Festo CP Lab User manual

Brand: Festo

Model: CP Lab

Type: User manual

Festo Didactic

CP Lab

05/2018

CPLab®

Manual

Branch

SAP Number

8058667

2 © Festo Didactic CP Lab ° Branch

Order number: 8092740

Status: 05/2018

Layout: 05/2018, Schober, Weiss

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

Internet: www.festo-didactic.com

E-Mail: [email protected]om

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

1 General safety instructions __________________________________________________________________ 5

1.1 Pictograms ___________________________________________________________________________ 6

1.2 Safety sockets_________________________________________________________________________ 7

1.3 Handling the system ___________________________________________________________________ 8

1.3.1 Dangers in handling the machine _____________________________________________________ 8

1.3.2 Safety precautions in standard operation ______________________________________________ 8

1.3.3 Dangers due to electric current _______________________________________________________ 8

1.3.4 Dangers due to pneumatic energy ____________________________________________________ 8

1.3.5 Maintenance – Servicing – Malfunction removal _________________________________________ 9

1.3.6 Organizational measures ____________________________________________________________ 9

1.3.7 Energy limiting _____________________________________________________________________ 9

1.3.8 Safe handling______________________________________________________________________ 9

1.4 Personnel ___________________________________________________________________________ 10

1.4.1 Notes on personnel ________________________________________________________________ 10

1.4.2 Training operations ________________________________________________________________ 10

1.4.3 Outside training operations _________________________________________________________ 10

1.5 Obligations of the operating company ____________________________________________________ 10

1.6 Obligations of the trainees _____________________________________________________________ 10

2 Introduction _____________________________________________________________________________ 11

2.1 Warranty and liability __________________________________________________________________ 11

2.2 Important notes ______________________________________________________________________ 11

2.3 Resources ___________________________________________________________________________ 12

3 Design and function _______________________________________________________________________ 14

3.1 Transport ____________________________________________________________________________ 14

3.2 Set up ______________________________________________________________________________ 14

3.2.1 General information _______________________________________________________________ 14

3.3 The CP Lab branch ____________________________________________________________________ 15

3.4 Stopper unit _________________________________________________________________________ 18

3.5 Branch ______________________________________________________________________________ 19

3.6 Connecting the CP Lab Switch ___________________________________________________________ 20

3.6.1 Pneumatic commissioning __________________________________________________________ 20

3.6.2 Electrical commissioning ___________________________________________________________ 21

3.6.3 Emergency stop system ____________________________________________________________ 22

4 Operation _______________________________________________________________________________ 23

4.1 Start the automatic sequence ___________________________________________________________ 23

4.2 Software Festo _______________________________________________________________________ 24

4.2.1 Find and select the PLC _____________________________________________________________ 24

4.2.2 Download the project ______________________________________________________________ 28

4.2.3 The PLC can be reset _______________________________________________________________ 32

5 Components _____________________________________________________________________________ 34

5.1.1 RFID Read/Write system ____________________________________________________________ 34

5.2 Controller Festo CECC __________________________________________________________________ 35

5.3 Valve terminal ________________________________________________________________________ 36

6 Extensions ______________________________________________________________________________ 37

Content

4 © Festo Didactic CP Lab ° Branch

6.1 Extension with an active corner _________________________________________________________ 37

6.2 Extension with a passive corner _________________________________________________________ 39

7 Spare part list ____________________________________________________________________________ 41

General safety instructions

1 General safety instructions

The laboratory or the classroom must be equipped in accordance with EN 50191:

 An emergency off device must be provided.

– At least one emergency off device must be located within, and one outside of the test area.

 The test area must be secured against unauthorised start-up.

– For example with a key switch

 The test area must be protected by residual current devices (RCDs).

– Type B residual current circuit breaker with a residual current rating of ≤ 30 mA

 The test area must be protected by overcurrent protection devices.

– Fuses or circuit breakers

 The test area must be overseen by a supervisor.

– A supervisor is a qualified electrician or a person who has received appropriate instruction, has

knowledge of the respective safety requirements and safety regulations and whose training has been

accordingly documented.

 No damaged or defective devices may be used.

– Damaged devices must be barred from further use and removed from the test area.

 24Vdc external power supply must be PELV and limited energy (150VA max)

General requirements for safe operation of the devices:

 Do not lay cables over hot surfaces.

– Hot surfaces are identified with a corresponding warning symbol.

 Maximum permissible current loads for cables and devices must not be exceeded.

– Always compare the current ratings of the device, the cable and the fuse.

– In the event that these are not the same, use a separate upstream fuse in order to provide

appropriate overcurrent protection.

 Devices with an earth terminal must always be grounded.

– If an earth connection (green-yellow laboratory socket) is available, it must always be connected to

protective earth. Protective earth must always be connected first (before voltage), and must always be

disconnected last (after voltage).

 If not otherwise specified in the technical data, the device is not equipped with an integrated fuse.

Warning

This is a Class A product. In a domestic environment, this product may cause radio

interference in which case the user may be required to take adequate measures

General safety instructions

6 © Festo Didactic CP Lab ° Branch

1.1 Pictograms

This document and the described hardware include warnings concerning possible hazards which may arise if

the system is used incorrectly. The following pictograms are used:

Warning

Non-observance of this pictogram may result in serious personal injury or damage

to property.

Caution

Non-observance of this pictogram may result in personal injury or damage to

property.

Warning

This pictogram indicates that the device must be switched off and its mains plug

must be removed from the electrical outlet before installation, repair, maintenance

and cleaning work. Observe the manual, in particular all safety instructions. Non-

observance may result in severe personal injury or damage to property.

Warning

This pictogram indicates danger of being burned if hot surfaces (up to roughly

85 C) are touched.

Important

This symbol emphasizes important information for correct machine handling.

Failure to pay attention to this symbol may result in damages to the machine or to

its surroundings.

Information

This symbol indicates operational tips and especially useful directions. This

symbol assists you to make optimal use of all of your machine’s functions.

General safety instructions

1.2 Safety sockets

If not otherwise specified in the technical data, the following colour codes apply to the power supply and

signal connections for components included in Festo Didactic’s learning system for automation and

technology.

Colour

Function

Colour

Function

Voltage greater than SELV

e.g. line voltage of 90 to 400 V AC per conductor

(grey)

24 V DC

(red)

Neutral conductor

(grey/blue)

0 V DC

(blue)

Protective conductor

(green-yellow)

Safety extra-low voltage,

signal input/output

(black)

The specified protection class and safe use can only be assured if laboratory safety cables supplied by Festo

Didactic are used.

Damaged laboratory safety cables must be immediately barred from further use

and removed from the test area.

4mm safety plugs can enter socket/outlet of other voltage systems.

PE 4mm plug can be disconnected without a tool.

General safety instructions

8 © Festo Didactic CP Lab ° Branch

1.3 Handling the system

1.3.1 Dangers in handling the machine

The installation has been constructed technologically up to date and in conformance with the recognized

rules of safety engineering. Nevertheless, during operation it is possible that harm might be caused to the

user or third parties or that the installation or other property might get damaged. Therefore, the installation

has to be handled according to specified operational use in perfect technical condition only.

Safety endangering malfunctions cannot be tolerated during training and have to be removed immediately.

The system is to be used only:

 for its intended purpose and

 In absolutely safe conditions.

Faults impairing safety must be rectified immediately!

1.3.2 Safety precautions in standard operation

Put the installation into operation only, once all of the protection settings are completely functional.

At least, before starting operation, check the installation for externally visible damages and for the reliability

of the safety devices.

Do not grip into the installation while in operation.

Before circuit construction, circuit disassembly and circuit modification: switch off air pressure and power

supply.

General safety regulations are to be observed: DIN 58126 and VDE 0100.

1.3.3 Dangers due to electric current

As soon as maintenance is completed, check the function reliability of the safety devices.

Only trained experts in electric or electronic engineering are permitted to carry out work on the electric

supply system.

The terminal boxes are to be kept closed at all times. Access must be permitted only under supervision of a

member of the training staff.

Do not activate electric limit switches manually during fault search. Tools are to be used.

Only low voltage 24VDC is to be used.

Warning: There is a risk of arc flash, direct electric shock or indirect electric shock

if unit is power with wrong type of voltage source

1.3.4 Dangers due to pneumatic energy

Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt air pressure supply

immediately. Caution! When the air pressure supply is activated, cylinders may move in or out.

Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In this case, keep on holding

the end of the tube. Do not exceed the permitted operating pressure. See data sheets.

General safety instructions

1.3.5 Maintenance – Servicing – Malfunction removal

Carry out adjustments and inspections as instructed, in accordance with the specified intervals. (see

Datasheets)

Secure the compressed air and electricity supplies to prevent unintentional start-up. During inspections,

maintenance and repair work, the machine must be de-energized, de-pressurized and secured against

unexpected restart. All screw connections released during maintenance, inspection or repair work must be

checked to ensure correct re-tightening.

1.3.6 Organizational measures

All existing safety devices must be checked at regular intervals.

1.3.7 Energy limiting

There is a risk of fire if power supply is not of the energy limited (150VA) type

1.3.8 Safe handling

Safe handling of heavy equipment must be guaranteed! There is a risk of musculoskeletal harm if

instructions are not followed.

General safety instructions

10 © Festo Didactic CP Lab ° Branch

1.4 Personnel

1.4.1 Notes on personnel

Basically two situations have to be considered, concerning matters on personnel.

 Activities during training operations

 Activities outside training operations

1.4.2 Training operations

Trainees are permitted to work with the machine only under strict supervision of an experienced person or

an instructor.

Activities of trouble-shooting and fault correction are to be checked by the instructor. Special care should be

taken regarding safety aspects.

1.4.3 Outside training operations

Activities in the areas of maintenance, service and repair are to be carried out by only persons with

appropriate technical qualifications.

1.5 Obligations of the operating company

The operating company undertakes to allow only those persons to work with the system who:

 Are familiar with the basic regulations regarding work safety and accident prevention and have been

instructed in the use of the system

 Have read and understood the chapter concerning safety and the warnings in this manual

Personnel should be tested at regular intervals for safety-conscious work habits.

1.6 Obligations of the trainees

All persons who have been entrusted to work with the system undertake to complete the following steps

before beginning work:

 Read the chapter concerning safety and the warnings in this manual

 Observe the basic regulations on occupational safety and accident prevention.

Introduction

2 Introduction

2.1 Warranty and liability

In principle all our „Terms and Conditions of Sale“ apply. These are available to the operating authority

upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage

are excluded if these can be traced back to one or several of the following causes:

 Use of the system not in accordance with its intended purpose

 Incorrect assembly, commissioning, operation and maintenance of the system

 Operation of the system using faulty safety equipment or incorrectly fitted or non-operational safety or

protective devices

 Non observance of notes in the manual regarding transport, storage, assembly, commissioning,

operation, maintenance and setting up of the system

 Unlawful constructional modifications on the system

 Inadequate monitoring of components subject to wear

 Incorrectly carried out repairs

 Catastrophes as a result of foreign bodies and vis major.

Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and/or

other third parties which may occur during the use/operation of the system other than purely in a training

situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.

2.2 Important notes

The basic requirement for safe use and trouble-free operation of the system is to observe the fundamental

safety recommendations and regulations.

This manual contains important notes concerning the safe operation of the system.

The safety recommendations in particular must be observed by anyone working on the system.

Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be

observed.

Introduction

12 © Festo Didactic CP Lab ° 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:

Pallet carrier

These pallet carriers are available for transporting the pallets.

Pallet

These pallets are available for receiving always one workpiece.

Introduction

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

14 © Festo Didactic CP Lab ° Branch

3 Design and function

3.1 Transport

Care is to be taken that the transport of the stations is to be executed only by a suitable transport vehicle.

Warning

The route of transport is to be cleared in advance, to be accessible to the transport

vehicle. Installation of warning signs or barriers may be required.

The transport boxes are to be opened with care, as additional components, such

as computers may be contained in the delivery, which are to be protected from

falling out.

Attention

Once the transport box has been opened and the possibly contained additional

components removed, the station can be taken out to be transported to its

destination by means of two fork-lifts or one fork-lift truck.

Please check the stability of all of the profile connectors by means of an Allen key

size 6. The connectors may have come loose during transport, due to inevitable

vibration.

Pay special attention to all overhanging components. Sensors and similar small

parts are very easily damaged in case of improper transport.

The stations are not to be picked up by or even under the mounted feet –

increased risk of becoming trapped or contused.

3.2 Set up

3.2.1 General information

The installation is to be set up in a frost-free room with maximum relative air humidity of 70%.

In countries with an atmospheric humidity over 70% and temperatures above 25 degrees Celsius are the

premises to provide an air-conditioning system for constant surroundings conditions.

To comply with the regulatory guidelines, sources of electrical interference such as welding plants, large

motors and contactors are to be checked for electromagnetic compatibility in advance and screened where

necessary.

To ensure fault-free operation a load-bearing floor is required to avoid settling.

Allow sufficient distance between the installation and the wall of the room.

Any dust originating from construction work has to be kept off the installation (by covering).

Design and function

3.3 The CP Lab branch

The CP Lab switch consists of

 a 80mm wide and 700mm long conveyor with a branch. The length of the branch is 300mm and consists

of an executing and an introductory band.

 a base frame

 a control box for the control system and other electrical components

 Coupling sensors are located on the base frame to facilitate simple communication with other, directly

connected CP Lab tapes.

 Capacitive sensors are located at the beginning and at the end of the CP Lab tape, which detect the

pallet on the conveyor belt.

 A switch which can guide the goods carriers onto the conveyor belt or straight out

 three 24 V motors

The task of the CP Lab switch is to carry out warp carriers with and without workpieces on CP Factory

Module or a Robotino. In addition, goods can be imported from CP Factory modules or from a Robotino into

the CP Lab system.

Design and function

CP Lab branch front view

Position

Description

Position

Description

Valve terminal

Scalance Ethernetswitch (option)

24V Power supply XZ3 – motor MA3

Emergency switch

24V Power supply XZ2 – motor MA2

Switch automatic on SF2

24V Power supply XZ1 – motor MA1

Capacitive sensor conveyor end

Festo PLC CECC-LK

Conveyor / insert conveyor

Branch

Insert stopper Q4MB4

Stopper main conveyor

Separating stopper Q4MB3

Capacitive sensor conveyor start BG13

Coupling sensor transmitter GF8

Conveyor / Main conveyor

Conveyor / separating conveyor

Coupling sensor forward station

Coupling sensor receiver KF8

Starting current limiter QA2 - motor MA2

Design and function

CP Lab branch rear view

Position

Description

Position

Description

Starting current limiter QA3 - motor MA3

Starting current limiter QA1 - motor MA1

Coupling sensor next station BG14

Design and function

3.4 Stopper unit

The stopper unit is located bevor the separating conveyor of the CP Lab branch. The carrier runs over the

extended stopper unit. The screw (pos. 1 picture below) runs into the slot of the carrier. At the end of the

slot the carrier is stopped.

With the help of the sensors at the stopper unit, the carrier can be identified. There are two ways for

identifying:

 Variant 1

It is identified by 4 inductive sensors; for this exercise, the carriers may be provided with grub screws at

different positions.

 Variant 2

The identity is read by the RFID sensor.

Position

Description

Position

Description

Stopper and guide screw for carrier

Inductive sensor

150395 / SIEN-M8NB-PS-S-L

Sprung stopper ratchet

Inductive sensor

150395 / SIEN-M8NB-PS-S-L

Sensor for stopper retracted

574334 / SMT-8M-A-PS-24V-E-0,3-M8D

Inductive sensor

150395 / SIEN-M8NB-PS-S-L

Stopper

157211 / AEVUZ-16-5-P-A

Inductive sensor

150395 / SIEN-M8NB-PS-S-L

Flow control supply air

193967 / GR-QS-4

RFID read-write head M18

Siemens 6GT2821-1AC32

Flow control exhaust air

193967 / GR-QS-4

Design and function

3.5 Branch

Position

Description

Position

Description

Lever to separate carriers

One-way flow control valves inlet air

193967 / GR-QS-4

Turning cylinder

1565425 / DSM-T-6-90-P-FW

One-way flow control valves outlet air

193967 / GR-QS-4

Proximity switch

551373 / SMT-10M-PS-24V-E-2,5-L-OE

Branch position straight BG1

Branch position separating BG2

Design and function

3.6 Connecting the CP Lab Switch

All sensors and actuators are permanently wired to the controller and do not have to be connected.

Communication is via Ethernet directly with the PLC.

3.6.1 Pneumatic commissioning

The mechanic mounting must be finished and completed. At first you have to connect the CP Lab branch to

the pneumatic system of the room. The corresponding service unit has to be provided by the customer and

should be placed right next to it. The quick coupling plug has got a nominal size of 5 mm. If the local system

has got a nominal size of 7.9 mm, it is possible to exchange the quick coupling plug of the service unit for a

bigger one (adapter 1/8 to 1/4 necessary).

Now the station can be supplied by 6 Bar and the pneumatic commissioning is completed.

The connection is made at the valve terminal (1)

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Festo CP Lab User manual

Festo CP Lab User manual

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