Festo CP Factory User manual

Festo Didactic

CP Factory

02/2018

CP Factory

®

Manual

Basic module branch

2 © Festo Didactic CP Factory ° Basic module branch

Order number:

Status: 02/2018

Layout: 02/2018, Schober, Weiss

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

Internet: www.festo-didactic.com

E-Mail: did@de.festo.com

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

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.

Content

3

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

Content

4 © Festo Didactic CP Factory ° Basic module branch

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

General safety instructions

5

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.

General safety instructions

6 © Festo Didactic CP Factory ° Basic module branch

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.

General safety instructions

7

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)

24 V DC

(red)

neutral conductor

(grey/blue)

0 V DC

(blue)

protective earth conductor

(green-yellow)

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.

General safety instructions

8 © Festo Didactic CP Factory ° Basic module branch

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.

General safety instructions

9

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.

Introduction

10 © Festo Didactic CP Factory ° Basic module branch

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.

Introduction

11

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:

Pallet carrier

These pallet carriers are available for transporting the pallets.

Pallet

These pallets are available for receiving always one workpiece.

Introduction

12 © Festo Didactic CP Factory ° Basic module branch

External production parts

Workpieces Description

CP back cover

no 111

CP board

no 120

CP fuse

no 130

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.

Production parts

Workpieces Description Workpieces Description

CP no fuse

no 211

CP part no fuse

no 1211

CP fuse on the left

No. 212

CP part fuse on the left

No. 1212

CP fuse on the right

no 213

CP part fuse on the right

no 1213

CP fuses both

no 214

CP part both fuses

no 1214

CP part customer

no 1210 freely selectable

Design and function

13

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

14 © Festo Didactic CP Factory ° Basic module branch

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.

CP Factory Basic module branch

Design and function

15

Position Description

1 Corner pulley/no other module attached

2 Conveyor front side

3 Main switch

4 Manometer

5 Stopper unit front side

6 Maintenance unit

7

Touch panel

Variant 1 / Festo panel

Variant 2 / Siemens panel

8 Ethernet interface

9 Supply lines

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

11 Stopper inward transfer

12 Conveyor inward transfer

13 Conveyor outward transfer

14 Branch outward transfer

15 Stopper unit back side

16 Conveyor rear side

17 Corner pulley/no other module attached

18 Emergency stop button

19 Controller on pushbutton

20 E-Board

21 Pressure switches (option for energy monitoring)

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.

Construction of the branch module - example

Position Designation

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

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

Design and function

17

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.

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

1 Operation as single station / not put together

2 Operation as single station / stations are put together

3 Operation in combination with an additional station

Design and function

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

Design and function

19

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

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

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

tools.

Design and function

3.4.1 Supply of the branch module

CP Factory supply

Position Description

1 Inlet port for connection tube with voltage, communication and pneumatics

2 Connection plug K2-XZ1

3 Connection plug K2-XZ2

4 Outlet port for the connection tube of a further module

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Festo CP Factory User manual

Festo CP Factory User manual

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