 switches off (If available) the drive motor of the device and triggers a conveyor belt stop, which is canceled

when the switch is left without an acknowledgment. To be displayed via a red warning light.

Switch 3 is to be integrated in the emergency stop circuit of the conveyor system. A restart is only possible when the

device is no longer in the danger zone and an acknowledgment has been made using an appropriate button. Restart

the conveyor system directly from the perspective of the assembly device.

Program the functions of the warning lights and explain the different switching states of the roller lever switches in the

hardware workshop.

The integration of the signals in the conveyor technology control must be coordinated with the supplier of the conveyor

technology and carried out by them. See the explanation of the responsibilities in the table below. Commissioning takes place

together with the supplier of the conveyor technology.

Scope Equipment / conveyer system

1. Line shutdowns for manipulators resp. devices

Delivery and installation of the line stop switch A

500-1000 500 500

Puffer/Anschlag

Bewegungsrichtung

Sic

her

er -

Ban

dst

opp

Band

sto

pp

War

nle

uchte


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Delivery and installation of release button and display on site A

Delivery and installation of transitions for switches, buttons and displays up to the

control cabinet of the conveyor technology A

Place the transitions in the control cabinet of the conveyor system. B

Hardware installations in the control cabinet of the conveyor technology B

Software integration and further processing on the conveyor technology side B

A = scope of contractor

B = system supplier commissions conveyor technology supplier

5.9.3 Profile freedom from assembly devices

In the case of permanently installed assembly devices, ensure the freedom from profiles compared to the assembly line by

means of a profile isolator. Stop the conveyor movement when leaving the profile isolator. Design the profile release switch

as a roller lever switch or initiator after coordination with the automation technology planning.

The scope of delivery of the contractor includes the delivery, installation of the profile isolator as well as the delivery and

installation of the transition to the module box / control cabinet of the conveyor technology. In addition, indicate the freedom

from the profile by a simple signal lamp, according to the hardware workshop.

6 Virtual Commissioning

6.1 Explanations

To secure the PLC logic, the robot programs (sequence, interaction, error behaviour) and to check the design status, a virtual

commissioning (VIBN) must be carried out for selected plant areas. Carry out the virtual commissioning in coordination with

the responsible specialist departments of the AG. The ARG / PLC can be seen as a unit for virtual commissioning.

The contractor must provide proof (system software qualification certificate) that he can provide a VCOM within the scope

requested by the client.

6.2 Description of Performances

The contractor is responsible for all requirements and activities required for the VCOM. Subcontracting and let the schedule

agree by the responsible person for the client. Present the finished simulation result to the client.

Show a VCOM as a separate item in the offer.

Ensure the following functionalities by means of the simulation:

Automatic operation of the entire system and sections. Test the system fill levels from a transport good to a full system taking

into account all types planned for the system.

Test the manual operation with the visualization software created for the system. Another important aspect in manual operation

is the smooth transfer of the goods to be transported to other operating mode levels.

All technology components (e.g. function components for roller conveyors, cross chains, etc.) as well as components for drive

technologies and robots must be simulated.


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6.2.1 Simulation Station

The contractor must set up a simulation station for the implementation of the VCOM. The simulation station must be available

from the start of construction to the SOP of the project. The simulation station consists of a computer with the WinMOD

software from Mewes & Partner and a computer with the RF Suite software from EKS InTec.

The simulation station also includes a system controller and an operating unit (panel PC or laptop) that meet the project

specifications.

6.2.2 Simulation Model

Create all plant models required for the VCOM as contractor performance. Insofar as there are guidelines and Guidelines for

the construction of the system model and the implementation of the VCOM (Co-Applicable Documents-II-B03-03-01

Ausführungsanweisung Virtuelle Inbetriebnahme), use these and implement them. For virtual commissioning, the

contracting authority will provide the library and project support. However, they do not claim completeness.

At the end of the project, hand over the created plant models including all newly created behaviour models of WinMOD and

RF Suite-Components to the client. Transfer the data in a file format with which further processing of the models is possible.

7 Infeed and Infrastructure

Depending on the current intensity required, a high-current rail (> = 160A) or a power distributor (<160A) is the transfer point

for the entire electrical power.

The scope of delivery of the contractor includes the possible delivery / setting of the tap-off boxes, fuses, feeder cables,

mechanical and electrical installation material. For the calculation, it is assumed that the cable is 100m long.

The contractor is obliged to present his feed-in concept to the respective energy supply of the plant after commissioning. In

the design discussion on site, it is determined which of the existing infrastructure (cable routes, tap-off boxes, power and cable

distributors, etc.) can / must be used by the contractor.

The precise connection value, the simultaneity factor, the cos φ, the harmonic content as well as the exact location of the

respective control cabinet must be communicated to the AG in writing 6 weeks before the control cabinet is delivered.

The Contractor is obliged to carry out any necessary measures to reduce network interference in order to comply with the limit

values according to EN 61000-2-4. The AG reserves the right to measure compliance with the limit values during idle, run-up

and normal operation.

7.1 Power Supply Concept

Use a feed cabinet to distribute the electrical energy within the system. The contractor must choose the appropriate version

according to the size and content of the system.

Feed the following components of the system in from the feed cabinet:

In front of the main switch

sub-distribution

from this plant and workplace lighting u. maintenance outlets

Network cabinet (of the manufacturing plant)

Large screen display (of the production plant)

Large screen display (of the production plant)•

Process device PC (of the production plant)

After the main switch


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process systems e.g. adhesive controls, screwdriver controls etc.

robot

cabinet of operating means

drives cabinet

decentralized drive technology

decentralized 24V distributor ED

7.2 Compensation

7.3 Lightening

The workplace and system lighting is included in the scope of delivery and is in accordance with the “Technical rule for

workplaces” ASR A3.4 to be carried out.

The resulting VW guideline "Quality requirements for lights“, QA7-E-530 describes the approved luminaires and details of

the execution.

Design the workplace and system lighting so that it can be switched from a separate central point independently of the system.

In addition, it is possible to provide remote switching. Divide the lighting into several useful switching groups.

The lighting concept must be coordinated with the automation technology planning and the customer.

For system areas above the hall lighting (e.g. area shelf storage, control cabinet platforms, shed arches, penthouse etc.), separate

lighting sufficient for maintenance work (nominal illuminance> = 200 lx) must be installed.

7.4 Maintenance Sockets

Provide two maintenance sockets in the systems near the control panels for each protection circuit.

8 Switch cabinet

Create all cabinets according to the sample or reference documents.

Control cabinets must be set up so that they are free of vibrations, with a free space between individual control cabinet

groups.

The distance between the power and control cables must be as large as possible during installation and cable entries in order

to avoid EMC interference.

Observe the following minimum clearances mu when installing the control cabinets:

Tür Tür Tür

1100mm 700mm 1700mm 700mm

220

0m

m

600mm 600mm 600mm

1100 = 600 mm door + 500 mm escape route, 1700 = 2x600mm door + 500 mm escape route


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Fig. 9 Schematic representation of control cabinet installation with minimum dimensions

Note: It cannot be assumed that the doors will open 180 ° in an emergency (e.g. due to pull-out floor in the cabinet or

cooling units).

If, in exceptional cases, the installation of the cabinets back to back or in an escape without free space between the groups is

approved by the client (e.g. due to space problems), they must be separated from each other with suitable fire protection

material (e.g. heraclitus panels) by at least 4 cm.

Install cooling devices in the control cabinet door. Evaporate any condensate that has formed in a targeted manner. Roof

devices are generally not permitted.

No components may be installed or built into the side walls.

8.1 Control cabinet concept

Construct control cabinets generally modularly as described below.

For small systems, combined cabinet variants are also possible after consultation with the automation-planning department.

8.1.1 Cabinet Modules

Fig. 10 Schematic representation of the cabinet concept

FC = feed cabinet

Cabinet with main switch, switch disconnector including undervoltage release and consumption measurement, 400V

distribution.

BS = cabinet of operating means *

Safety PLC, switches, PN / PN couplers, 24V = design and switchboard.

DED = decentralized energy distributor 24V DC

Switch cabinet as dec. 24V = design and switchboard.

DC = drive cabinet

Use for central frequency converters e.g. NC axes, hold-down devices, roller test benches.

Create all control cabinets based on the sample or reference documents.

Standardize the components within the production plant. Use components from one manufacturer for the same functions. A

manufacturer / manufacturer mix is prohibited.


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Always supply the same components with a uniform hardware, software and firmware version. List the stands in the final

documentation.

Power Supplies / Buffer Modules

In the event of unsafe power grid conditions, a buffer module must be set on the primary side to compensate for short-term

voltage drops.

If required, connect power supplies in parallel on the secondary side.

A parallel connection of control contacts to increase the switching capacity is not permitted.

To avoid voltage drops due to huge cable lengths, the 24 V DC supply must be installed decentral in the field in large

systems or when the control cabinets are installed on stages. A detailed consultation takes place in the construction meeting.

Fuse-Free Design

Create the power distribution in a fuse-free design. The following points are permitted as line protection elements:

Miniature circuit breakers with characteristic B or C with auxiliary contact

For I / O modules, max. Protect 32 digital inputs or 16 digital outputs via a circuit breaker

Motor protection switch with auxiliary contact

Fuse Check

From the circuit breaker outlet, design all circuit breakers and motor circuit breakers with signalling contacts. Evaluate the

signalling contacts are to be evaluated in terms of control technology in the PLC. In consultation with the planning

department of automation technology, form meaningful groupings for the evaluation for up to ten queries.

8.1.2 Air conditioning of the switch cabinet

The basic ambient temperatures to be observed are described in Concern unified specification (KELH) Part I-B09, Section

1.7 Ambient Conditions. If the use of an air conditioner results from the heat calculation that requires documentation, take

the following conditions into account:

A solution without an air conditioning unit should preferably be sought, and the size of the control cabinet adjusted

if necessary

It must be ensured that there are no impermissible temperatures for the components used in the control cabinets or

housings

Air conditioners are generally installed in the control cabinet door above the components with the highest power loss

The installation of air conditioning units on side walls is only possible in exceptional cases, after consultation with

the automation technology planning department

The use of roof air conditioners is not permitted

9 Montage und Installation

Parts or components carrying external voltage that are connected in front of the main switch must be installed separately

completely covered and specially marked. Remove the cover only with tools.

All incoming and outgoing lines in the control cabinet must not be connected directly to the switchgear, but must be routed

via terminal strips.

Exceptions to this are: data / fieldbus lines


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cables of position encoders and analog signals

serial couplings

outgoing cables from 24V DC fuse distributors, provided that these can be fully connected

feed-supply

Motor and encoder cables from frequency converters

Cables that are connected directly to terminal strips or 24V DC fuse distributors must not be routed through the wiring

bracket of the control cabinet wiring system. Cables for the control cabinet lighting must also be routed separately inside the

cabinet outside the wiring bracket. Cross connections within a control cabinet group lay generally through the base.

Completely pre-assembled M12 installation cables are permitted up to 10 m. Installation cables with LED connectors must

generally be used.

An extension or denomination of lines is generally not permitted.

Moving Lines

For constantly moving cables, use highly flexible cables with a PUR jacket. These should always be as short as possible,

taking into account the accessibility of the plug connections. When designing these lines, use a uniform length where

possible. Take into account the design and assignment of the plug connections if the cables match.

For each moving line there is a replacement line completely assembled with plugs as well as suitable brackets for proper

storage, part of the scope of delivery or spare parts package.

The contractor must check all replacement lines together with the responsible maintenance on site. The contractor must

install the brackets, including the replacement cables, in the immediate vicinity of the installation site, in coordination with

the responsible maintenance department.

Operating Means

Fixe operating means on vibrating or vibrating machine parts in a vibration-dampened manner.

If decentralized, intelligent peripherals (e.g. PROFINET modules) are used in terminal boxes, bus housings with a weld-

resistant clear cut-out in the cover must be used. A wiring duct must be installed above and below the terminal strip in

terminal boxes without I / O modules. If possible, integrate terminal boxes flush into the protective grille.

´Design emergency stop buttons below a height of 1.5m with a protective collar. Install all emergency stop buttons along

conveyor lines in such a way that they can be moved in two levels by at least 1.5 meters in each direction without having to

disconnect the cable.

Install safety devices in such a way that they can be exchanged securely.

When connecting solenoid valves (e.g. maintenance unit) via plug connectors in accordance with EN 175301-803, delete

voltage peaks in the cubic plug.

Cable entry on operating means must be from below, if possible. Lay a draining bend for the side cable entry. Permit cable

entries from above.

9.1 Wiring Concept for Electric and Media

In addition to Concern Unified technical Specification (KELH) Part I-B09, the compartments in the cable ducts are divided

as follows:

❶ optical fibre, data, bus and encoder cables

❷ 24V DC cables, equipotential bonding

❸ 230V/ 400V AC cables, equipotential bonding


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❹ compressed air

Fig. 11 Cable duct division

The medium air ❹ is installed in a separate chamber or duct, on one level with the ducts for the electrical cables.

9.2 Installation Execution

The 24 V DC supply lines must have a cross section of at least 2.5 mm².

Plug connections, loops and bundling of cables within cable ducts are not permitted. Fastening the cables to the system using

cable clips or plastic ducts is not permitted.

Protect all electrical parts and components in the field against mechanical damage. Design the covers so that diagnostic displays

on the devices remain visible.

Install cables and lines in galvanized metal ducts with removable lids right up to the component (max. distance 10 cm). If it is

not possible to lay them in ducts, lay the cables in protective hoses.

If the ambient conditions allow, omit the cover from a height of two meters above accessible areas.

In principle, lay cable ducts in such a way that they do not significantly impair the accessibility to maintenance within the

system. This requires coordination with the responsible specialist departments (electrical department, maintenance, operator).

In walk-in areas outside the protection area, put transitions made of checker plate with yellow-black markings over cable ducts.

As far as possible, carry out the installation of cables and conceal lines in construction parts. It must be possible to implement

connectors.

Provide cable ducts are generally with covers. Exceptions to this are routing in the belt superstructure.

Create individual, separate cable routes for the following scope:

230V / 400V AC supply lines (supply line for control cabinet feed, lines for sockets and lighting outside the production system).

Cable routes to data distribution cabinets.

9.3 Fieldbus Connection

9.4 Mechanical Design

Fasten and protect mechanically all signal transmitters (initiators, limit switches, reading points etc.).

Design mechanical brackets for the signal transmitters and RFID readers to be mechanically stable and three-

dimensionally adjustable.


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Provide signal generators installed directly in the area of worker workplaces with transparent, quickly removable

covers.

Design mechanical brackets for camera / lighting systems so that they enable exact fixation in all three axes.

Machine vibrations must not interfere with the identification process.

Devices with high leakage currents, which are fed in via bus bars, must be installed and installed with two locally

separated protective conductor pantographs.

Cover encoders, readers etc. installed in the floor of accessible work areas flush with a maintenance flap with a viewing

window.

Query movements directly, no cylinder sensors are permitted.

9.5 Marking

All equipment installed in the switch cabinet must be marked in duplicate. The designation is:

1. on the unit (removable label carrier or, if not available, on the wiring frame).

2. on the marking plate on the connecting wire.

On non-pluggable components, label each core with a terminal designation (or terminal designation). The only exception is

the connection to terminal blocks, potential distributors and rider protection elements.

For each control, it is necessary to place the type plate at the specified location on the control cabinet.

Describe all stations by marking the installation site according to the wiring diagram. Place the description so that it is

legible from the control panel concerned.

All markings must be machine-made with released components.

9.6 Equipotential bonding / EMC

Design machines and systems in such a way that when using protective enclosures or fences, no further protective measures,

such as Access restrictions due to electromagnetic fields.

In the safety concept, the limits of the exposure areas according to DGUV regulation 15 must be shown and information

about the electromagnetic field strengths occurring, if necessary for different operating states.

In order to be able to discharge static charges in a targeted manner, connect all electrically conductive components to each

other in a low-tube configuration. At least once, in the case of larger systems (e.g. conveyor technology) every 20 meters,

potential equalization to the building must take place.

In production cells, install potential rails at central points, which are connected in a low-tube configuration to the

equipotential bonding of the hall. Lay the equipotential bonding conductors in the "24V chamber" of the cable duct. Connect

cable ducts generally to the equipotential bonding of the building on both sides, but for longer distances at least every 20

meters with a low resistance. Connect all electrically conductive components of the production system to the equipotential

bonding bar with low resistance.


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Connect the control cabinet housing to the PE rail with a green-yellow conductor of> = 10mm² Cu. Connect the doors to the

cabinet using a ground strap. Connect the wiring frame to the cabinet housing with good conductivity and to the PE rail as

well.

All control cabinets within ground a control cabinet group with at least 16mm² in a star shape from the power distribution

cabinet.

In accordance with the relevant accident prevention regulations, the contractor must ensure that the production systems do

not pose any health risks to the system operators and people passing by. This includes people with active electronic food aids

(e.g. pacemakers). Exceeding the permissible limit values of exposure area 2, which may affect workplaces or the immediate

outside area of the systems, is not permitted. Measures required to achieve the protection goal must be taken into account

when designing the system.

Examine and take into account the electromagnetic compatibility of the individual components, cables and wire during the

construction by means of suitable measures.

The measures should include:

• Coordinated earthing (short cables, large cross-sections, defined connection points)

• Connect metal parts well with one another over a large area (metal on metal, also with cable trays)

• Avoid unnecessary cable length (no cable loops in the control cabinet)

• Shielding of encoder cables• Isolated PLC input / output modules

• Earth strap on the control cabinet doors• Apply shielding to shielding rails over a large area

• Contactors, relays etc. provide generally with interference suppressors

Set up switched inductors at a sufficient distance from processor-controlled assemblies.

The measures should include:

Coordinated earthing (short cables, large cross-sections, defined connection points)

Connect metal parts well with one another over a large area (metal on metal, also with cable trays)

Avoid unnecessary cable length (no cable loops in the control cabinet)

Shielding of encoder cables

Potential-isolated PLC input / output modules

Earthing strap on the control cabinet doors

Apply shielding to shielding rails over a large area

Contactors, relays etc. are generally to be provided with interference suppressors

Set up switched inductors at a sufficient distance from processor-controlled assemblies.

9.6.1 Protection Potential Compensation

9.6.2 Function Potential Compensation

10 Commissioning

As soon as the system is in productive operation, the system must be tested in good time before the start of production after

every intervention (especially after weekend conversions) to ensure trouble-free start-up. the contractor's specialist staff must

ensure the start-up support at the subsequent start of production.


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10.1 On-Site Data Backup

10.2 Substitute Material On-Site

11 Robot Programming

12 Documentation

The contractor must integrate the documentation of provided materials and equipment into the overall system

documentation.

The customer specified the execution of the electrical documentation in his specification.

Obtain area-specific documentation requirements from the responsible electrical department and observe them.

If, for technical reasons, components have to be used that are not included in the approval list, the documentation must be

accompanied by a description in which an exchange of the components is explained gradually up to the complete restart.

Software Documentation

Create the documentation of the software with the respective programming system using all the possibilities provided by the

system. If line comments or network headings cannot be used to describe functions adequately, a supplementary description

must be created.

The minimum scope of the documentation includes:

Symbolic designation of the I / Os from the circuit diagram

Network headings / instruction comment

Symbolic (meaningful) designation of the flags and data bits

Symbol comment for each symbol

Block comments block comments

The supplier documents his functional modules in detail (parameter description, flowchart, structure chart, etc.).

13 Acceptance

13.1 Preconditions

13.2 Safety Check

The following requirements are necessary for this:

installer certificate that the electrical system complies with the provisions of the DGUV

Test report according to IEC 60364-6 / EN 60204-1

BWS acceptance report

Safety components have been checked and are in operation

Chapter Electrics available in the operating instructions

Client's staff have been instructed


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13.3 Acceptance Procedure (Start-Up Management)

14 Training and instruction

14.1 Definitions

14.2 Minimum scope of training and instruction

For special, not conceptual system components, e.g. special adhesive controls, path detection systems, etc., the contractor

carries out a training of the operating and maintenance personnel. In addition to the initial training, provide a second post-

training. The contractor prepares training material and the required system descriptions must be d by in Czech (national

language) for the plants in Czech Republic and in English eventually in the national language for all other plants.

The type and implementation of the training and the training material needs to be agreed by the operator in advance. Provide

the training in the national language using an interpreter.

Basic training, e.g. for programmable logic controllers (PLC), standard fieldbus systems (e.g. PROFINET) etc. are not

included in the scope of delivery.

Before the systems are taken over by the operating and maintenance personnel, the contractor must provide instructions in

the national language.

In addition to the theoretical instruction, there is also a practical demonstration of handling performance.

Driving the system including operating the process systems.

Detecting, evaluating and eliminating faults.

Change logic parts and parameters.

Restart after total failure (eg after voltage interruptions).

After consultation with the operator, instruction is always given at the installation site of the system.

Upon request, the operating and maintenance personnel should be given the opportunity to familiarize themselves with the

system structure and control logic during system construction and commissioning right up to system takeover.

The duration of both instruction and training is based on the complexity of the system and must be carried out until

the learning content has been conveyed.

The contractor agrees the instruction / training with the maintenance / operator. For each training course, the

contractor must document the training content, duration of the training, participants and attendance.

The contractor provides system-specific training on structure, purpose and function.

Technical Specification ŠKODA AUTO a.s. Part II-MO-03 ...

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