Festo CP Lab User Manual

Download

CPLab®

Manual CP Lab conveyor

Festo Didactic CP Lab 03/2017

Order-No.: Date: 07/2017 Layout: 07/2017, Schober Filename: CP-L-CONV-GB-A001.doc

Note

Where only pronouns such as he and him are used in this manual, these pronouns are of course intended to refer to both male and female persons. The use of a single gender should not be construed as gender discrimination; it’s intended solely to make the manual easier to read and the formulations easier to understand.

Intended use

This installation was developed and manufactured for 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.

Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any third parties occurring when the installation is used for any purpose apart from training, except Festo Didactic has caused such injury or harm intentionally or by grossly negligence.

At CP factory installations, it is not permissible to experiment with hazardous live voltages.

Reproduction, distribution and utilisation of this document, as well as the communication of its contents to others without explicit authorisation, are prohibited. Offenders shall be held liable for payment of damages. All rights reserved, in particular the right to file patent, utility model and registered design applications.

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

2 © Festo Didactic CP Lab conveyor

Content

1 General safety instructions ________________________________________________________________ 5

1.1 Pictograms _________________________________________________________________________ 6

1.2 Safety sockets ______________________________________________________________________ 7

1.3 Note to electrical access of facility ______________________________________________________ 7

1.4 Handling the system _________________________________________________________________ 8

1.4.1 Dangers in handling the machine ___________________________________________________ 8

1.4.2 Safety precautions in standard operation _____________________________________________ 8

1.4.3 Dangers due to electric current _____________________________________________________ 8

1.4.4 Dangers due to pneumatic energy ___________________________________________________ 8

1.4.5 Maintenance – Servicing – Malfunction removal ________________________________________ 8

1.4.6 Organizational measures __________________________________________________________ 9

1.5 Personnel __________________________________________________________________________ 9

1.5.1 Notes on personnel _______________________________________________________________ 9

1.5.2 Training operations _______________________________________________________________ 9

1.5.3 Outside training operations ________________________________________________________ 9

1.6 Obligations of the operating company ___________________________________________________ 9

1.7 Obligations of the trainees ____________________________________________________________ 9

2 Introduction ___________________________________________________________________________ 10

2.1 Warranty and liability ________________________________________________________________ 10

2.2 Important notes ____________________________________________________________________ 10

2.3 General information CP Lab system ____________________________________________________ 11

2.3.1 Application modules _____________________________________________________________ 12

2.4 Resources _________________________________________________________________________ 19

3 Design and function ____________________________________________________________________ 21

3.1 Transport _________________________________________________________________________ 21

3.2 Set up ____________________________________________________________________________ 21

3.2.1 General information _____________________________________________________________ 21

3.3 The CP Lab conveyor ________________________________________________________________ 22

3.4 Stopper unit _______________________________________________________________________ 24

3.5 Drive variants ______________________________________________________________________ 26

3.6 Signal generator ____________________________________________________________________ 28

3.7 Electrical connections _______________________________________________________________ 29

3.8 Connecting a CP Lab ________________________________________________________________ 31

3.8.1 Pneumatic Commissioning ________________________________________________________ 31

3.8.2 Electrical Commissioning _________________________________________________________ 32

3.8.3 Modus switch __________________________________________________________________ 33

3.8.4 Emergency Stop System __________________________________________________________ 34

3.9 Extended functions with applications ___________________________________________________ 35

3.9.1 Assembly of the application _______________________________________________________ 35

3.9.2 Pneumatic connection of applications _______________________________________________ 37

3.9.3 Electrical connection of applications ________________________________________________ 38

3.10 Commissioning ____________________________________________________________________ 42

4 Operation _____________________________________________________________________________ 43

4.1 Software Siemens __________________________________________________________________ 43

Content

4.1.1 Compile the device configuration __________________________________________________ 43

4.1.2 Load device configuration into PLC _________________________________________________ 43

4.2 Software Festo _____________________________________________________________________ 47

4.2.1 Find and select the PLC ___________________________________________________________ 47

4.2.2 Download the project ____________________________________________________________ 51

4.2.3 The PLC can be reset _____________________________________________________________ 55

4.3 Menu structure of the CP Lab screen ___________________________________________________ 57

4.3.1 Menu prompting ________________________________________________________________ 58

4.4 Operation _________________________________________________________________________ 65

4.4.1 Message line and window ________________________________________________________ 67

4.4.2 Display of objects _______________________________________________________________ 68

5 Components __________________________________________________________________________ 69

5.1 Touch panel _______________________________________________________________________ 69

5.1.1 Front PCB XZ1 __________________________________________________________________ 70

5.1.2 Back PCB XZ2 __________________________________________________________________ 71

5.1.3 SYS link Cable - Interface _________________________________________________________ 73

5.1.4 RFID Read/Write system __________________________________________________________ 74

5.1.5 IO-Link DA-Interface (digital-analogue interface) ______________________________________ 75

5.1.6 Control systems ________________________________________________________________ 76

5.1.7 Signal Converter ________________________________________________________________ 78

5.1.8 Solenoid valve __________________________________________________________________ 80

6 Extensions ____________________________________________________________________________ 81

6.1 Extension with an active corner ________________________________________________________ 81

6.2 Extension with a passive corner _______________________________________________________ 83

4 © Festo Didactic CP Lab conveyor

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.

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.

General safety instructions

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. Nonobservance 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.

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:

6 © Festo Didactic CP Lab conveyor

General safety instructions

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)

Damaged laboratory safety cables must be immediately barred from further use and removed from the test area.

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.

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

1.3 Note to electrical access of facility

According to EN 60204-1 (VDE 0113-1) part 8.2.8, a supply cable with an additional protective conductor is required for the supply of the CP factory installations. Since a leakage current of >10mA can flow depending on the configuration, an additional protective conductor with 10mm² is necessary.

Please see also DIN EN 60204-1.

General safety instructions

Faults impairing safety must be rectified immediately!

1.4 Handling the system

1.4.1 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.

1.4.2 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.

1.4.3 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.

1.4.4 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.

1.4.5 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.

8 © Festo Didactic CP Lab conveyor

General safety instructions

1.4.6 Organizational measures

All existing safety devices must be checked at regular intervals.

1.5 Personnel

1.5.1 Notes on personnel

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

 Activities during training operations  Activities outside training operations

1.5.2 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.

1.5.3 Outside training operations

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

1.6 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.

1.7 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.

10 © Festo Didactic CP Lab conveyor

Introduction

2.3 General information CP Lab system

The Festo Didactic Learning System is designed to meet a number of different training and vocational requirements. The modules of the CP Lab are industry-orientated vocational and further training. The hardware consists of didactically for didactic training industrial components. The stations provides an appropriate system for practice-orientated education/classes of the following key qualifications

 Social competence,  Technical competence and  Method competence

Moreover, training can be provided to instil team spirit, willingness to cooperate and organizational skills. Actual project phases can be taught by means of training projects, such as:

 Planning,  Assembly,  Programming,  Commissioning,  Operation,  Maintenance  Fault finding and  Trouble shooting.

This manual describes the handling of the pallet transfer system. It contains explanations and descriptions of all the processes required for operation. Facts are partly described with the help of graphics or images sub serving an easier understanding.

The CP Lab system is developed for all apprentices who want to move something. It doesn’t matter if the education is for electro- or metal profession, for mechatronics, technician- or engineer education.

Concept

During technical lessons for pupils we use our simple models with O-ring drive. In the CP Lab system the material flow is realized with a common industrial belt. In industrial, automated production, special belts are essential part of the production system. Products with different measurements are transported on belts with different widths or on double belts.

Transfer system with modules

The transfer system is a modular system which consists of two essential components. First the transfer line which can be equipped with different drive concepts and second the constitutive modules for topics like sensors, electrical positioning, handling, assembling, camera inspection, barcode scanning, RFID and many others.

Introduction

2.3.1 Application modules

 CP application module output

For removing workpieces from the system Complexity medium, electro pneumatic module

 CP application module drilling

For drilling housing parts Complexity simple, electro pneumatic module

12 © Festo Didactic CP Lab conveyor

Introduction

 CP application module iDrilling

For drilling housing parts Complexity simple, electro-pneumatic module with controller with web interface for cyber-physical system

 CP application module labeling

In order to label workpieces with a label Complexity high, electro pneumatic module

Introduction

 CP application module manual work

For the manual processing of pallets and / or workpieces on a stopper Complexity simple, software module

 CP application module Camera inspection

With camera for checking object properties Complexity high, Festo Camerasystem with evaluation software

14 © Festo Didactic CP Lab conveyor

Introduction

 CP application module magazine

For feeding housing parts. Different in the magazine rear cover and magazine front cover Complexity simple, electro pneumatic module

 CP application module Measuring

For quality assurance Complexity high, processing of analog input signals

Introduction

 CP application module Muscle press

For pressing the housing parts Complexity simple, electro pneumatic module (pneumatic muscle)

 CP application module Pick by light

Hand workplace where workpieces are provided for assembly. Complexity, electrical module

16 © Festo Didactic CP Lab conveyor

Introduction

 CP application module press

For pressing the housing parts Complexity simple, electro pneumatic module

 CP application module heat tunnel

For heating workpieces for thermal processing Complexity medium to high, control engineering module with analog processing and PWM

Introduction

 CP application module turning

For turning workpieces Complexity medium, electro pneumatic module

18 © Festo Didactic CP Lab conveyor

Introduction

2.4 Resources

The training equipment of this system consists of several resources to be used depending on the process selection. The following resources are available:

Carrier

These carriers are available for the transport of the pallets.

Pallet

These pallets are available for receiving one workpiece each.

Introduction

Workpiece

description

CP back cover No. 111

CP – Platine Nr. 120

CP Fuse Nr. 130

CP front cover

No. 110 - Is a CNC milling machine in the plant, the front cover can also be produced there and thus becomes the production part.

Workpiece

description

workpiece

description

CP without fuse

No. 211

CP customer part without fuse

No. 1211

CP fuse left

No. 212

CP Customer part with fuse left

No. 1212

CP fuse right

No. 213

CP Customer part with fuse right

No. 1213

CP both fuses

No. 214

CP Customer part with both fuses

No. 1214

CP customer part

No. 1210

External production parts

Production parts

20 © Festo Didactic CP Lab conveyor

Design and function

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 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.

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 conveyor

The CP Lab conveyor consists of

 a 80mm wide and 700mm long pallet transfer system  a basic frame  a control cabinet for controlling and further electrical components  a control panel on a mike boom  On the basic frame, there are coupling sensors for an easy communication with other directly connected

CP Lab conveyors.

 At the start and at the end of the CP Lab conveyor, there are capacitive sensors which recognize the

pallet on the CP Lab conveyor.

 A stopper unit with different ways of identification which stops and identifies the pallet.  A 24V geared motor which can be replaced by other motors. On the motor, there is an incremental

encoder for detecting the rotational speed.

The CP Lab conveyor is designed for transporting pallets with workpieces to move back and forth or for transporting them to further CP Lab conveyors. Easy tasks can be realized here. It is also possible to extend the CP Lab conveyor with different applications. This way, the field of activity can be extended as desired.

22 © Festo Didactic CP Lab conveyor

Design and function

Position

Description

Position

Description

Carrier

Scalance Ethernet switch (optional)

On-off valve

Control panel / Touch panel

Capacitive sensor start of conveyor

Basic frame

Conveyor

Control cabinet for electrical components and controlling

Coupling sensor previous station

Pallet transfer system front view

Design and function

Position

Description

Position

Description

Stopper unit

2-quadrant controller for motor

Valve with manual override for stopper unit

24 V motor

Capacitive sensor end of conveyor

IO-Link DA-Interface

Coupling sensor following station

Circuit board backside XZ2

CP Lab conveyor rear view

3.4 Stopper unit

The stopper unit is located in the middle of the CP Lab conveyor. 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. It is also possible to use the first of the inductive sensors for controlling; in this case the first grub screw is read and reports the position of the workpiece at the stopper.

24 © Festo Didactic CP Lab conveyor

Design and function

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

Valve stopper with manual override 574351 / VUVG-L10-M52-MT-M5-1P3

Design and function

3.5 Drive variants

It makes no difference whether it is a DC motor, an AC motor or a servo motor – the conveyor can be combined with all motors in no time. The professional couplings or toothed belt drives impart a maximum of industrial practice with the best possible didactic modularity.

24 V DC geared motor

3x230 V AC three phase asynchronous motor with gear unit and self-ventilation

26 © Festo Didactic CP Lab conveyor

Design and function

400 V AC asynchronous motor with gear unit and self-ventilation

Design and function

Position

Description

Light barrier channel B (BG7) / signal or coupling sensor is selectable with switch on the circuit board (left turning signal, right coupling sensor)

Light barrier channel A (BG8) / signal or coupling sensor is selectable with switch on the circuit board (left turning signal, right coupling sensor)

3.6 Signal generator

The drive unit is provided with an encoder with 8 cut-outs. The encoder is interrogated by 2 light barriers, which makes the evaluation of the rotational speed possible. One turn is 125,6mm

28 © Festo Didactic CP Lab conveyor

Design and function

3.7 Electrical connections

Electrical connections

The shaft encoder has got 2 channels, channel A is connected with the output unit BG8, channel B is connected with the output unit BG7. The output units can be connected alternatively to the coupling sensors. (left turning signal, right coupling sensor) The iPort is connected to the I/O link master of the ET200 SP. Instead of the controller, it is possible to install a I/O Terminal.

Design and function

Further electrical connections

The potentiometers of the control panel are connected to the 15 pole SubD plug on the control panel. There are also 4 I/O signals on this plug. The cable is connected to XZ1 /X12. The external power supply is connected with lab cables at the XZ1. With the SYSlink plug, applications are connected to the controller.

30 © Festo Didactic CP Lab conveyor

Design and function

Position

Description

Supply air from room supply or compressor

Air connection for applications

3.8 Connecting a CP Lab

The CP lab has got several components which have to be connected when starting up. The description for the procedure will be explained in the following chapters.

3.8.1 Pneumatic Commissioning

The mechanic mounting has to be completed and finished. At first, the CP Lab conveyor has to be connected to the pneumatic system of the room. The required service unit has to be provided by the customer and should be in the immediate vicinity of it. The quick coupling plug has got a nominal size of 5mm. If the present system is provided with a nominal size of 7.9mm, it is possible to replace the quick coupling plug of the service unit by a bigger one (an adapter 1/8 to ¼ will be required). After execution, the station can be supplied with 6bar, and the pneumatic commissioning is finished.

Pneumatic connection

Design and function

3.8.2 Electrical Commissioning

Now the CP Lab conveyor has to be supplied with electric power (24V). The external power supply has to be connected as follows: 0V to XZ2 clamp 1 24V to XZ2 clamp 2 PE to XZ2 clamp 4 The appliances are connected to the other corresponding clamps.

Wiring the CP Lab conveyor

32 © Festo Didactic CP Lab conveyor

Design and function

3.8.3 Modus switch

Independent if the Festo Didactic IO-Link-DA-Interface is used as IO-Link-Device or an field bus node, the wiring of the I-Port-interface hast to be changed. This is done by the circuit board: Switch position: Lower position 1=CTEU: A field bus node can be set on the Festo Didactic IO-Link-DA-Interface. Upper position 2= IO-Link: The Festo Didactic IO-Link-DA-Interface is used as an IO-Link-device.

Design and function

3.8.4 Emergency Stop System

The touch panel is provided with an Emergency Stop mushroom actuator. With a 5 pole cable, the Emergency Stop mushroom actuator is connected to the power supply XZ1. The voltage (24VDC) is supplied to the system with the clamp XZ1 from an external power supply unit. As a permanent positive (24VB), this voltage is then lead into the touch panel with the M12 cable. In the touch panel, the first NC contact of the Emergency Stop mushroom actuator connects the switched positive (24VNA) with 24VB. That means, if you press the Emergency Stop mushroom actuator, the 24VNA will be separated from 24VB as well as all other objects at clamp XZ1 supplied by 24VNA. The second NC contact of the Emergency Stop mushroom actuator is used as a signal contact for the SPS and is located on inlet 1.5.

34 © Festo Didactic CP Lab conveyor

Design and function

3.9 Extended functions with applications

3.9.1 Assembly of the application

The assembly of an application is very easy. At first, 2 slot nuts M5 are put into the rear slot of the front cross profile of the CP Lab conveyor. There are also 2 slot nuts M5 to be put into the first slot of the rear cross profile. After that, the slot nuts have to be adjusted/moved to the distance of the application profiles.

Inserting slot nuts

Design and function

Now you put on the application. The slot nuts must be placed below the mounting brackets so that you can screw in the screws.

Put on the application

With raised head screws M5x8, the mounting brackets of the application are now connected with the cross profiles, but not yet tightened. When all screws are put into position, the application can still be moved to the position required. Once you have determined the position, all screws must be tightened.

36 © Festo Didactic CP Lab conveyor

Design and function

3.9.2 Pneumatic connection of applications

The pneumatic connection is effected according to the following sketch. You have to put one end of the tube (nominal size 4) into the QS plug of the valve terminal at the application. You have to put the second end of the tube on the on-off valve of the CP Lab conveyor. When you open the on-off valve, the application is supplied with compressed air.

Pneumatic connection of the application

Design and function

3.9.3 Electrical connection of applications

The applications are linked with the ET200SP through a SysLink interface. The SysLink cable is directly connected with the control system and comes out at the rear side of the CP Lab conveyor. The SysLink plug (XJ11) of the cable is plugged in at the application. Communication is made via I/O.

Electronic connection of the application

38 © Festo Didactic CP Lab conveyor

Design and function

Name

Clamp at ET200 SP

SysLink cable

SysLink plug

Application IN0

KF2 / clamp: 1 (l0)

WG21 / GYPk

XG2: 1

Application IN1

KF2 / clamp: 2 (l1)

WG21 / RDBU

XG2: 2

Application IN2

KF2 / clamp: 3 (l2)

WG21 / WHGN

XG2: 3

Application IN3

KF2 / clamp: 4 (l3)

WG21 / BNGN

XG2: 4

Application IN4

KF2 / clamp: 5 (l4)

WG21 / WHYE

XG2: 5

Application IN5

KF2 / clamp: 6 (l5)

WG21 / YEBN

XG2: 6

Application IN6

KF2 / clamp: 7 (l6)

WG21 / WHGY

XG2: 7

Application IN7

KF2 / clamp: 8 (l7)

WG21 / GYBN

XG2: 8

Name

Clamp at ET200 SP

SysLink cable

SysLink plug

Application OUT0

KF4 / clamp: 1 (O0)

WG21 / WH

XG4: 1

Application OUT1

KF4 / clamp: 2 (01)

WG21 / BN

XG4: 2

Application OUT2

KF4 / clamp: 3 (02)

WG21 / GN

XG4: 3

Application OUT3

KF4 / clamp: 4 (03)

WG21 / YE

XG4: 4

Application OUT4

KF4 / clamp: 5 (04)

WG21 / GY

XG4: 5

Application OUT5

KF4 / clamp: 6 (05)

WG21 / PK

XG4: 6

Application OUT6

KF4 / clamp: 7 (06)

WG21 / BU

XG4: 7

Application OUT7

KF4 / clamp: 8 (07)

WG21 / RD

XG4: 8

Name

SysLink cable

SysLink plug

24VB

WG21 / WHPK

XZ1/X11: VB

0VB

WG21 / WHBU

XZ1/X11: 0 XZ1/X11: 0V

24VA

WG21 / BK

XZ1/X11: VA

0VA

WG21 / PKBN

XZ1/X11: 0V

0VA

WG21 / PUR

XZ1/X11: 0V

Description Interface Inputs

Description Interface Outputs

Description Interface Voltage

Design and function

The application can also connect to an I/O terminal; via a SysLink interface they are directly connected. The SysLink plug (XJ11) of the cable is plugged in at the application. Communication is made via I/O.

Electronic connection of the application

40 © Festo Didactic CP Lab conveyor

Design and function

XZ1 out

XD1 in

XD1 out

To application

X11 - VB

XG1: 24VB

XJ1:22

APP_24VB

X11: 0V

XG1: 0VB

XJ1:23

APP_24VB

X11: VA

XG1: 24VA

XJ1:10

APP_24VB

X11: 0V

XG1: 0VA

XJ1:11+12

APP_24VB

X14:1

XG1:1 / I0

XJ1:13

APP_DI0

X14:2

XG1:2 / I1

XJ1:14

APP_DI1

X14:3

XG1:3 / I2

XJ1:15

APP_DI2

X14:4

XG1:4 / I3

XJ1:16

APP_DI3

X14:5

XG1:5 / I4

XJ1:17

APP_DI4

X14:6

XG1:6 / I5

XJ1:18

APP_DI5

X14:7

XG1:7 / I6

XJ1:19

APP_DI6

X14:8

XG1:8 / I7

XJ1:20

APP_DI7

X15:1

XG1:9 / O0

XJ1:1

APP_DO0

X15:2

XG1:10 / O1

XJ1:2

APP_DO1

X15:3

XG1:11 / O2

XJ1:3

APP_DO2

X15:4

XG1:12 / O3

XJ1:4

APP_DO3

X15:5

XG1:13 / O4

XJ1:5

APP_DO4

X15:6

XG1:14 / O5

XJ1:6

APP_DO5

X15:7

XG1:15 / O6

XJ1:7

APP_DO6

X15:8

XG1:16 / O7

XJ1:8

APP_DO7

I/O terminal

I/O terminal XD1

Design and function

3.10 Commissioning

For the CP Lab conveyor, an initial start-up has been made ex works. Please follow the following instructions in order to be able to work with CP Lab conveyor as well as with a possibly present application:

1. Connect up the power supply 230 V AC for the power supply unit.

2. The power supply unit 24 V DC with ports +24V/0V/earth are connected correctly to the CP Lab

conveyor. The power supply unit is switched on.

3. The CP Lab conveyor is supplied by approx. 6 bar compressed air. At the initial start-up, you have to see

for that the pressure is being increased step by step in order to prevent unforeseeable events.

4. Now you can work with the CP Lab conveyor and the possibly present applications.

42 © Festo Didactic CP Lab conveyor

Operation

4 Operation

The operation is explained with the help of an example. There might be deviations with other applications.

4.1 Software Siemens

In order to be able to work with the module, it is required to load the corresponding software into the PLC and the HMI touch panel of the device. In the following the sequence to load the software, is explained as an example. The sequence for the HMI touch panel is equal to the sequence for the PLC.

 The control must be connected to the programming computer.  The control must be in the „stop“ position.  The Siemens Software has to be started and the corresponding project has to be loaded.

4.1.1 Compile the device configuration

The graphic generated device configuration has to be compiled (translate) into a readable machine code for the SPS.

It is possible to do the compilation with the "Compile" button from the toolbar or via an integrative load process. The compiling process has to be faultless in anyway.

4.1.2 Load device configuration into PLC

To load the device configuration or the PLC program to the PLC, it is necessary to mark the PLC at the navigation window. After that, the loading process can be started.

1. Mark the PLC and press the “Download to device” button at the toolbar.

Load the projection into the PLC

Operation

2. At the very first download it is necessary to configure the PG/PC interface. The interface is for the

connection between the programming device and the PLC.

Choose the interface parameters and search the connected PLC with the “Start search” button. If the

PLC is founded, press the “Load” button.

Configure the PG/PC interface

44 © Festo Didactic CP Lab conveyor

Operation

3. First it is checked if it is necessary to compile the project. If yes, the compilation is executed.

Compile the project

4. If the compilation was successful, the actions of the TIA-Portal during the load process are announced.

Please read each single action (for detailed information it is possible to open the action with the black

arrows) and start the loading process.

Confirm actions of loading process

Operation

5. After loading process, start the PLC. Therefor activate the „Start all“ box and press the „Finish“ button

End of loading process

6. Check if the PLC is going into RUN mode.

46 © Festo Didactic CP Lab conveyor

Operation

Position

Description

Step 1: Double click in this field

Step 2. Device window

Devices announcement

In case Festo Field Device Tool is installed, the devices can be found with this tool

Step 3: Type IP address here

4.2 Software Festo

4.2.1 Find and select the PLC

Insert IP Address and confirm with OK.

Operation

The view for the Device can be changed in Tools --> Options --> Device Editor

1. Scan network to find devices.

48 © Festo Didactic CP Lab conveyor

Operation

1. POUs window: the project elements here will be downloaded to all devices

2. In the Devices window, open the required device, right click and set as active application

Operation

3. Then the title becomes dark.

4. Finally, choose the right device and set as active path as well.

5. The title of the chosen device becomes dark.

50 © Festo Didactic CP Lab conveyor

Operation

4.2.2 Download the project

1. Click on the build button (F11)

2. No errors

Operation

3. Click on the login button or Online --> Login

4. This is downloading the project as well

5. After downloading the project, the PLC always in stop mode (7)

6. The green colour shows that the PLC is logged in (4)

7. Then click on Start (5)

52 © Festo Didactic CP Lab conveyor

Operation

8. PLC is running

After logged in the PLC always in debug mode: the state is visible in runtime

9. Wrong hardware configuration shown with a red triangle

Operation

10. Variable values can be changed by writing it in to the “Prepared value” cell

11. Then Debug--> Write values

This loading all the values which are written into the “Prepared value” cell

After the project downloaded and the PLC shutdown, the project is lost. To keep the project on the PLC at the next startup, a boot application should be created

12. Create boot application: this project will be start at the next startup of the PLC

(In case the boot application is not used, and a mistake appears in the code, by switching off and on the PLC, the original project will be restarted)

54 © Festo Didactic CP Lab conveyor

Operation

4.2.3 The PLC can be reset

1. Reset warm: just reinitializing the variables – mostly used

2. Reset cold: restart the PLC

3. Reset origin: clears the project from the PLC

When the program needs to be edited, it has to logout from the PLC

1. Logout button

Operation

If the project is downloaded into the PLC and just some small changes has been done, the following message window appears:

1. Keeps the variables in their original values and the changes are done as well

2. Downloading the project and reinitializing the variables

3. Logging into debug mode without the changes

1. In case there are pointers or other special tools used in the project, after editing the code, a “Clean all”

is recommended. This recalculates the memory allocation.

56 © Festo Didactic CP Lab conveyor

Operation

Position

Description

Menu designation (main menu or submenu) OR in case of an active error or an error message, this field also serves as a display

Main menu

Submenu in main menu

Content varies depending on the main menu and the submenu

Display of operation mode

Display Default or MES Mode

4.3 Menu structure of the CP Lab screen

Operation

4.3.1 Menu prompting Home – Operation Mode

Home - Overview

58 © Festo Didactic CP Lab conveyor

Operation

Home – User Mode

Home – I/O Test

Operation

Setup - Application

Setup - belt

60 © Festo Didactic CP Lab conveyor

Operation

Setup - Stopper

Operation

Parameter - Application

62 © Festo Didactic CP Lab conveyor

Operation

Parameter - Transitions

Parameter - Conveyor

Operation

System - Settings

64 © Festo Didactic CP Lab conveyor

Operation

Position

Description

Flashing button demands adjusting (release for adjusting mode has been given) – press button – adjusting mode is made active

4.4 Operation

A flashing button invites the user to carry out an action. A button with a statically blue background indicates that the function described in the button text is active.

Operation

Position

Description

Automatic mode is displayed

=> press button – Automatic mode is made active

Position

Description

Flashing button indicates that automatic mode is active

Automatic mode can be stopped at the end of the cycle of the active process

Operation

Position

Description

Error/warning is active – if you click on the message line, the message window will be called up

Position

Description

The error/warning is displayed in the message window and can be acknowledged with this button. The acknowledgement is effected as a single acknowledgement.

4.4.1 Message line and window

Operation

4.4.2 Display of objects

It generally applies:

Inputs: green when active Outputs: orange when active Buttons/User interactive fields: grey backgrounds with blue text change to blue backgrounds with black text as soon as they are active.

Components

Position

Description

X2 Sub D 15 pole/ input

X2 Sub D 15pole /output

Touch screen

Potentiometer RA1

Potentiometer RA2

START illuminated push-button green / button SF1/ light PF1

SF1 / X2: 1 / I0

PF1 / X2: 2 / Q0

STOP button red /button SF2

SF2 / X2: 3 / I1

Locking selector switch (no further allocation in the system programme)

SF3 / x2: 5 / I2 7

RESET illuminated push-button white / button SF4 / light PF2

SF4 / X2: 7 / I3

PF2 / X2: 4 / Q1

Q1 indicator light white / light PF3

PF3 / X2: 6 / Q2

Q2 indicator light white / light PF4

PF4 / X2: 8 / Q3

Emergency Stop / button SF5 – at M12 panel plug

5 Components

5.1 Touch panel

You control the system with the touch panel. The upper control row is optionally available.

Components

Function

XZ1

Start Button / SF1

X12:1

Stop button / SF2

X12:3

Switch operation panel / SF3

X12:5

Reset button / SF4

X12:7

Start lamp / PF1

X12:2

Reset lampn / PF2

X12:4

Lamp Q1 / PF3

X12:6

Lamp Q2 / PF4

X12:8

5.1.1 Front PCB XZ1

XZ1 PCB operation panel connection

Components

5.1.2 Back PCB XZ2

Components

Function

Controller

XZ2 in

XZ2 out

Sensor / Actor

Identcode Bit 0

KF21:I18.0 / XZ3:A1

X2:1

X6:1

BG1 / Identcode Bit 0

Identcode Bit 1

KF21:I18.1 / XZ3:A3

X2:3

X6:2

BG2 / Identcode Bit 1

Identcode Bit 2

KF21:I18.2 / XZ3:A5

X2:5

X6:3

BG3 / Identcode Bit 2

Identcode Bit 3

KF21:I18.3 / XZ3:A7

X2:7

X6:4

BG4 / Identcode Bit 3

Reserve

KF21:Q18.0 / XZ3:A1

X2:2

X6:19

Reserve

KF21:Q18.1 / XZ3:A3

X2:4

X6:20

Reserve

KF21:Q18.2 / XZ3:A5

X2:6

X6:21

Reserve

KF21:Q18.3 / XZ3:A7

X2:8

X6:22

Function

Controller

XZ2 out

Sensor / Actor

Pallet at left end

KF3:I1.6 / XG3:7

X6:13

BG5

Pallet at right end

KF3:I1.7 / XG3:8

X6:14

BG6

Transport direction to right

KF5:Q1.4 / XG5:5

X6:27

QA1:RE motor controller

Transport direction to left

KF5:Q1.5 / XG5:6

X6:28

QA1:LI motor controller

Transport slow speed

KF5:Q1.6 / XG5:7

X6:29

QA1:SL motor controller

Open stopper

KF5:Q1.7 / XG5:8

X6:30

QM1-MB1

Function

Controller

XZ2 in

XZ2 out

Sensor / Actor

Coupling receiver right

KF21:I18.4 / XZ3:B1

X3:1

X6:5

KG1

Coupling receiver left

KF21:I18.5 / XZ3:B3

X3:3

X6:6

KG2

Stopper opened

KF21:I18.7 / XZ3:B7

X3:7

X6:8

BG9

Coupling sender left

KF21:Q18.4 / XZ3:B2

X3:2

X6:23

GF1

Coupling sender right

KF21:I18.5 / XZ3:B4

X3:3

X6:24

GF2

XZ2 Connections to PLC

Components

SYSlink PIN

Bit

Name

Syslink PIN

Bit

Function

01 0 Output AX.0

13 0 Input EX.0

02 1 Output AX.1

14 1 Input EX.1

03 2 Output AX.2

15 2 Input EX.2

04 3 Output AX.3

16 3 Input EX.3

05 4 Output AX.4

17 4 Input EX.4

06 5 Output AX.5

18 5 Input EX.5

07 6 Output AX.6

19 6 Input EX.6

08 7 Output AX.7

20 7 Input EX.7

24V

Power supply

24V

Power supply

24V

Power supply

24V

Power supply

5.1.3 SYS link Cable - Interface

Syslink – allocation

Components

Clamp read-write head

Cable

I/O Link

TF1:1 / 24 V

XTF1:1 / BN

XG1/X12:1 - L+

TF1:3 / 0V

XTF1:3 / BU

XG1/X12:3 - L-

TF1:4 / Data

XTF1:4 / BK

XG1/X12:2 - C/Q

5.1.4 RFID Read/Write system

The RFID read-write head describes and/or reads the data from a RFID data storage medium which is located on the bottom of the carrier. Any information concerning the workpiece can be read or transmitted. The read-write head is directly connected to the I/O link of the ET200SP.

Read-write head RF210R IO-Link

TW-R16-B128 RFID data storage medium

Components

Position

Description

I-Port –here the data are transmitted to the I/O link of the ET200SP. It is possible to remove the 5 pole cable and to replace it by an adapter plug. With the help of the CTEU bus knot it will be possible to adapt different bus systems to the system.

The following bus systems are available presently: PN, PB, CC-Link, CAN, DeviceNet, Ether Cat

The allocation of the 5 pole cable is as follows: Clamp 1 – 24 VB / cable has a brown stranded wire Clamp 2 – 24 A / cable has a white stranded wire Clamp 3 – OVB / cable has a blue stranded wire Clamp 4 – Data / cable has a black stranded wire Clamp 5 – OVA / cable has a grey stranded wire

Data channel A

Data channel B

5.1.5 IO-Link DA-Interface (digital-analogue interface)

The I- port is an interface between the ET200SP and the sensors and actuators wired on the mini I/O terminals. The order number is 8038559.

I-Port KF11

Components

Position

Description

ET200SP / CPU1512SP F-1PN / K1-KF1 / 6ES7512-1SK00-0AB0

DI / 8x 24VDC / K1-KF2 / 6ES7131-6BF00-0CA0

DI / 8x 24VDC / K1-KF3 / 6ES7131-6BF00-0CA0

DO / 8x 24VDC 0,5A / K1-KF4 / 6ES7132-6BF00-0CA0

DO / 8x 24VDC 0,5A / K1-KF5 / 6ES7132-6BF00-0CA0

CM / 4x IO-Link ST / K1-KF6 / 6ES7137-6BD00-0BA0

5.1.6 Control systems

The control unit regulates all processes as well as the communication in the CP Lab conveyor. Different control systems can be used. It is possible that a I/O Terminal is installed instead of an controller.

ET200SP with CPU1512

ET200 SP

Components

Position

Description

ET200SP / IM155-6 PN HF / K1-KF1 / 6ES7155-6AU00-0CN0

DI / 8x 24VDC / K1-KF2 / 6ES7131-6BF00-0CA0

DI / 8x 24VDC / K1-KF3 / 6ES7131-6BF00-0CA0

DO / 8x 24VDC 0,5A / K1-KF4 / 6ES7132-6BF00-0CA0

DO / 8x 24VDC 0,5A / K1-KF5 / 6ES7132-6BF00-0CA0

CM / 4x IO-Link ST / K1-KF6 / 6ES7137-6BD00-0BA0

ET200SP with IM155

ET200 SP

Components

5.1.7 Signal Converter

The signal converter is a fibre optic unit with a teachable switching point.

Signal converter 552796 / SOE4-FO-L-HF2-1P-M8

WARNING Not to be used as a safety component! Electric voltage! Before you work on the electricity, you have to switch off the voltage.

Components

Mounting and Setting

Connecting the plastic fibre optic cable

1. Open the clamp strap.

2. Insert the fibre optic cable to the stop into the holder (you have to overcome the resistance when

inserting at the O ring)

3. Close clamp strap.

Setting sensitivity in a running process (turning conveyor motor)

1. Adjust the fibre optic cable to the object: => LED green is flashing, LED yellow is undefined.

2. Only the running process is in the optical path; press the button for approx. 3s until both LEDs are

flashing simultaneously.

3. Press button again until there is at least one process cycle executed in the optical path.

a) green LED is flashing for a short time and starts lighting up, => sensitivity settings are saved, sensor

is ready for operation.

b) both LEDs are flashing simultaneously => Sensor cannot detect the object, no sensitivity settings are

saved.

Setting the start function (N.O. / N.C.)

1. Press button for approx. 13 s => LEDs are flashing alternately.

2. Release button: => green LED is flashing.

3. While the green LED is flashing, on every pressing of the button, the start function is inverted. The

current function is indicated by the yellow LED.

4. Don’t press the button for 10 s: => set function is saved, sensor is ready for operation.

Factory setting / maximum sensitivity (default)

1. No object in the sensing range. Press button for approx. 3 s until both LEDs are flashing simultaneously.

2. No object in the sensing range. Press button for approx. 1 s.

=> Sensor is set at maximum sensitivity.

=> Sensor has its factory setting again

Pilot line (ET) / Process of external Teach-in

•3 s at +UB / determine teach point 1

•open

•3 s at +UB / determine teach point 2

•open setting saved, end of external Teach

Components

5.1.8 Solenoid valve

The solenoid valve controls the cylinder of the stopper unit. The solenoid valve has got a manual override (see pos.1). When you press it (non-locking), the cylinder drives the stopper unit down as long as you press it. When you press the manual override and turn it (locking), the cylinder drives down with long-lasting effect.

Solenoid valve 574351 / VUVG-L10-M52-MT-M5-1P3

Components

6 Extensions

6.1 Extension with an active corner

In order to make a circulation of several CP Lab conveyors, it is possible to assemble the CP Lab conveyors in the rectangle and to connect the conveyors with active corners. A motor drives the corner and the carrier is transported to the following CP Lab conveyor. The active corners are connected in parallel to the motor used, the corner is mounted on the left side of the CP Lab conveyor. The coupling sensors of the conveyors are simply forwarded to the following CP Lab conveyor using light guide bridges.

Example concatenation 4 CP Lab conveyors with active corners

Components

Position

Description

Outside guard railing

Turning table

Inside guard railing

Motor

Coupling sensor transmission

Screw

Motor connection (see Circuit diagram p.13)

Components

6.2 Extension with a passive corner

In order to achieve a circulation from several CP Lab conveyors, it is possible to assemble the CP Lab conveyor in the rectangle and to connect the conveyors with passive corners. The corners are equipped with balls which enable the carrier to be transported without drive to a further band mounted at a right angle. The coupling sensors of the conveyors are simply forwarded to the following CP Lab conveyor using light guide bridges.

Example concatenation 6 CP Lab conveyors with passive corners

Components

Position

Description

Ball caster

Passive guard railing

Coupling sensor transmission

Components

Festo Didactic SE Rechbergstraße 3 73770 Denkendorf Germany

Internet: www.festo-didactic.com E-mail: did@de.festo.com

Festo CP Lab User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual