Festo CP Factory User manual

Festo CP Factory User manual

CP Factory

®

Manual

Basic module branch

Festo Didactic

CP Factory

02/2018

Order number:

Status:

Layout:

02/2018

02/2018, Schober, Weiss

CP-F-BRANCH-GB-A002.doc File Name:

© Festo Didactic SE, 73770 Denkendorf, Germany, 2018

Internet: www.festo-didactic.com

E-Mail: [email protected]

Intended use

This installation was developed and manufactured only for the use in basic and further training in the fields of automation and communications. The training company and/or the training staff must ensure that the trainees observe the safety precautions described in the accompanying manuals.

Furthermore this manual describes setup and possible uses of the singular stations. It contains all information and data required for commissioning, maintenance and operation.

Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any third parties which may occur when the installation is used beyond a genuine training situation, except Festo Didactic has caused such injury or harm intentionally or by grossly negligence.

Experimenting on CP Factory / CP Lab systems with hazardous live voltage is not allowed.

This manual, all text and illustrations included, is protected by copyright. Any utilization outside the limits of the copyright law and other than training purposes are not permissible without our definite approval. This applies in particular to reproductions, operations, translations, micro filming and the storing and processing into electronic systems. Distribution of this documentation, as well as reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences are liable to compensation. All rights reserved, especially the right to execute registrations concerning patents, designs for use and patterns.

Intended use also comprises observing all instructions in the operating manual and carrying out the inspection and maintenance works.

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© Festo Didactic CP Factory ° Basic module branch

Content

1 General safety instructions __________________________________________________________________ 5

1.1 Pictographs ___________________________________________________________________________ 6

1.2 Safety terminal sockets _________________________________________________________________ 7

1.3 Information for the electrical connection of the systems ______________________________________ 7

1.4 Handling the system ___________________________________________________________________ 8

1.4.1 Dangers when using the machine _____________________________________________________ 8

1.4.2 Safety precautions in normal operation ________________________________________________ 8

1.4.3 Dangers caused by electrical energy ___________________________________________________ 8

1.4.4 Dangers caused by pneumatic energy _________________________________________________ 8

1.4.5 Maintenance and fault clearance______________________________________________________ 8

1.4.6 Organizational measures ____________________________________________________________ 8

1.5 Staff _________________________________________________________________________________ 9

1.5.1 Instructions regarding the staff _______________________________________________________ 9

1.5.2 Training operations _________________________________________________________________ 9

1.5.3 Beyond training operations __________________________________________________________ 9

1.6 Commitment of the operator _____________________________________________________________ 9

1.7 Commitment of the trainees _____________________________________________________________ 9

2 Introduction _____________________________________________________________________________ 10

2.1 Warranty and liability __________________________________________________________________ 10

2.2 Important information _________________________________________________________________ 10

2.3 Resources ___________________________________________________________________________ 11

3 Design and function _______________________________________________________________________ 13

3.1 Transport ____________________________________________________________________________ 13

3.2 Set up ______________________________________________________________________________ 13

3.2.1 General notes ____________________________________________________________________ 13

3.3 The basic module branch _______________________________________________________________ 14

3.3.1 General information _______________________________________________________________ 14

3.4 Mechanical construction _______________________________________________________________ 16

3.4.1 Supply of the branch module ________________________________________________________ 20

3.5 Electrical assembly ____________________________________________________________________ 22

3.5.1 Wiring Diagram ___________________________________________________________________ 27

3.5.2 Emergency-Stop Structure __________________________________________________________ 29

3.5.3 Emergency-stop with central control __________________________________________________ 32

3.5.4 Connection of application module ____________________________________________________ 34

3.5.5 Pneumatic port of application module ________________________________________________ 36

3.5.6 Electrical connection of applications __________________________________________________ 37

3.6 Commissioning _______________________________________________________________________ 38

3.6.1 Pneumatic commissioning __________________________________________________________ 38

3.6.2 Electrical commissioning ___________________________________________________________ 38

3.7 Adjusting the sensors _________________________________________________________________ 39

3.7.1 Proximity switch (stopper Identsensor) _______________________________________________ 39

3.7.2 Proximity switch (stopper cylinder) ___________________________________________________ 41

3.7.3 Proximity switch (branch cylinder) ___________________________________________________ 43

3.8 Adjusting the one-way flow control valves _________________________________________________ 45

© Festo Didactic CP Factory ° basic module branch

Content

3

Content

4

3.9 Visual inspection _____________________________________________________________________ 47

3.10 Starting up _________________________________________________________________________ 47

4 Operation _______________________________________________________________________________ 48

4.1 General operating instructions __________________________________________________________ 48

4.1.1 Conduct guidelines ________________________________________________________________ 48

4.1.2 Operating guidelines ______________________________________________________________ 48

4.2 The control units of the basic module branch ______________________________________________ 49

4.2.1 Touch Panel ______________________________________________________________________ 50

4.3 Sequence description of the branch module _______________________________________________ 53

4.4 Switching on the station _______________________________________________________________ 57

4.4.1 Sequence Description Automatic ____________________________________________________ 57

4.4.2 Process description Cycle End _______________________________________________________ 57

4.5 Operating modes _____________________________________________________________________ 58

4.5.1 Automatic mode __________________________________________________________________ 58

4.5.2 Setting operation _________________________________________________________________ 58

4.6 Operating the HMI touch panel __________________________________________________________ 58

4.6.1 Menu architecture from operation panel ______________________________________________ 59

4.6.2 Menu navigation __________________________________________________________________ 60

4.6.3 Display operation modus ___________________________________________________________ 61

4.6.4 Operation mode Home _____________________________________________________________ 62

4.6.5 Operating mode Setup _____________________________________________________________ 68

4.6.6 Operation mode Parameters ________________________________________________________ 74

4.6.7 Operation mode System - settings ___________________________________________________ 79

4.7 Operator assistance and simulate application on free AP ____________________________________ 80

4.7.1 Generic sequence simulation ________________________________________________________ 81

4.7.2 Operator assistance with display of pictures ___________________________________________ 82

4.7.3 Operator assistance with call of htm-page _____________________________________________ 84

4.8 Automatic operation __________________________________________________________________ 85

4.8.1 Start automatic ___________________________________________________________________ 85

4.8.2 Stop automatic ___________________________________________________________________ 87

4.9 Manually describe the RFID tag__________________________________________________________ 88

5 Components _____________________________________________________________________________ 90

5.1 Electrical components _________________________________________________________________ 90

5.1.1 2 Quadrant Controller ______________________________________________________________ 90

5.2 PLC Siemens _________________________________________________________________________ 94

5.3 PLC Festo CECC _______________________________________________________________________ 95

5.4 Turck Interface _______________________________________________________________________ 96

5.5 Scalance Ethernet Switch ______________________________________________________________ 97

5.6 RFID with Ethernet ___________________________________________________________________ 100

5.7 RFID with CanBus ____________________________________________________________________ 104

5.7.1 Mini Terminal ____________________________________________________________________ 105

5.7.2 SYS link interface ________________________________________________________________ 109

5.8 Mechanic components ________________________________________________________________ 110

5.8.1 Motor of Conveyor _______________________________________________________________ 110

5.8.2 The stopper unit _________________________________________________________________ 111

5.8.3 The branch ______________________________________________________________________ 113

5.8.4 Transportation of the Basic Module branch ___________________________________________ 114

© Festo Didactic CP Factory ° Basic module branch

General safety instructions

1 General safety instructions

The laboratory resp. the classroom must be equipped according to the rules of EN 50191:

There must be Emergency Stop equipment in the training area and at least one Emergency Stop outside the training area.

The training area must be protected against any unauthorized switching-on, e.g. by key-operated switches.

The training area must be protected by fault current protective circuit (RCD).

– RCD circuit breaker with differential current ≤ 30 mA, type B.

The training area must be protected by overcurrent protections -

– fuses or circuit breakers

The training area must be supervised by a person who is responsible for the activities.

– This person must be a skilled electrician or a person instructed in electrical engineering with the knowledge of all safety requirements and safety precautions on file.

• Any damaged device or faulty device may not be used.

– Any faulty or damaged device has to be blocked and removed from the training area.

General requirements regarding a safe operation of the devices:

• Do not lay cables over hot surfaces.

– Hot surfaces are marked with a corresponding warning symbol.

• The permitted power loads of cables and devices may not be exceeded.

– Do always compare the current values of the device, the cable and the fuse.

– In case of non-compliance, you have to use a separate upstream fuse as an appropriate overcurrent protection.

• Any device with earth connection must always be grounded.

– If there is a ground connection (green-yellow laboratory socket) available, the connection to the protective ground must always be effected. The protective ground must always be contacted first

(before voltage) and must only be separated last (after voltage separation).

• If not specified differently in the technical data, the device does not have an integrated fuse.

© Festo Didactic CP Factory ° basic module branch

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General safety instructions

1.1

Pictographs

This document and the described hardware contain information on possible dangers which may occur when using the system improperly. The following pictographs are used:

Warning

This means that in case of disregarding the rules, serious personal injury or material damage may occur.

Caution

This means that in case of disregarding the rules, personal injury or material damage may occur.

Warning

This means that prior to any mounting, repair, maintenance or cleaning operations, you have to switch off the device and to disconnect the power plug. Please observe the manual, especially all information on safety. In case of disregarding, serious personal injury or material damage may occur.

Warning

This means that you could burn yourself when touching hot surfaces

(temperatures up to 85 ° Celsius).

Important

Here you find important information for an appropriate handling of the machine.

Disregarding this symbol may lead to malfunctions at the machine or in its surrounding area. i

Information

This means that you obtain tips for the use and especially useful information.

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© Festo Didactic CP Factory ° Basic module branch

General safety instructions

1.2

Safety terminal sockets

If not specified differently in the technical data, the following colour coding applies for the power and signal supplies with components of the FESTO Didactic learning system automation and technics.

Colour Meaning Colour Meaning

Voltage bigger protective low voltage, e.g. supply voltage 90 to 400 V AC conductor (grey) neutral conductor

(grey/blue) protective earth conductor

(green-yellow)

24 V DC

(red)

0 V DC

(blue) protective low voltage signal input/signal output

(black)

The specified protection categories and the safety can only been guaranteed when using Festo Didactic safety laboratory cables.

Any damaged or faulty safety laboratory cables have to be blocked instantly and to be removed from the training area.

1.3

Information for the electrical connection of the systems

For the supply of the CP-Factory/ CP-Lab systems, according to the regulations of the EN 60204-1 (VDE

0113-1) part 8.2.8, a supply cable with an additional protective earth conductor is required. Since a leakage current of > 10mA may flow depending on the expansion, an additional protective earth conductor with

10mm² is required.

See also DIN EN 60204-1.

© Festo Didactic CP Factory ° basic module branch

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General safety instructions

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1.4

Handling the system

1.4.1

Dangers when using the machine

The system has been constructed in accordance with the state of the art and the recognized safety rules.

Nevertheless, there might occur dangers to life and limb of the user or a third person when used, as well as negative impact on the system or on other material assets.

You may only use the system:

• for the intended use

• in excellent condition concerning safety regulations

Any faults which might affect the safety must be eliminated instantly!

1.4.2

Safety precautions in normal operation

Please use the system only if all safety devices are fully functional.

Please inspect the system regarding externally discernible damages and the functionality of the safety devices at least before starting the operation.

Do not touch the running station.

Before any circuit assembly, disassembly or modifications in a circuit:

Switch off the compressed air supply and the power supply.

Observe the general safety regulations: DIN 58126 and VDE 0100.

1.4.3

Dangers caused by electrical energy

After finishing the maintenance works you have to check the safety devices regarding their function.

Only an electrically or electronically trained person is allowed to execute operations on the electrical supply.

The terminal boxes have to be kept close all of the time. Any access is only allowed if supervised by a training person.

Please do not operate electrical limit switches manually when searching for an error, but use the tools.

Please do only use low voltage 24 VDC.

1.4.4

Dangers caused by pneumatic energy

Tubes coming off due to compressed air may cause injuries. Take away the pressure instantly.

Caution! When switching on the compressed air, the cylinders may drive in or out automatically.

Do not uncouple the tubes when under pressure. Exception: Debugging. In this case, you have to hold the tube end tight. Do not exceed the permitted working pressure. See also data sheets.

1.4.5

Maintenance and fault clearance

Carry out all prescribed setting and servicing work in due time (see data sheets).

Protect the compressed air and the electrics against an accidental commissioning.

During all maintenance, servicing or repair works, the machine must be disconnected from the power supply and the compressed air supply, and it must be protected against an unintentional restart.

Please check that all screw connections which have been loosened during the maintenance, servicing or repair works are firmly seated.

1.4.6

Organizational measures

All existing safety equipment has to be checked regularly.

© Festo Didactic CP Factory ° Basic module branch

General safety instructions

1.5

Staff

1.5.1

Instructions regarding the staff

Regarding the staff, there are basically two starting situations to be considered.

• activities during the training operation

• activities not connected with the training operations.

1.5.2

Training operations

The trainees are only allowed to work on the machine if supervised by a skilled person or the instructor.

Any activities concerning fault finding and elimination are controlled by the instructing person.

Safety regulations have to be observed here in particular.

1.5.3

Beyond training operations

All activities concerning maintenance, servicing and repair may only be executed by a person with sufficiently professional qualifications.

1.6

Commitment of the operator

The operators commit themselves to only allowing the work at the CP-Factory/ CP-Lab to a person who:

• is familiar with the principle directions of work safety and accident prevention and has been instructed in the handling of the CP-Factory / CP-Lab,

• has read and understood the safety chapter and the warnings in this manual.

The safety-conscious working of the staff should be checked at regular intervals.

1.7

Commitment of the trainees

Before they start work, all persons in charge of works at the system commit themselves to:

• read the safety chapter and the warnings in this manual,

• observe the basic principles about work safety and accident prevention.

© Festo Didactic CP Factory ° basic module branch

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Introduction

2 Introduction

2.1

Warranty and liability

Basically, our “General Terms and Conditions“ apply, which have been made available for the user since the conclusion of the contract at the latest.

Any warranty and liability claims for personal or material damage will be excluded, if they result from one or more of the following causes:

• any non-intended use of the system

• any improper mounting, commissioning, operating and servicing of the system

• any operating of the system with faulty safety devices or safety and protective devices which have not been mounted properly or are not functioning

• any disregarding of the information in the manual concerning transport, storage, mounting, commissioning, operation, servicing and setting-up of the system

• any unauthorized constructional alterations on the system

• insufficient monitoring of installation parts which are subject to wear and tear

• any improperly executed repairs

• any major emergencies caused by external influence and force majeure.

Festo Didactic herewith rules out any legal responsibility for damages of the trainee, the training company and/or a third party which might occur when using the system beyond a genuine training situation, unless the damage has been caused by Festo Didactic intentionally or due to gross negligence.

2.2

Important information

Knowing the basic safety instructions and the safety rules is a basic prerequisite for the safe handling and the trouble-free operation of the system.

This manual contains the most important information in order to operate the system in a way that meets the safety demands.

The safety instructions in particular have to be observed by any person working with the system.

Furthermore all rules and instructions concerning accident prevention applying to the deployment location have to be observed.

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© Festo Didactic CP Factory ° Basic module branch

2.3

Resources

The training equipment of the system consists of several resources. They are used depending on the process selection.

The following resources are available:

Introduction

Pallet carrier

These pallet carriers are available for transporting the pallets.

Pallet

These pallets are available for receiving always one workpiece.

© Festo Didactic CP Factory ° basic module branch

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Introduction

External production parts

Workpieces Description

CP back cover no 111

CP board no 120

CP fuse no 130

Production parts

Workpieces

CP front cover no 210 - if there is a CNC milling machine integrated in the system, the front cover can also be produced there , thus becoming a production part.

Description Workpieces Description

CP no fuse no 211

CP fuse on the left

No. 212

CP fuse on the right no 213

CP fuses both no 214

CP part customer no 1210 freely selectable

CP part no fuse no 1211

CP part fuse on the left

No. 1212

CP part fuse on the right no 1213

CP part both fuses no 1214

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© Festo Didactic CP Factory ° Basic module branch

3 Design and function

3.1

Transport

On delivery of the stations, special attention must be payed on transporting them only by a suitable industrial truck.

The weight of a station may amount up to 500 kg. i

Warning

Before the transport, all supply roads must be cleared to be passable for the industrial truck. If necessary, you have to install warning signs or barrier tapes.

When opening the transport boxes you have to be very careful because additional components like computers may also be delivered with the box and have to be protected against dropping out.

Caution

If the transport box is opened and the possibly additional components are taken out, you can remove the station and bring it to its place of destination. Please check the stability of all profile connectors with an Allen key size 4-6. It might happen that the connectors are loosened during the transport due to inevitable vibrations. Please pay special attention to any protruding components, sensors or other small parts may easily be damaged during an improper transport. Do not grab the station at or even under the pedestals – high risk of being crushed or jammed!

3.2

Set up

3.2.1

General notes

You have to install the system in a frost-free room with a maximum relative humidity of 70 % and a maximum ambient temperature of 25 ° Celsius. In countries with a higher humidity or higher temperatures, you have to install air-conditioning systems for constant ambient conditions. You first have to check any electrical disturbing sources like welding systems, big motors and contactors regarding their EMC and if necessary to shield them in order to obtain the values permitted in the guidelines. A stable ground is essential for a trouble-free operation in order to avoid subsidences. You have to see for an appropriate distance between the system and the wall. Keep away any dust from the station resulting from construction works (covering).

Design and function

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© Festo Didactic CP Factory ° basic module branch

Design and function

3.3

The basic module branch

3.3.1

General information

The basic module branch consists of a 1200 mm long two-track conveyor line. The conveyors are 80 mm wide. On the rear side of the module, there is a two-track branch where carriers can be transferred outward and inward in a loop. On the conveyors boards are transported on carriers.

The carriers are equipped with a read/write ID system. This ID system represents a very important part of the CP Factory System. The carriers are written with the current data of the workpiece to be transported.

Thus all information required for the process is carried together with the workpiece/ carrier and is available at every operating position.

It is possible to split the branch module into two parts, the back conveyor line with branch and the front conveyor line. At the front conveyor line it is possible to mount an application; at the back conveyor line this is not possible. Therefor the front conveyor line reacts like a basic module and is not explained in detail. All processes in this manual are for the back conveyor line – also for the branch module.

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CP Factory Basic module branch

© Festo Didactic CP Factory ° Basic module branch

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17

18

19

20

21

12

13

14

15

8

9

10

11

Position

4

5

6

1

2

3

7

Description

Corner pulley/no other module attached

Conveyor front side

Main switch

Manometer

Stopper unit front side

Maintenance unit

Touch panel

Variant 1 / Festo panel

Variant 2 / Siemens panel

Ethernet interface

Supply lines

Turck I/O module with RFID interface for attachment of 2 read/write heads

Stopper inward transfer

Conveyor inward transfer

Conveyor outward transfer

Branch outward transfer

Stopper unit back side

Conveyor rear side

Corner pulley/no other module attached

Emergency stop button

Controller on pushbutton

E-Board

Pressure switches (option for energy monitoring)

Design and function

© Festo Didactic CP Factory ° basic module branch

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Design and function

3.4

Mechanical construction

In contrast to the two-sided basic module, the branch module has been constructed for the operation from one side only. The rear side of the branch module has got two short conveyors for the inward and outward transfer of workpiece carriers. With the help of branchs the workpiece carriers are transferred outward in a loop or transferred inward from a loop. The basic module has been equipped with mechanically adjustable feet. If the moving of the basic module is required, you can lower the basic module onto its rollers and transport it easily.

1

2

Construction of the branch module - example

Position Designation

Branchs are in the position “do not transfer workpiece carriers outward”

Branchs are in the position „transfer workpiece carriers outward/inward“ (branch is optional)

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© Festo Didactic CP Factory ° Basic module branch

Design and function

The modules can be operated in two ways - as a single station or in combination with other modules. When combined with another module, it is necessary to replace the deflection at the end of the conveyor by a support plate. The branch is an exception, if this is operated as a single station, it is not possible to discharge or to infiltrate carriers.

1

2

3

Options for assembly example

With the pluggable deflections there are different possibilities to control the transport flow. Depending on this, different modules can be operated individually or in combination.

Position Designation

Operation as single station / not put together

Operation as single station / stations are put together

Operation in combination with an additional station

© Festo Didactic CP Factory ° basic module branch

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Design and function

18

Mounting as a single station – example

Position Designation

1+2 Corner pulley – the pallet carrier is reversed from one conveyor to the other conveyor on the branch module

© Festo Didactic CP Factory ° Basic module branch

Design and function

Example for mounting in combination with an additional module

Position Designation

1

Replacement guide board (support plate) in combination with an additional module – here the workpiece carrier is not reversed but transferred to the following module

Corner pulley – the workpiece carrier is reversed from one conveyor to the other conveyor on the module. 2

The corner pulley and the support plate have only been put together and can easily be exchanged without tools.

© Festo Didactic CP Factory ° basic module branch

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Design and function

3.4.1

Supply of the branch module

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3

4

1

2

CP Factory supply

Position Description

Inlet port for connection tube with voltage, communication and pneumatics

Connection plug K2-XZ1

Connection plug K2-XZ2

Outlet port for the connection tube of a further module

© Festo Didactic CP Factory ° Basic module branch

Design and function

Position Description

1

2

3

4

Emergency chain linking

Pressure

Network

400 V

© Festo Didactic CP Factory ° basic module branch

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Design and function

3.5

Electrical assembly

The branch module has got an electric board on the front side for the electrical components of the module.

This electric board has been mounted in the right part of the housing.

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Electric board front side Beispiel

© Festo Didactic CP Factory ° Basic module branch

Design and function

Electric board front side with Siemens controller

© Festo Didactic CP Factory ° basic module branch

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Design and function

Position Designation

10

11

12

13

6

7

8

9

14

15

3

4

5

1

2

CPU

Power supply unit 24 V

Emergency stop Unit

ELEC AUX CIRCUIT

Receptacle

Fuses

Emergency stop board

Clamps

I/O Terminal

Analog Terminal

Start-up current limiter

Start-up current limiter

Start-up current limiter

Start-up current limiter

Ethernet switch

BMK Description / Ordernumber

K5-KF1

K1-TB1

K1-F2-KF1

K1-FC4

K1-XJ4

Festo CECC / 574418

Festo CACN-3A-1-10 / 2247682

Siemens / 3SK1111-2AB30

Murr Elektronik / 9000-41042-0100600

K1-FC1 + K1-FC2

K1-F2-XZ2

K1 XD0-K1-XD13

K1-XD15

K1-XD16A

K1-QA1

K1-QA2

K1-QA3

K1-QA4

K1-XF1

UM 45-D15SUB/B

Kaleja M-MZS-4-30 / 06.05.020

Kaleja M-MZS-4-30 / 06.05.020

Kaleja M-MZS-4-30 / 06.05.020

Kaleja M-MZS-4-30 / 06.05.020

Siemens Scalance XB008 / 6GK5008-OBAOO-1AB2

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© Festo Didactic CP Factory ° Basic module branch

Design and function

Electric board front side with Festo controller

© Festo Didactic CP Factory ° basic module branch

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Design and function

Position Designation

10

11

12

13

6

7

8

9

14

15

16

3

4

5

1

2

CPU

Power supply unit 24 V

Emergency stop Unit

ELEC AUX CIRCUIT

Receptacle

Fuses

Emergency stop board

Clamps

Turck Interface

Start-up current limiter

Start-up current limiter

Start-up current limiter

Start-up current limiter

Ethernet switch

Analog Terminal

I/O Terminal

BMK Description / Ordernumber

K5-KF1

K1-TB1

K1-F2-KF1

K1-FC4

K1-XJ4

Festo CECC / 574418

Festo CACN-3A-1-10 / 2247682

Siemens / 3SK1111-2AB30

Murr Elektronik / 9000-41042-0100600

K1-FC1 + K1-FC2

K1-F2-XZ2

K1 XD0-K1-XD13

K5-KF2 – K5-KF41 Turck BL20-GWBR-CANOPEN

K1-QA1

K1-QA2

K1-QA3

K1-QA4

Kaleja M-MZS-4-30 / 06.05.020

Kaleja M-MZS-4-30 / 06.05.020

Kaleja M-MZS-4-30 / 06.05.020

Kaleja M-MZS-4-30 / 06.05.020

K1-XF1

K1-XD16A

K1-XD15

Siemens Scalance XB008 / 6GK5008-OBAOO-1AB2

UM 45-D15SUB/B

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© Festo Didactic CP Factory ° Basic module branch

3.5.1

Wiring Diagram

Design and function

Wiring diagram with Siemens controller

© Festo Didactic CP Factory ° basic module branch

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Design and function

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Wiring diagram with festo controller

© Festo Didactic CP Factory ° Basic module branch

3.5.2

Emergency-Stop Structure

Design and function

1

2

3

4

Structure of the emergency- stop system example

Position Name

Emergency-stop pushbutton F2-FQ1 / to emergency stop board X4:1: X4:3; X4:5; X4:7

Reset Pushbutton 1S2 / to PNOZ S33+S34; indicator light terminal strip 24VNA/0V+

Emergency stop board for emergency chain linking / F2-XZ2

Emergency stop Unit / F2-KF1

© Festo Didactic CP Factory ° basic module branch

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Design and function

Board Emergency-Stop interconnection

F2-XZ2-X1

Emergency-stop coupling input / If there is no previous station, you have to attach a bypass plug here or at the system plug.

F2-XZ2-X2

Emergency-stop coupling output 1 / If there is no subsequent station, you have to attach a bypass plug here or at the system plug.

F2-XZ2-X3

Emergency-stop coupling output 2 / for the connection of a further module or an external machine (e.g. for the basic module shunt – another module can be placed here at the junction, or a CNC processing machine, for example, can be placed at a bypass), otherwise you have to attach a bypass plug.

F2-XZ2-X4

Terminal clips for control panel, power supply, Emergency-stop relay.

Example for Emergency-stop linking with 3 modules

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© Festo Didactic CP Factory ° Basic module branch

Design and function

Enabling the Emergency-stop

If the Emergency-stop button has been pressed, a fault is indicated at the HMi. If you click on the message line at the top, the fault will be indicated in the main window.

1.

The emergency-stop situation is indicated in the message line. If you click on this line, the message will appear in the main window.

2.

Display of the emergency-stop situation.

3.

When the emergency-stop situation is eliminated, you have to disconnect the emergency-stop pushbutton. Then you have to press the blue illuminated pushbutton “Adjusting”. Now you can acknowledge the message by pressing the button at the HMI. The module can now be restarted.

4.

If the module has been connected with other modules, the emergency-stop is effective at all stations and must therefore be acknowledged at every station by pressing the illuminated push-button

“Adjusting” and acknowledging the error at the HMi

© Festo Didactic CP Factory ° basic module branch

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Design and function

3.5.3

Emergency-stop with central control

32

Structure of the emergency-stop system

At the central emergency-stop (power cabinet), a central emergency-stop control unit PNOZ-X8P is connected with one of the modules. The connection to one of the modules is effected by the energy supply.

Enabling the emergency-stop

If the emergency-stop has been pressed at any station, an error message is displayed at every HMI. First you have to find out the station where the emergency-stop has been pressed. At this module, you can click on the message line at the top at the HMI, where the error message will be displayed in the main window.

© Festo Didactic CP Factory ° Basic module branch

Design and function

1.

Emergency-stop situation is displayed in the message line. If you click on the line, the message will appear in the main window.

2.

Display of the emergency-stop situation.

3.

If the emergency-stop situation has been eliminated, you have to disconnect the emergency-stop pushbutton. After that, you have to press the blue illuminated pushbutton “adjusting”. Now you can acknowledge the message by pressing the button at the HMI. The module can now be re-started. The emergency-stop is effective at every station, therefore it has to be acknowledged at every station at the

HMI with the illuminated pushbutton “adjusting” and by acknowledging the error at the HMI. ?

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Design and function

3.5.4

Connection of application module

The mounting of an application module is very easy. At first, 2 slot nuts M5 are put into the front slot of the front cross profile. Then two other slot nuts are put into the back slot of the profile. Afterwards the slot nuts have to be adjusted to the distance of the application module profiles. The following example is exemplary for all application modules, these are all mounted in the same way.

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Put in slot nuts

Then you install the application module. The slot nuts must be placed now under the mounting brackets so that the screws can be fixed.

© Festo Didactic CP Factory ° Basic module branch

Design and function

Mounting of the application module

With fillister-head screws M5x8, the mounting brackets of the application module are now connected to the cross profiles, but not fastened yet. When all screws are placed, the application module can still be moved to the position required. Please make sure that the workpieces can be transferred correctly like here at the application module magazine. Once the position has been fixed, you only have to tighten the screws and to put the covers on the mounting brackets.

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Design and function

3.5.5

Pneumatic port of application module

Pneumatic port is done on the principle of the following sketch. The application module is connected from the valve terminal to the on-off valve at the conveyor. You only have to plug the tube (nominal size 4) into the QS plug.

Pneumatic connection of the application module

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© Festo Didactic CP Factory ° Basic module branch

Design and function

3.5.6

Electrical connection of applications

Connection with sys link plugs

The applications are connected to the electric board by I/O. The I/O terminal (1) of the application is connected to the I/O terminal XMA on the electric board (2).

The example refers to the connection to a basic module linear, it is possible that when connecting to another module the terminal designations of the I / O terminal differ.

If an application module has more than 8 I / O, the cable of the second I / O box is connected to the I / O terminal XMB on the electric board.

Electrical connection example with Festo controller

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Design and function

3.6

Commissioning

The module has got several components which have to be connected on commissioning. The procedure will be described in the following chapters.

3.6.1

Pneumatic commissioning

The mechanic assembly must be finished. First you have to connect the module to the pneumatic system of the room. The service unit required has to be provided by the customer and should be within close proximity. The quick coupling plug has got a nominal size of 5 mm. If the respective system is equipped with

7.9 mm nominal size it will be possible to exchange the coupling plug of the service unit by a bigger one

(adapter 1/8 to 1/4 required). Then the station can be supplied with 6 bar and the pneumatic commissioning is finished.

3.6.2

Electrical commissioning

Now the module must be supplied with electric voltage (400 V). The voltage has to be provided by the customer. Furthermore, an expert installation must be guaranteed.

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© Festo Didactic CP Factory ° Basic module branch

3.7

Adjusting the sensors

3.7.1

Proximity switch (stopper Identsensor)

Design and function

Position Description

1

Sensor stopper identify sensor / 150395 (SIEN-M8NB-PS-S-L)

1 position (BG21/BG31/BG41)

2 position (BG22/BG32/BG42)

3 position (BG23/BG33/BG43)

4 position (BG24/BG34/BG44)

Screw to clamp the sensor 2

The proximity switches are used for controlling the pallet.

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Design and function

Requirements

– Stopper unit is attached to the conveyor.

– Electrical connection of the proximity switches is set up.

– Power supply is available.

Procedure

1.

The stopper is in upper position, a pallet is stopped at the stopper.

2.

Shift the switch as long as the switching status display (LED) appears.

3.

Shift the proximity switch into the same direction by a few millimetres as long as the switching status display disappears.

4.

Shift the proximity switch halfway between the start-up and end position.

5.

Tighten the locking screw of the proximity switch with an Allen key SW 1,3.

6.

Check the position of the proximity switch by repeated removing the pallet.

Documents

Data sheets / operating instructions

Proximity Switch 150395 (SIEN-M8NB-PS-S-L)

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© Festo Didactic CP Factory ° Basic module branch

3.7.2

Proximity switch (stopper cylinder)

Design and function

Position Description

1

Sensor stopper down/ 574334 (SMT-8M-A-PS-24V-E-0,3-M8D)

(BG20) / (BG30) / (BG30) / (BG40)

The proximity switches are used for controlling the end position of the cylinder for the stopper. The proximity switches react to a permanent magnet on the piston of the cylinder.

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Design and function

Requirements

– Cylinder stopper is attached to the conveyor.

– Pneumatic port of the cylinder is set up.

– Compressed air supply is switched on.

– Electrical connection of the proximity switches is set up.

– Power supply is available.

Procedure

1.

The cylinder is in its end position to be queried.

2.

Shift the proximity switch as long as the switching status display (LED) appears.

3.

Shift the proximity switch into the same direction by a few millimetres as long as the switching status display disappears.

4.

Shift the proximity switch halfway between the start-up and end position.

5.

Tighten the locking screw of the proximity switch with an Allen key SW 1,3.

6.

Check the position of the proximity switch by repeated test runs of the cylinder.

Documents

Data sheets / operating instructions

Proximity Switch 574334 (SMT-8M-A-PS-24V-E-0,3-M8D)

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© Festo Didactic CP Factory ° Basic module branch

3.7.3

Proximity switch (branch cylinder)

Design and function

Position Description

1

2

Sensor outward transfer straight line/ 551373 (SMT-10M-PS-24V-E-2,5-L-OE)

(BG30)

Sensor outward transfer bend off/ 551373 (SMT-10M-PS-24V-E-2,5-L-OE)

(BG31)

The proximity switches are used for controlling the end position of the cylinder for the branch. The proximity switches react to a permanent magnet on the piston of the cylinder.

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Design and function

Requirements

– Branch is attached to the conveyor.

– Pneumatic port of the cylinder is set up.

– Compressed air supply is switched on.

– Electrical connection of the proximity switches is set up.

– Power supply is available.

Procedure

1.

The cylinder is in its end position to be queried.

2.

Shift the proximity switch as long as the switching status display (LED) appears.

3.

Shift the proximity switch into the same direction by a few millimetres as long as the switching status display disappears.

4.

Shift the proximity switch halfway between the start-up and end position.

5.

Tighten the locking screw of the proximity switch with an Allen key SW 1,3.

6.

Check the position of the proximity switch by repeated test runs of the cylinder.

Documents

Data sheets / operating instructions

Proximity Switch 551373 (SMT-10M-PS-24V-E-2,5-L-OE)

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© Festo Didactic CP Factory ° Basic module branch

3.8

Adjusting the one-way flow control valves

Design and function

1

2

One-way flow control valves

Pos Description

One-way flow control valves GRLA for stopper cylinder

One-way flow control valves GRLA for stopper cylinder

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Design and function

46

1

2

One-way flow control valves

Pos Description

One-way flow control valves GRLA for branch cylinder

One-way flow control valves GRLA for branch cylinder

© Festo Didactic CP Factory ° Basic module branch

Design and function

One-way flow control valves are used for the regulation of the exhaust air volume of double-acting drive units. In the opposite direction the air flows through the flow control valve having a full cross-sectional flow.

The piston is clamped between air cushions by free supply air and throttled exhaust air (improvement of the operating behaviour even if the load changes).

Requirements

– Pneumatic port of the cylinders is set up.

– Compressed air supply is switched on.

Procedure

1.

At first, turn off both one-way control valves completely. Then turn them on by about one rotation.

2.

Start a test run.

3.

Turn on the one-way flow control valves slowly as long as the required piston speed has been reached.

Documents

Data sheets

One-way flow control valve (193138)

3.9

Visual inspection

Visual inspection must always be done before starting up!

Before starting the station, please check:

• the electrical connections

• the correct fit and condition of the supply ports

• the mechanic components regarding visible faults (cracks, loose connections etc.)

• the function of the Emergency Stop

Please make sure that all damages discovered are removed before starting the station!

3.10

Starting up

For the basic module branch, an „initial start-up“ ex works has already been conducted. In order to be able to work with the modules and the applications, you have to carry out the following measures:

1.

You have to provide the mains supply 230 VAC for the module.

2.

The module is supplied by about 6 bar compressed air. On initial start-up, please pay attention to slowly increasing the pressure (herewith unpredictable events are prevented).

3.

Now you can work with the modules.

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Operation

4 Operation

The chapter operation describes the control units required for operating and their connections. The functions of the control units are freely programmable for the user and have not been assigned yet in delivery state.

The following operating instructions must therefore be considered universal.

4.1

General operating instructions

Operating the system requires some rules that have to be strictly observed. Any offence against these rules may cause errors in the process. Damage to physical health may also not be excluded. Users are strongly advised to stick to the following rules.

4.1.1

Conduct guidelines

Manual interference during the operation is prohibited.

• In case of a larger audience, a mechanical barrier is required.

It is prohibited to pull off any live cables.

• Keep away from water of any kind.

4.1.2

Operating guidelines

The systems may only be operated by instructed persons.

• Operation has to be effected according to the manual.

Any uncontrolled pressing of the various switches/buttons of all control units has to be prevented.

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4.2

The control units of the basic module branch

Operation

3

4

1

2

5

6

CP Factory control panel only at front side

Position Description

Main switch -QB1

Manometer

Touch Panel – PH1 / Festo panel or Siemens panel possible

Emergency- stop switch – F2-FQ1

Network socket- XPN3

Controller on pushbutton – F2-SF1

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Operation

4.2.1

Touch Panel

50

Siemens TP 700 Comfort

Supply voltage

Type of supply voltage

Rated value (DC) permissible range, lower limit (DC) permissible range, upper limit (DC)

Input current

Current consumption (rated value)

Starting current inrush I²t

Power

Power consumption, typ.

Processor

Processor type

Memory

Flash

RAM

Memory available for user data

DC

24 V

19.2 V

28.8 V

0.5 A

0.5 A²·s

12 W

X86

Yes

Yes

12 Mbyte

© Festo Didactic CP Factory ° Basic module branch

Operation

Festo CDPX Panel

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Operation

Feature

Recipe memory

Events per event buffer

Alarms

Java script file size per page

Supported PLC protocol

Real-time clock deviation

Number of colours

Number of system LEDs

Display

Display property

Display size

Backup battery

Operating voltage range DC

Display resolution

Nominal operating voltage DC

Current consumption at nominal operating voltage

CE mark (see declaration of conformity)

Storage temperature

Relative air humidity

Protection class

Ambient temperature

Authorisation

PLC interface

USB interface

Ethernet interface

Mounting type

Materials note

Programming software

values

WVGA, 800x480 Pixel

24 V

0,7 A to EU directive for EMC

-20 ... 70 °C

5 - 85 % non-condensing

IP65 front, IP20 back

0 ... 50 °C

C-Tick c UL us - Listed (OL)

Ethernet

RS485

Yes

RJ45 10/100 MBd

Front panel installation

Conforms to RoHS

Designer Studio

32 Kilobyte

2,048

2,000

8 Kilobyte

CODESYS 2.3

CODESYS 3.X

ModbusRTU Client

ModbusRTU Server

ModbusTCP Client

ModbusTCP Server

130 s / month

64 k

1

TFT colour

Touchscreen

7"

Li battery, rechargeable

18 ... 30 V

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© Festo Didactic CP Factory ° Basic module branch

4.3

Sequence description of the branch module

Operation

4

5

6

1

2

3

Position Description

Sensor straight track passed

Stopper branch feed in

Branch

Stopper basic track

Sensor branch track

Stopper branch

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Operation

Sequence description stopper feed in

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© Festo Didactic CP Factory ° Basic module branch

Operation

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Operation

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© Festo Didactic CP Factory ° Basic module branch

4.4

Switching on the station

1.

All EMERGENCY STOP signal transmitters (push buttons, door contact, light barriers, etc.) are not activated or activated and unlocked.

2.

Switch on the main switch

3.

Reset button lights up blue, HMI is started

4.

Acknowledge all errors and warnings at the HMI.

4.4.1

Sequence Description Automatic

1.

Press the Automatic button on the module's control cabinet.

2.

Stoppers are retracted

3.

Workpiece is transported in circulation mode

4.

The automatic button lights up blue, the automatic mode is displayed.

5.

If a carrier moves into the module / application module, this will execute your automatic process. The operation of the module / application module is, however, only started if the operation in MES is intended for this resource and the resource can also carry out this operation.

6.

The Busy displays become active.

7.

During this time, the automatic sequence is executed in the application.

8.

The next resource and operation are written to the RFID chip

9.

When the module / application module is ready, the display changes back to the original state and the stopper is retracted

10.

The carrier moves out of the working position and is available to further modules / application modules.

4.4.2

Process description Cycle End

1.

An automatic run is active.

2.

Press the button Cycle End.

3.

The module/application module will execute the run until cycle end. During this time, the button Cycle

End has got a red background.

4.

The stoppers are extended.

5.

The conveyors are stopped.

Operation

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Operation

4.5

Operating modes

4.5.1

Automatic mode

MES mode

In the MES mode, all processes of the MES software are started, executed and controlled centrally.

Therefore all stations must be set to the MES mode and the automatic mode must be started.

Default Mode

The automatic sequence is not centrally controlled in the default mode, all information from the transition tables (see chapter "Schematic process flow") is read and processed separately at each station.

4.5.2

Setting operation

In the setting operation, all sensors can be displayed and actuators can be controlled from the HMI. This is used in fault finding or on commissioning.

4.6

Operating the HMI touch panel

Operating the basic modules is always the same procedure. A basic module with the application module drilling serves as an example here. Any additional operating possibilities are described separately in the corresponding manuals. The operation is not depending on the type of the operating panel, Festo and

Siemens Panels have got the same functions.

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© Festo Didactic CP Factory ° Basic module branch

4.6.1

Menu architecture from operation panel

This description serves as an example; it is made with a base module and a drilling application. Some of the functions are not available if there is no application mounted.

Operation

4

5

6

Position Description

1

2

3

Description of menu (main or submenu) OR in case of an active Error or an error message, this field is also for announcement

Main menu (always shown the same)

Operating mode Home:

Here the module can be controlled, the mode (default / MES) can be selected, the automatic or the set-up mode can also be operated.

Operating mode Setup:

Here, the application can be operated manually in setup mode

Operating mode Parameter:

The parameters of the application are set here, a simulation can be started, the transitions can be defined, or the tape can be set

System type:

Here the system parameters such as language, time, etc. are set

Submenu in the main menu

Changing content, depending on the main menu

Changing content, depending on the main or submenu

Announcement of operation mode automatic or set up

Announcement of default or MES Mode

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Operation

4.6.2

Menu navigation

General operation notice

White buttons with blue letters – function is active

White buttons with black letters – function is not active

Blue buttons – function is active – waiting for insert

Grey buttons with grey letters – function not available at the moment

Grey buttons with blue letters – function can be executed

Green advice – Sensor/function is active

Orange device – announce an actor

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Position Description

1

2

If you click on the blue marked field (no matter where you are in the menu), the following window will open (Pos 2)

Operating window – the operating window is always the same and allows a fast operating of the station

© Festo Didactic CP Factory ° Basic module branch

4.6.3

Display operation modus

In the Home operating mode on the Overview page, different states can be displayed depending on the mode (MES or Default).

Operation

In the upper right-hand area, the order data of the workpiece carrier are displayed in the MES mode, while the RFID status code is displayed in the default mode.

The status of the application is displayed in the lower right area, which is independent of the selected mode.

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Operation

4.6.4

Operation mode Home

Submenu operating mode

62

4

5

1

2

3

Operation mode is active, the setup can be started or an operation mode can be selected.

Position Description

Reset Button

Automatic Button: An automatic sequence is started depending on the mode (Default / MES)

Setup button: Here the application module can be controlled manually and sensors can be displayed. To put an application module into operation or suitable for troubleshooting.

There is no difference in the mode - the setup mode is independent of the default or MES mode.

End Button: The currently active operating mode is stopped here.

Select the mode:

Default - Automatic sequence is executed with the stored transitions

MES software is fully controlled by MES software

© Festo Didactic CP Factory ° Basic module branch

Submenu overview MES Mode

Operation

Position Description

1

2

3

Application area: here the status of the mounted application is displayed or the parameters are entered.

Start: Green when started

Ready: Green when ready

Init Pos .: Green when the basic position is reached

Reset: Green when the application is directed

Busy: Green when the application processes an order

RFID busy: green if RFID should be activated

Application activate: green when the application is logged on to the basic module

Parameter 1: Display ob active parameter number

Parameter 2: Display ob active parameter number

Parameter 3: Display ob active parameter number

Parameter 4: Display ob active parameter number

Area Order Carrier ST1 - the information provided by MES are standing on the workpiece carrier

Carrier ID: Carrier number

ONo: Order number

OPos: Order position

PNo: Part number

OpNo: Operation number

ResID: Resource ID

Area Order Carrier ST2 - the information provided by MES are standing on the workpiece carrier

Carrier ID: Carrier number

ONo: Order number

OPos: Order position

PNo: Part number

OpNo: Operation number

ResID: Resource ID

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Operation

Submenu overview Default Mode

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© Festo Didactic CP Factory ° Basic module branch

Position Description

1

2

3

Application area: here the status of the mounted application is displayed or the parameters are entered.

Start: Green when started

Ready: Green when ready

Init Pos .: Green when the basic position is reached

Reset: Green when the application is directed

Busy: Green when the application processes an order

RFID busy: green if RFID should be activated

Application activate: green when the application is logged on to the basic module

Parameter 1: Display ob active parameter number

Parameter 2: Display ob active parameter number

Parameter 3: Display ob active parameter number

Parameter 4: Display ob active parameter number

Area RFID ST1 assembly position: here are the informations read out by the RFID tag ST1

In: here is the transition of the incoming condition

Out: here is the transition which is written down to the RFID before leaving the application module

Carrier init: Here you can specify whether the carrier is to be initialized. If this option is activated, every incoming product carrier is processed independently of the RFID condition code with the settings of the "Init" line of the transition table.

Number:

Set: determines in this context, how many goods carriers should be initialized according to the above procedure.

Act: Shows how many goods carriers have been initialized.

Area RFID ST2 assembly position: here are the informations read out by the RFID tag ST1

In: here is the transition of the incoming condition

Out: here is the transition which is written down to the RFID before leaving the application module

Carrier init: Here you can specify whether the carrier is to be initialized. If this option is activated, every incoming product carrier is processed independently of the RFID condition code with the settings of the "Init" line of the transition table.

Number:

Set: determines in this context, how many goods carriers should be initialized according to the above procedure.

Act: Shows how many goods carriers have been initialized.

Operation

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65

Operation

Submenu user

Here it is possible to create different operators. The function is independent of the selected mode (MES or default)

Click on the button "User Dialog" to open the following window.

66

If you click on the User or Password fields, the input window opens and the user data can be entered.

© Festo Didactic CP Factory ° Basic module branch

Here the user data can be entered, confirm with the return key.

Operation

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67

Operation

4.6.5

Operating mode Setup

The description in order to set up the installed application modules can be found in the respective manual of the application module.

Setup – belt 1-2

68

Position number description

1

2

3

4

5

Drive conveyor 1 right / left

Left: Conveyor moves counterclockwise to the left

Drive 1: Display conveyor belt 1

Right: conveyor moves clockwise to the right

To left: move conveyor to the left (actuator W1_QA1 is activated, lights up blue when active)

Slow pre selection: set the conveyor speed slowly

Slow: move the conveyor slowly (actuator W1_QA1 is activated, lights up blue when active)

To right: move conveyor to the right (actuator W1_QA1 is activated, lights up blue when active)

Drive conveyor 2 right / left

Left: Conveyor moves counterclockwise to the left

Drive 2: Display conveyor belt 2

Right: conveyor moves clockwise to the right

To left: move conveyor to the left (actuator W1_QA2 is activated, lights up blue when active)

Slow pre selection: set the conveyor speed slowly

Slow: move the conveyor slowly (actuator W1_QA2 is activated, lights up blue when active)

To right: move conveyor to the right (actuator W1_QA2 is activated, lights up blue when active)

Sensor BG26 Display conveyor input (light up green when active)

Sensor BG27 Display conveyor output (light up green when active)

Sensor BG56 Display conveyor input (light up green when active)

Sensor BG57 Display conveyor output (light up green when active)

© Festo Didactic CP Factory ° Basic module branch

Setup – belt 3-4

Operation

Position number description

1

2

3

4

5

Drive conveyor 3 right / left

Left: Conveyor moves counterclockwise to the left

Drive 3: Display conveyor belt 3

Right: conveyor moves clockwise to the right

To left: move conveyor to the left (actuator W1_QA3 is activated, lights up blue when active)

Slow pre selection: set the conveyor speed slowly

Slow: move the conveyor slowly (actuator W1_QA3 is activated, lights up blue when active)

To right: move conveyor to the right (actuator W1_QA3 is activated, lights up blue when active)

Drive conveyor 4 right / left

Left: Conveyor moves counterclockwise to the left

Drive 4: Display conveyor belt 4

Right: conveyor moves clockwise to the right

To left: move conveyor to the left (actuator W1_QA4 is activated, lights up blue when active)

Slow pre selection: set the conveyor speed slowly

Slow: move the conveyor slowly (actuator W1_QA4 is activated, lights up blue when active)

To right: move conveyor to the right (actuator W1_QA4 is activated, lights up blue when active)

Sensor BG26 Display conveyor input (light up green when active)

Sensor BG27 Display conveyor output (light up green when active)

Sensor BG56 Display conveyor input (light up green when active)

Sensor BG57 Display conveyor output (light up green when active)

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Operation

Setup – Stopper 1

70

Position number description

1

2

3

4

5

Shut down stopper down: Move stopper downwards (actuator G_MB20 is activated, lights up blue when active)

W1_MB20: Sensor W1_BG20 stopper down (lit green when active)

Stopper: display stopper

Area RFID

MES Mode: Display of order data

Default Mode: Display of the RFID state

Describe and read the RFID area initialize: set RFID data to zero read: Read out RFID data write: write current data on RFID

Delete data: all data in the input mask is deleted - not directly on the RFID (for easier entry)

Area Display of the active sensors (lit green when active) and actuators (lit orange if active) on the stopper

Display of the RFID read status

© Festo Didactic CP Factory ° Basic module branch

Setup – Stopper 2

Operation

4

5

Position number description

1

2

3

Shut down stopper down: Move stopper downwards (actuator W1_MB50 is activated, lights up blue when active)

W1_BG50: Sensor W1_BG50 stopper down (lit green when active)

Stopper: display stopper

Area RFID

MES Mode: Display of order data

Default Mode: Display of the RFID state

Describe and read the RFID area initialize: set RFID data to zero read: Read out RFID data write: write current data on RFID

Delete data: all data in the input mask is deleted - not directly on the RFID (for easier entry)

Area Display of the active sensors (lit green when active) and actuators (lit orange if active) on the stopper

Display of the RFID read status

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Operation

Setup – Stopper 3

Position number description

1

2

3

Shut down stopper down: Move stopper downwards (actuator W1_MB40 is activated, lights up blue when active)

W1_BG40: Sensor W1_BG40 stopper down (lit green when active)

Stopper: display stopper

Handshake signals Robotino

Sender: Sensor GF35 blue if active (send signal to Robotino - Robotino must be activated)

Receiver: Sensor KG35 green if active (Robotino detected)

Area Display of the active sensors (lit green when active) and actuators (lit orange if active) on the stopper

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© Festo Didactic CP Factory ° Basic module branch

Setup – Shunt

1

Position number description

Area Display of the active sensors (lit green when active) and actuators (lit orange if active) on the stopper

Operation

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73

Operation

4.6.6

Operation mode Parameters

Set parameters of the application module on the HMI

To set up the application module, the application module must be set to setup mode.

1.

On the Start screen, click Setup

74

Change to parameter page (1) and select application (2).

© Festo Didactic CP Factory ° Basic module branch

Operation

5

6

7

Position number description

1

2

3

4

Here the application module can be activated (tick set). If no application module is activated, the carrier is stopped at the stopper and released again without processing.

Here a simulation of the application module can be selected (tick set). This function is helpful if the application module is not available, but the function should be integrated into a process. See chapter operator assistance and simulate application on free AP

Here it can be determined in simulation mode whether a operator assistance or the application module should be simulated. See chapter operator assistance and simulate application on free AP

If the processing end is to be confirmed, a check mark must be set here. The process is only continued if this has been confirmed at the HMI, otherwise the process is automatically continued after the end of processing.

The desired return value can be entered here

Here you can enter the time required for the simulation.

If the check box is set when activating as an I-device, an i-application module must also be located at the working position. This means that the application module has its own intelligence. This intelligence is then responsible for controlling the application. In the case of an application without its own intelligence, this is adopted by the controller of the basic module and no check is to be made.

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75

Operation

Submenu transitions 1

If the submenu Transitions is selected, the transitions of the mounted application module are displayed.

The transitions of all other application modules can be found in the corresponding manuals of the application modules.

Submenu transitions 2

76

If the transitions 2 submenu is selected, the transitions of the points are displayed.

© Festo Didactic CP Factory ° Basic module branch

Submenu conveyor 1

Position number description

1

2

3

4

Stop belt 1 before start application: the belt is stopped before the application begins to start

Belt 1 Start / Stop by sensors: Hook set when the belt should be switched automatically with the sensors.

Switch on when Sensor at belt beginning signals a carrier, switch off when the sensor at the end of the belt signals the carrier passing by

Belt 1 energy saving mode with sensors:

If no workpiece is detected on the belt via the sensors, the belt is switched off

Stopper 1: Check the jam at the belt outlet:

The carrier is only released from the stopper if the belt is not occupied at the belt outlet.

Operation

© Festo Didactic CP Factory ° basic module branch

77

Operation

Submenu conveyor 2

78

Position number description

1

2

3

4

5

Belt 2 Start / Stop by sensors: Hook set when the belt should be switched automatically with the sensors.

Switch on when Sensor at belt beginning signals a carrier, switch off when the sensor at the end of the belt signals the carrier passing by

Belt 2 energy saving mode with sensors:

If no workpiece is detected on the belt via the sensors, the belt is switched off

Stopper 2: Check the jam at the belt outlet:

The carrier is only released from the stopper if the belt is not occupied at the belt outlet.

At 0% branch off, all carriers without order automatically go straight over the branch. at 50%, every second carrier without an order bends at the branch at 100%, each carrier bends without an order

This setting can be used to ensure that "empty" carriers pass behind the branch. For example, if there is a

AS/RS from where products are released.

Option docking with robotino activated:

If a robotino is to pick up / deliver the carrier at the branch, this option must be activated with a hock.

© Festo Didactic CP Factory ° Basic module branch

4.6.7

Operation mode System - settings

Operation

3

4

5

12

13

14

8

9

6

7

10

11

15

16

The system can be set in this operation mode

Position number Description

1

2

Button Calibrate Screen - If buttons react inaccurately, calibration of the touch screen can be restored

Button call cleaning screen - the screen can be cleaned here. The touch function is interrupted and unintentional operation is excluded

Daylight time set – activate summer time

Daylight time reset – activate winter time

Send test mail – send test mail to eMailserver (all error messages are sent from the hmi to a eMailserver on the MES4 PC – this function is to test if the configuration is ok.)

Terminate Runtime: The runtime is terminated and returned to Windows.

Button system control: Windows system control is opened

Button Transfer: Runtime is closed and the transfer mode of the HMI is called

Flag displays only current language. By clicking on button next to the flag language can be switched

Button switch language: here the language can be changed

Input field for date / time. Click on the "Set time & date" button to accept date / time

Display date and time of the PLC

Display date and time of the HMI touch panel

Display of the MES IP address additionally the IP of the MES can be set here. (Password protected) User: festo,

PW: festo)

Input fields for your own resource number, query port and status port of the MES connection

Button set time & date: The time and date of the HMI touch panel can be set here.

© Festo Didactic CP Factory ° basic module branch

79

Operation

4.7

Operator assistance and simulate application on free AP

The following chapter is valid for all basic modules (Bypass, Linear, branch). It is explained by way of example on the basic module Linear.

80

Selection of the mode via the touch panel

Each free application position, which is not equipped with an application module, can provide a simple operator assistance and a simulate application.

Thus every free AP provides the following functions in default mode as well as in MES mode:

1.

Generic sequence simulation

2.

Operator assictance

The application function is added with a fitted application module

1.

Process simulation of the application

2.

Operator assictance

3.

Application Function

© Festo Didactic CP Factory ° Basic module branch

4.7.1

Generic sequence simulation

1.

If the mode is simulate application and a carrier moves into the application, it is stopped. The application procedure is simulated, this is indicated by the following screen.

Operation

2.

The processing time in this case is 10 sec. This can be set in the parameters. The current time is indicated by the bar in progress. At the end of the simulation, the return value is transferred to MES.

3.

The carrier is released from the application position.

© Festo Didactic CP Factory ° basic module branch

81

Operation

4.7.2

Operator assistance with display of pictures

82

7

8

5

6

9

10

2

3

4

0

1

1.

If the mode is set to operator assistance (application mode must be set to Standard) and a carrier moves into the application, it will be stopped.

2.

The worker now has to complete the specified work task. This is specified in the transition table and consists of the element (parameter 1) and the action (parameter 2).

Parameter 1 / Element Parameter 2 / Aktion

No element

Front cover

Back cover

Printed circuit board

Front fuse (in direction of transport)

Rear fuse (in direction of transport)

Both fuses

Workpiece

Reserve_8

Reserve_9

Reserve_10

7

8

5

6

9

10

2

3

4

0

1

No action

Check

Extract

Assemble

Insert

Apply

Rework

Reserve_7

Reserve_8

Reserve_9

Reserve_10

© Festo Didactic CP Factory ° Basic module branch

3.

In this case, element 2 and action 4 are specified in the transitions. The worker must insert a backcover.

4.

If the worker has completed the task, he must press the Confirm button to complete the task. The data is transmitted to MES

5.

The carrier is released from the application position.

Operation

© Festo Didactic CP Factory ° basic module branch

83

Operation

4.7.3

Operator assistance with call of htm-page

1.

If the mode of the application is set to "operator assistance" (application mode must be set to call of

HTML page / only possible in MES mode) and a carrier moves into the application, it will be stopped.

2.

The worker now has to complete the specified work task. This is described on a html page, which must be created by the customer. The URL of this page, which must be present on the MES PC, can be specified in the work plan of the MES. This worker guide (depending on the html page content) is started if the OpNo 510 is selected for the AP in the work plan and the URL points to this URL link in the work step

84

3.

In this case, the html page was designed so that a work instruction for mounting the front fuse appears in the worker's guidance.

4.

If the worker has completed the task, he must press the Confirm button to complete the task. The data is transmitted to MES

5.

The carrier is released from the working position.

© Festo Didactic CP Factory ° Basic module branch

4.8

Automatic operation

4.8.1

Start automatic

The operation is the same for all application modules and modules, for the description the basic module is used with an application module Drilling.

The general rule:

A blinking button is a prompt to start an action.

A button with a glowing background indicates that the action described on the button is currently being executed.

A gray button with a blue font indicates that this function is selectable.

1.

Switch on the station and wait until HMi is raised. The following screen appears

Operation

2.

Press Setup button

© Festo Didactic CP Factory ° basic module branch

85

Operation

3.

Select the default or MES mode, for the example the default mode is selected

4.

Press the automatic button

86

5.

Automatic is active

© Festo Didactic CP Factory ° Basic module branch

4.8.2

Stop automatic

6.

Press the cycle end button, the automatic sequence is immediately stopped.

Operation

© Festo Didactic CP Factory ° basic module branch

87

Operation

4.9

Manually describe the RFID tag

In order to describe a goods carrier with a specific ID, or to get information on which data is stored on the goods carrier, it is possible to read this data or to describe the tag.

For this, it is necessary that a goods carrier with a functioning tag is at one of the stopper positions and the station is switched on.

88

1.

Activate the default mode.

2.

Select the Setup mode

3.

Select the stopper from the setup menu on the left

4.

If an RFID is detected, this is indicated by "tag present". (TF80 and button "tag present" are green)

5.

The data of the RFID tag can be read out and displayed by pressing the "read" button.

6.

Press the Delete Data button

For easier input, all data is only deleted in the input mask, the data remains on the tag itself.

© Festo Didactic CP Factory ° Basic module branch

7.

Enter the desired data in the field (all fields which are white in background can be edited)

MES Mode

Carrier ID - displays or enter the carrier number

ONo - the order number is displayed or entered here

OPos - the order position is displayed or entered here

PNo - the part number is displayed or entered here

Resource - here the resource is displayed or entered

Operation - the number of the operation is displayed or entered here

DefaultMode

State code - here the state code for the start condition is entered, if these match the transition tables, the parameters are read out and the automatic sequence of the application is started.

Parameter 1 = 1 - Input of the 1 parameter value (e.g., 1 / left side drilling)

Parameter 1 = 2 - Enter the 2 parameter value (e.g., 2 / right side drilling)

Parameter 1 = 3 - Input of the 3 parameter value (e.g., 3 / both sides drilling)

Parameters 2 - 4 - not used in this example

8.

Press the "Write" button to write the changes made to the tag.

Operation

© Festo Didactic CP Factory ° basic module branch

89

Components

5 Components

5.1

Electrical components

5.1.1

2 Quadrant Controller

90

Description

Electronics for DC motors excited by magnet up to about 200 W

The module M-MZ-4-30 is a two-quadrant motor control for DC motors with anti-clockwise and clockwise rotation. It guarantees a safe starting and stopping as well as the control of the rotational direction of motors. In off-state, the load is short-circuited which results in a dynamic braking. By the inlet SLOW, you can switch over from slow speed (adjustment at Tr1) to high speed. At the inlet STOP a limit switch can be installed.

Use:

Motor controls for brushed motors

Electronic load relay for solenoid valves and various loads

Characteristics

Anti-clockwise and clockwise rotation

Switch-over from high speed to the speed adjusted at the TR.1

Port for limit switch for stop

Short-circuit proof and temperature protected

Limitation for starting circuit

© Festo Didactic CP Factory ° Basic module branch

Technical Data

Type: M-MZS-4-30 / Item No. 06.05.020

Technical Data

Control circuit

Input A1/A2

A1=Start clockwise

A2=Start anticlockwise

Input A3/A4

A3=slow drive

A4=Stop

Start wave

Stop wave

Allowed range

Shift wave

Allowed range

8

5

0-35

8

0-35

Adjustment range for turning speed with trimmer at front plate (typical)

0 to max. turning speed

Start delay at A1 and A2 to 24V < 2

Load circle Nominal voltage (power supply) Ub/range

Load current/constant load

Input current at Un /without load circle

Loading current Imax. T=1 sec.

Current detection at short

De-energize time at short

24 (19-30)

3/5 depends on switching frequency

T 10 mA

20

95 Typ. (45-140)

80-400

Other data Current entry at stop

Allowed surrounding temperature

DIN VDE-regulations

Any assembly position / DIN-rail assembly

<20

-20 to +40

0110, 0160 in parts

No / Yes

Housing

Dimensions

Weight

Temperature / short guard

Connection type screw connection

Plastic housing light grey

59x77x50

Approx. 100

Yes / Yes

4mm², 2,5mm²

Yes

(ms)

(VDC)

(A)

(mA)

(C°)

(mA)

(A)

A

µs

G mm

(V)

(V)

(V)

(V)

(V)

Components

© Festo Didactic CP Factory ° basic module branch

91

Components

Connection Diagramm

92

Motor MA1

Input/Output

Control – K5-KF10 / Q0.0 / 0x:1

Control – K5-KF10 / Q0.1 / 0x:2

Control – K5-KF10 / Q0.2 / 0x:3

Conveyor motor DC / -XJM1:4

Conveyor motor DC / -XJM1:3

Starting Current Limiter

QA1 / X1:re

QA1 / X1:li

QA1 / X1:sl

QA1 / X2:M1

QA1 / X2:M2

Description

Transport 1: direction to the right

Transport 1: direction to the left

Transport 1: slow speed

Conveyor motor connection

Conveyor motor connection

© Festo Didactic CP Factory ° Basic module branch

Motor MA2

Input/Output

Control – K5-KF10 / Q0.3 / 0x:4

Control – K5-KF10 / Q0.4 / 0x:5

Control – K5-KF10 / Q0.5 / 0x:6

Conveyor motor DC / -XJM2:4

Conveyor motor DC / -XJM2:3

Motor MA3

Input/Output

Control – K5-KF10 / Q0.6 / 0x:7

Control – K5-KF10 / Q0.7 / 0x:8

Control – K5-KF10 / Q1.7 / 0x:8

Conveyor motor DC / -XJM3:4

Conveyor motor DC / -XJM3:3

Motor MA4

Input/Output

Control – K5-KF10 / Q0.6 / 0x:7

Control – K5-KF10 / Q0.7 / 0x:8

Control – K5-KF10 / Q1.7 / 0x:8

Conveyor motor DC / -XJM3:4

Conveyor motor DC / -XJM3:3

Starting Current Limiter

QA2 / X1:re

QA2 / X1:li

QA2 / X1:sl

QA2 / X2:M1

QA2 / X2:M2

Starting Current Limiter

QA3 / X1:re

QA3 / X1:li

QA3 / X1:sl

QA3 / X2:M1

QA3 / X2:M2

Starting Current Limiter

QA4 / X1:re

QA4 / X1:li

QA4 / X1:sl

QA4 / X2:M1

QA4 / X2:M2

Description

Transport 2: direction to the right

Transport 2: direction to the left

Transport 2: slow speed

Conveyor motor connection

Conveyor motor connection

Description

Transport 3: direction to the right

Transport 3: direction to the left

Transport 3: slow speed

Conveyor motor connection

Conveyor motor connection

Description

Transport 4: direction to the right

Transport 4: direction to the left

Transport 4: slow speed

Conveyor motor connection

Conveyor motor connection

Components

© Festo Didactic CP Factory ° basic module branch

93

Components

5.2

PLC Siemens

94

Siemens ET 200 SP / CPU 1512SP F-1PN

For detailed information see electrical circuit diagram.

© Festo Didactic CP Factory ° Basic module branch

5.3

PLC Festo CECC

The Festo controller is just one part (order number; 574418-CECC-LK)

Components

Festo CECC

Position Description

1

2

USB interface

Ethernet interface RJ 45

3 CanOpen interface

Comment

For external memory

For external PC (for programming with CodeSys) or for external operation panel

CDPX

To connect CanOpen slaves

© Festo Didactic CP Factory ° basic module branch

95

Components

5.4

Turck Interface

96

Turck interface

For detailed information see electrical circuit diagram.

© Festo Didactic CP Factory ° Basic module branch

5.5

Scalance Ethernet Switch

Components

Siemens Scalence X208 Ehternet switch

The SCALANCE X208 has eight RJ-45 jacks for the connection of end devices or other network segments.

© Festo Didactic CP Factory ° basic module branch

97

Components

Product properties

SCALANCE X-208

Operating Instructions, 12/2011, A5E00349864-19

TP ports / Connector pinout

On the SCALANCE X208, the TP ports are implemented as RJ--45 jacks with MDI-X assignment (Medium

Dependent Interface–Autocrossover) of a network component.

RJ-45 jack

Pin number

Assignment

Pin 8 n. c.

Pin 7 n. c.

Pin 6 TD-

Pin 5 n. c.

Pin 4 n. c.

Pin 3 TD+

Pin 2 RD-

Pin 1 RD+

NOTICE

TP cords or TP-XP cords with a maximum length of 10 m can be connected to the RJ-45

TP port. With the IE FC cables and IE FC RJ-45 plug 180, an overall cable length of up to 100 m is permitted between two devices depending on the cable type.

Autonegotiation

Autonegotiation means the automatic detection of the functionality of the port at the opposite end. Using autonegotiation, repeaters or end devices can detect the functionality available at the port of a partner device allowing automatic configuration of different types of device. With autonegotiation, two components connected to a link segment can exchange parameters and set themselves to match the supported communication functionality.

Note

If an IE switch port operating in autonegotiation mode is connected to a partner device that is not operating in autonegotiation mode, the partner device must be set permanently to half duplex mode. If an IE switch port is set permanently to full duplex, the connected partner device must also be set to full duplex. If the autonegotiation function is disabled, the MDI/MDI-X auto crossover function is also inactive. This means it may be necessary to use a crossover cable.

98

© Festo Didactic CP Factory ° Basic module branch

Note

The SCALANCE X208 is a plug-and-play device that does not require settings to be made for commissioning.

MDI /MDIX autocrossover function

The advantage of the MDI /MDIX autocrossover function is that straight-through cables can be used throughout and crossover Ethernet cables are unnecessary. This prevents malfunctions resulting from mismatching send and receive wires. This makes installation much easier for the user. IE Switches X-200 support the MDI / MDIX autocrossover function.

NOTICE

Please note that the direct connection of two ports on the switch or accidental connection over several switches causes an illegal loop. Such a loop can lead to network overload and network failures.

Auto polarity exchange

If the pair of receiving cables are incorrectly connected (RD+ and RD- swapped over), the polarity is reversed automatically.

Components

© Festo Didactic CP Factory ° basic module branch

99

Components

5.6

RFID with Ethernet

100

3

4

5

6

7

1

2

Turck - BLCEN-2M12MT-2RFID-A

The Ethernet module with RFID Interface has got the equipment identifier K2-KF80

Position Order Number 6811484

Ethernet connection RSSD-RSSD 441-2M

Ethernet connection RSSD-RSSD 441-2M

Rotary coding switch for addressing

RFID connection socket RK4.5T-5-RS4.5T/S2500 for read-write head 1

RFID connection socket RK4.5T-5-RS4.5T/S2500 for read-write head 2

Power supply

Power supply

© Festo Didactic CP Factory ° Basic module branch

I/O data mapping

The BLident RFID-a interface modules cannot be controlled by the process data only. In any case, there is a software functional module required in the control. The functional module has been standardized for the

RFID systems and is called Proxy Ident Block (PIB).

Input Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Chanel 0

Chanel 1

2

3

0

1

Output Byte

Status word channel 0- low byte

Status word channel 0- high byte

Status word channel 1- low byte

Status word channel 1- high byte

Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Chanel 0

Chanel 1

2

3

0

1

Bit 7 Bit 6 Bit 5

Control word channel 0- low byte

Control word channel 0- high byte

Control word channel 1- low byte

Control word channel 1- high byte

Components

© Festo Didactic CP Factory ° basic module branch

101

Components

102

Wiring of the Ethernet module to the RFID interface (example)

Pos Name

3

4

5

1

2

6

7

Turck read-write head TB-M18-H1147 (equipment identifier G-TF80)

Turck read-write head TB-M18-H1147 (equipment identifier G-TF81)

Controller ET200SP / CPU 1512SP F-1PN (equipment identifier K5-KF1)

Ethernet cable from Turck module to controller (via Scalance)

Turck cable from Turck read-write head to Turck module

Turck cable from Turck read-write head to Turck module

Turck Ethernet module with RFID interface (equipment identifier K2-KF80)

© Festo Didactic CP Factory ° Basic module branch

Components

RFID read-write head

The Turck RFID read-write head is mounted on the stopper unit on the conveyor.

Its designation is TB-M18-H1147.

Name

Operating voltage

DC rated operating current

Operating voltage

Data transfer

Working frequency

Read-write distance

10…30 VDC

0-80 mA

DC

Inductive coupling

13,56 MHz max. 30 mm

© Festo Didactic CP Factory ° basic module branch

103

Components

5.7

RFID with CanBus

104

Read/write head

Metal thread M18 x 1

Application

Switching output

Operating voltage [V]

Current consumption [mA]

Protection class

Operating frequency [MHz] standard

Distance to the ID tag * [mm]

Distance between read/write heads [mm]

Ambient temperature [°C]

Storage temperature [°C]

Protection

Displays / operating elements

Connection

Wiring

4

5

2

3

Detection of objects on transport equipment and in mobile applications

CANopen interface

9...32 DC

< 50 (24 V) / < 80 (12 V)

III

13.56

ISO 15693

≤ 18

≥ 50 side

≥ 100 front

-40...85

-40...85

IP 67 / IP 69K

1 LED green continuous light Preoperational mode

1 LED green flashing light Operational mode

1 LED Red flashing light Error

1 LED yellow continuous light tag communication

M12 connector

1 Not used

U+

GND

CAN_H

CAN_L

© Festo Didactic CP Factory ° Basic module branch

5.7.1

Mini Terminal

Components

Multi-pin plug distributor

The multi-pin plug distributor is designed for the inputs and outputs of the station. You can connect PNP sensors and two-pole actuators there. The connection is effected by three-pole M8x1 plugs, and the bus terminal by a 15pole sub-D plug connector. The operating status is displayed on yellow LEDs.

Pin allocation on the multi pin plug distributor

Pin allocation 15pole sub-D plug connector

Signal lines Pin 1 to Pin 12

• DC 24V

0V

Pin 13

Pin 14 and Pin 15

Pin allocation M8 socket corresponding to IEC 947-5-2

• slots 0 to 11

Signal line

• DC 24V

0V socket 4 socket 1 socket 3

© Festo Didactic CP Factory ° basic module branch

105

Components

XD20 – Multi pin distributor MPV1

15-pole D-Sub Pin Bit

3

4

5

1

2

6

7

8

9

10

11

12

13

14 and 15

7

8

9

10

3

4

1

2

5

6

11

12

13

14 and 15

XD30 – Multi pin distributor MPV2

15-pole D-Sub Pin Bit

Bit 6

Bit 7

Bit 8

Bit 9

Bit 0

Bit 1

Bit 2

Bit 3

Bit 4

Bit 5

Bit 10

Bit 11

+24 V

0V

Bit 0

Bit 1

Bit 2

Bit 3

Bit 4

Bit 5

Bit 6

Bit 7

Bit 8

Bit 9

Bit 10

Bit 11

+24 V

0V

Name

Stopper before outward transfer / -BG20

Stopper before outward transfer / -MB20

Pallet available identity sensor 1 / -BG21

Reserve

Identity sensor 2 / -BG22

Reserve

Identity sensor 3 / -BG23

Reserve

Identity sensor 4 / -BG24

Reserve

Option / downstream station free 1

Reserve / Option station occupied 1

Name

Outward transfer straight line / -BG30

Outward transfer / -MB30

Outward transfer bend off / -BG31

Reserve

Reserve

Reserve

Reserve

Reserve

Downstream station free 2 - option

Station occupied 2 - option

Downstream station free 3 - option

Station occupied 3 - option

106

© Festo Didactic CP Factory ° Basic module branch

3

4

5

1

2

6

7

8

9

10

11

12

13

14 and 15

XD40 – Multi pin distributor MPV3

15-pole D-Sub Pin Bit

7

8

9

10

3

4

1

2

5

6

11

12

13

14 and 15

XD50 – Multi pin distributor MPV4

15-pole D-Sub Pin Bit

Bit 6

Bit 7

Bit 8

Bit 9

Bit 0

Bit 1

Bit 2

Bit 3

Bit 4

Bit 5

Bit 10

Bit 11

+24 V

0V

Bit 0

Bit 1

Bit 2

Bit 3

Bit 4

Bit 5

Bit 6

Bit 7

Bit 8

Bit 9

Bit 10

Bit 11

+24 V

0V

Name

Stopper before infiltration / -BG40

Stopper before infiltration / -MB40

WT with stopper before infiltration / -BG41

Reserve

Gate area free (deflection) / -BG42

Reserve

Reserve

Reserve

Reserve

Reserve

Gate area free (straight) / -B45

Reserve

Name

Stopper 2/ -BG50

Stopper 2 / -MB50

Pallet available identity sensor 1 / -BG51

Reserve

Identity sensor 2 / -BG52

Reserve

Identity sensor 3 / -BG53

Reserve

Identity sensor 4 / -BG54

Conveyor infeed / BG56

Reserve

Conveyor outlet / BG57

© Festo Didactic CP Factory ° basic module branch

Components

107

Components

108

Pos

7

8

9

10

11

3

4

5

6

1

2

Designation

IN 1

IN 2

IN 3

IN 4

IN 5

Mounting hole

15 pole sub-D plug

PIN 1

PIN 9

Mounting hole M3

IN 0

Pos

18

19

20

21

12

13

14

15

16

17

Designation

OUT 2

OUT 3

OUT 4

OUT 5

Inscription label

PIN 8

PIN 15

Inscription label

OUT 0

OUT 1

© Festo Didactic CP Factory ° Basic module branch

5.7.2

SYS link interface

Components

01

02

03

04

05

06

07

08

09

10

11

12

Syslink allocation

SYSlink PIN Bit

2

3

0

1

4

5

6

7

24V

24V

0V

0V

Description

Output AX.0

Output AX.1

Output AX.2

Output AX.3

Output AX.4

Output AX.5

Output AX.6

Output AX.7

Power Supply

Power Supply

Power Supply

Power Supply

Syslink PIN Bit

13

14

15

16

17

18

19

20

21

22

23

24

2

3

0

1

4

5

6

7

24V

24V

0V

0V

Function

Input EX.0

Input EX.1

Input EX.2

Input EX.3

InputEX.4

Input EX.5

InputEX.6

Input EX.7

Power Supply

Power Supply

Power Supply

Power Supply

© Festo Didactic CP Factory ° basic module branch

109

Components

5.8

Mechanic components

5.8.1

Motor of Conveyor

110

Motor type 403438

The motor has got the equipment identifier / 3M1

Name

Nominal voltage UN /Volt

Idling speed n0 [min-1]

Rated torque MN [Nm]

Starting torque MA [Nm]

Gear ratio i

Connection resistance 2 vanes R [m

 ]

Connection resistance 4 vanes R [m

 ]

Protection class IP 30

Weight [kg]

36

120

2

16

53/2

3400

3000

30

1

© Festo Didactic CP Factory ° Basic module branch

5.8.2

The stopper unit

Components

3

4

5

1

2

6

7

8

9

CP Factory Stopper Unit

Position Description

Turck TB-M18-H1147 RFID read-write head / IFM DTM424 RFID read write head

Pallet available Ident sensor 1 / Ordernumber 150395 / SIEN-M8NB-PS-S-L

Pallet available Ident sensor 2 / Ordernumber 150395 / SIEN-M8NB-PS-S-L

Pallet available Ident sensor 3 / Ordernumber 150395 / SIEN-M8NB-PS-S-L

Pallet available Ident sensor 4 / Ordernumber 150395 / SIEN-M8NB-PS-S-

Stopping unit

Stopper cylinder / Ordernumber 157211 / AEVUZ-16-5-P-A

Sensor Stopper lowered / Ordernumber 574334 / SMT-8M-A-PS-24V-E-0,3-M8D one-way flow control valve / Ordernumber. 193967 / GR-QS-4

© Festo Didactic CP Factory ° basic module branch

111

Components

Diagram of pneumatics, Stopper Unit

112

© Festo Didactic CP Factory ° Basic module branch

5.8.3

The branch

Position Description

3

4

1

2

BG45 – gate area free (straight)

BG42 – gate area free (deflection)

BG30 – outward transfer straight line

BG31 – outward transfer bend off

Components

© Festo Didactic CP Factory ° basic module branch

113

Components

5.8.4

Transportation of the Basic Module branch

114

1

2

3

CP Factory Transportation methode

With the help of mechanically adjustable feet, you can lower the Basic Module ByPass and then put it on the rollers. In this way, an easy transport is possible. If you wind up the machine mounts, you can move the

Basic Module ByPass easily to another place.

Position Description

Star knob for adjusting the height of the machine mount

Roller

Lock nut for locking the machine mount in the position required

© Festo Didactic CP Factory ° Basic module branch

Festo Didactic SE

Rechbergstraße 3

73770 Denkendorf

Germany

Internet: www.festo-didactic.com

E-mail: [email protected]

© Festo Didactic CP Factory ° basic module branch

Components

115

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