Einphasiger Frequenzumrichter Micromaster 420

Festo Didactic

CP Factory

02/2018

CP Factory®

Manual basic module linear

Content

2 © Festo Didactic CP Factory ° Basic module linear

Order number:

Status: 02/2018

Layout: 02/2018, Schober, Weiss

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

© Festo Didactic SE, 73770 Denkendorf, Germany, 2018

Internet: www.festo-didactic.com

E-Mail: [email protected]

Intended use

This installation was developed and manufactured only for the use in basic and further training in

the fields of automation and communications. The training company and/or the training staff must

ensure that the trainees observe the safety precautions described in the accompanying manuals.

Furthermore this manual describes setup and possible uses of the singular stations. It contains all

information and data required for commissioning, maintenance and operation.

Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any

third parties which may occur when the installation is used beyond a genuine training situation,

except Festo Didactic has caused such injury or harm intentionally or by grossly negligence.

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

This manual, all text and illustrations included, is protected by copyright. Any utilization outside the

limits of the copyright law and other than training purposes are not permissible without our definite

approval. This applies in particular to reproductions, operations, translations, micro filming and the

storing and processing into electronic systems. Distribution of this documentation, as well as

reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences

are liable to compensation. All rights reserved, especially the right to execute registrations

concerning patents, designs for use and patterns.

Intended use also comprises observing all instructions in the operating manual and carrying out the

inspection and maintenance works.

Content

© Festo Didactic CP Factory ° Basic module linear 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 basic module linear ___________________________________________________________________ 14

3.3.1 General information _______________________________________________________________ 14 3.4 Mechanical setup _____________________________________________________________________ 16

3.4.1 Supply of the Basic Module _________________________________________________________ 20 3.5 Electrical installation __________________________________________________________________ 22

3.5.1 Cabling chart _____________________________________________________________________ 25 3.5.2 Emergency-stop structure __________________________________________________________ 27 3.5.3 Emergency stop with central control __________________________________________________ 30 3.5.4 Connection of application module ____________________________________________________ 32 3.5.5 Pneumatic port of application module ________________________________________________ 34 3.5.6 Electrical connections from application modules _______________________________________ 35

3.6 Commissioning _______________________________________________________________________ 36 3.6.1 Pneumatic commissioning __________________________________________________________ 36 3.6.2 Electrical commissioning ___________________________________________________________ 36

3.7 Adjusting the sensors _________________________________________________________________ 37 3.7.1 Proximity switch (stopper Identsensor) _______________________________________________ 37 3.7.2 Proximity switch (stopper cylinder) ___________________________________________________ 39

3.8 Adjusting the one-way flow control valves _________________________________________________ 41 3.9 Visual inspection _____________________________________________________________________ 42

Content


3.10 Starting up _________________________________________________________________________ 42 4 Operation _______________________________________________________________________________ 43

4.1 General operating instructions __________________________________________________________ 43 4.1.1 Conduct guidelines ________________________________________________________________ 43 4.1.2 Operating guidelines ______________________________________________________________ 43

4.2 The control units of the basic module linear _______________________________________________ 44 4.2.1 Touch Panel ______________________________________________________________________ 45

4.3 Sequence description stopper of the basic module linear ____________________________________ 48 4.4 Switching on the station _______________________________________________________________ 50

4.4.1 Sequence Description Automatic ____________________________________________________ 50 4.4.2 Process description Cycle End _______________________________________________________ 50

4.5 Operating modes _____________________________________________________________________ 51 4.5.1 Automatic mode __________________________________________________________________ 51 4.5.2 Setting operation _________________________________________________________________ 51

4.6 Operating the HMI touch panel __________________________________________________________ 51 4.6.1 Menu architecture from operation panel ______________________________________________ 52 4.6.2 Menu navigation __________________________________________________________________ 53 4.6.3 Display operation modus (MES/Default) ______________________________________________ 54 4.6.4 Operation mode Home _____________________________________________________________ 55 4.6.5 Operating mode Setup _____________________________________________________________ 60 4.6.6 Operation mode Parameters ________________________________________________________ 62 4.6.7 Operation mode System - settings ___________________________________________________ 66

4.7 Operator assistance and simulate application on free AP ____________________________________ 67 4.7.1 Generic sequence simulation ________________________________________________________ 68 4.7.2 Operator assistance with display of pictures ___________________________________________ 69 4.7.3 Operator assistance with call of htm-page _____________________________________________ 71

4.8 Automatic operation __________________________________________________________________ 72 4.8.1 Start automatic ___________________________________________________________________ 72 4.8.2 Stop automatic ___________________________________________________________________ 74

4.9 Manually describe the RFID tag__________________________________________________________ 75 5 Components _____________________________________________________________________________ 77

5.1 Electrical components _________________________________________________________________ 77 5.1.1 2 Quadrant Controller ______________________________________________________________ 77

5.2 PLC Siemens _________________________________________________________________________ 80 5.3 PLC Festo CECC _______________________________________________________________________ 81 5.4 Turck Interface _______________________________________________________________________ 82 5.5 Scalance Ethernet Switch ______________________________________________________________ 83 5.6 RFID with Ethernet ____________________________________________________________________ 86 5.7 RFID with CanBus _____________________________________________________________________ 90

5.7.1 Mini Terminal _____________________________________________________________________ 91 5.7.2 SYS link interface _________________________________________________________________ 94

5.8 Mechanic components _________________________________________________________________ 95 5.8.1 Motor of Conveyor ________________________________________________________________ 95 5.8.2 The stopper unit __________________________________________________________________ 96 5.8.3 Transportation of the Basic Module __________________________________________________ 98

General safety instructions


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

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

the training area.

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

switches.

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

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

• The training area must be protected by overcurrent protections -

– fuses or circuit breakers

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

– This person must be a skilled electrician or a person instructed in electrical engineering with the

knowledge of all safety requirements and safety precautions on file.

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

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

General requirements regarding a safe operation of the devices:

• Do not lay cables over hot surfaces.

– Hot surfaces are marked with a corresponding warning symbol.

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

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

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

protection.

• Any device with earth connection must always be grounded.

– If there is a ground connection (green-yellow laboratory socket) available, the connection to the

protective ground must always be effected. The protective ground must always be contacted first

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

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



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.

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Information

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



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.



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.



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


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


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


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.

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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


3.3 basic module linear

3.3.1 General information

The basic module linear consists of a two-lane conveyor line which is 1200 mm long. The conveyors are 80

mm wide.

The conveyors are for transporting boards on carriers.

The carriers are equipped with a read/write ID-system. This ID-system represents an important item of the

CP Factory System. Current data of the workpiece to be transported is written on the carriers. Thus all

information essential for the process is transported together with the carrier and is therefore available at

every station.

CP Factory Basic Module

Design and function


Position Designation

1 Corner pulley/no other module attached

2 Conveyor front

3 Master switch control panel

4 Manometer

5 Maintenance unit

6

Touch panel

Variant 1 / Festo panel

Variant 2 / Siemens panel

7 Ethernet interface

8 E-board for Basic Module linear

9 Multicontact plugs

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

11 Pressure switches (option for energy monitoring)

12 Conveyor back side

13 Substitute guide board / further module attached

14 Emergency stop

15 Controller on pushbutton

Design and function


3.4 Mechanical setup

The basic module linear has been constructed for operation from both sides. The sides are built identically;

there is an independent electrical system, pneumatics, a drive unit and the operation for every side. It is also

possible to install and operate an application module on only one side of the basic module linear. You can

continue controlling the other side by its own operating panel. The basic module linear is equipped with

mechanically adjustable feet. Should it be necessary to move the basic module linear to another place, it

can be lowered to its rollers and thus be transported easily.

Construction of Basic Module

Position Description

1 Operating side 1 (independent from side 2)

2 Operating side 2 (independent from side 1)

Design and function


The modules can be operated in two ways - as a single station or in a chain with further modules. When

connected to a further module, it is necessary to replace the deflection at the end of the band by means of a

support plate. The switch is an exception, if this is operated as a single station, it is not possible to eject or

introduce workpieces via the switches.

Installation Options example

With the pluggable tape deflections there are different possibilities to control the transport flow. Depending

on this, different modules can be operated individually or in combination.


1 Operation as independent Basic Module /not put together

2 Operation as independent Basic Module /Basic Module put together

3 Operation connected with another Basic Module

Design and function


Installation as independent basic module


1+2 corner pulley – the carrier is reversed from one conveyor to the other on the basic module

Design and function


Installation in combination with another Basic Module


1 Replacement guide board (support plate) if connected to another Basic Module – the carrier is not reversed but directed

to the next module

2 corner pulley – the carrier is reversed from one conveyor to the other conveyor on the Basic Module

The corner pulley and the support plate are only pinned and can be changed easily without tools.

Design and function


3.4.1 Supply of the Basic Module

CP Factory supply


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

Design and function



1 Emergency chain linking

2 Pressure

3 Network

4 400 V

Design and function


3.5 Electrical installation

Every basic module has got an electric board for the electrical components, on every operating side. This

electric board has been installed in the right part of the housing. If you use applications on the basic

module, they are plugged on the I/O terminals of the electric board. The electrical components vary

depending on the application. The electric board on the left side of the housing is designed for other basic

modules like, for instance, the basic module storage.

There are different placements from components possible, all variants are described here.

Electric board front side

Design and function


Electric board front side with Siemens controller

Position Designation BMK Description / Ordernumber

1 Power supply unit 24 V TB1 Festo CACN-3A-1-10 / 2247682

2 CPU K1-K5- Siemens ET200 SP CPU 1512SP F-1 P

3 ELEC AUX CIRCUIT FC4 Murr Elektronik / 9000-41042-0100600

4 Receptacle 203V XJ4

5 Fuses FC1 + FC2

6 Clamps

7 Analog Terminal XD16A UM 45-D15SUB/B

8 I/O Terminal XD6

9 Start-up current limiter QA1 Kaleja M-MZS-4-30 / 06.05.020

10 Emergency stop Unit F2-KF1 Siemens / 3SK1111-2AB30

11 Emergency stop board F2-XZ2

12 Ethernet switch XF1 Siemens Scalance XB008 / 6GK5008-OBAOO-1AB2

Design and function


Electric board front side with Festo controller

Position Designation BMK Description / Ordernumber

1 Power supply unit 24 V K1-TB1 Festo CACN-3A-1-10 / 2247682

2 CPU K5-KF1 Festo CECC / 574418

3 ELEC AUX CIRCUIT K1-FC4 Murr Elektronik / 9000-41042-0100600

4 Receptacle K1-XJ4

5 Fuses K1-FC1 + K1-FC2

6 Clamps K1 XD0-K1-XD13

7 Turck Interface K5-KF2 – K5-KF21 Turck BL20-GWBR-CANOPEN

8 I/O Terminal K1-XD15

9 Analog Terminal K1-XD16A UM 45-D15SUB/B

10 Start-up current limiter K1-QA1 Kaleja M-MZS-4-30 / 06.05.020

11 Emergency stop Unit K1-F2-KF1 Siemens / 3SK1111-2AB30

12 Emergency stop board K1-F2-XZ2

13 Ethernet switch K1-XF1 Siemens Scalance XB008 / 6GK5008-OBAOO-1AB2

Design and function


3.5.1 Cabling chart

Cabling chart frontside siemens controller

Design and function


Cabling chart frontside Festo controller

Design and function


3.5.2 Emergency-stop structure

Structure of the emergency-stop system

The emergency components from the back side are hard wired to the front side. The kind of controller

doesn’t matter for emergency system.

Position Name

1 E-Board backside

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

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

4 Emergency stop board for emergency chain linking / F2-XZ2

5 Emergency stop Unit / F2-KF1

Design and function


Circuit board emergency stop circuit

F2 XZ2-X1

Emergency stop coupling input / If no predecessor station is present, a bridge plug is to be installed here or

at the system plug.

F2 XZ2-X2

Emergency stop coupling Output 1 / If there is no following module, a bridge plug is to be installed here or

at the system plug.

F2 XZ2-X3

Emergency stop coupling output 2 / for the connection of a further module or an external machine (for

example for basic module branch - here a further module can be installed at the branch or a CNC processing

machine can be provided at a bypass) otherwise a bridge plug is to be provided.

F2 XZ2-X4

Connection terminals for control panel, power supply, emergency stop relay

Example emergency stop chaining with 3 modules

Design and function


Release emergency stop

If the emergency stop is pressed, an error message appears on the HMi. If you click on the message line at

the top, the error message appears in the main window.

1. Emergency stop situation is displayed in the message line. Clicking on the line displays the message in

the main window.

2. Indication of the emergency stop situation

3. If the emergency stop situation has been remedied, the emergency stop button must be withdrawn. The

blue illuminated pressure switch "Reset" must then be pressed. Now the message can be

acknowledged by pressing the button on the HMI. The module can now be restarted.

4. If the module is connected to further modules, the emergency stop acts at all stations and therefore the

emergency stop situation must be acknowledged at all stations with the illuminated pressure switch

"Reset" and with acknowledgment of the error on the HMi.

Design and function


3.5.3 Emergency stop with central control

Construction of the emergency stop system

For the central emergency stop (Power cabinet), a central emergency stop control unit PNOZ-X8P is

connected to one of the modules. The connection to one of the modules is via the power supply.

Release emergency stop

If the emergency stop is pressed at any station, an error message appears on all HMi. First you have to find

out at which station the emergency stop was pressed. This module can then be clicked on the message line

at the top of the HMI, where the error message appears in the main window.

Design and function


1. Emergency stop situation is displayed in the message line. Clicking on the line displays the message in

the main window.

2. Indication of the emergency stop situation

3. If the emergency stop situation has been remedied, the emergency stop button must be withdrawn. The

blue illuminated pressure switch "straightening" must then be pressed. Now the message can be

acknowledged by pressing the button on the HMI. The module can now be restarted. The emergency

stop acts at all stations and must therefore be acknowledged at all stations by means of the illuminated

pressure switch "Reset" and the acknowledgment of the fault on the HMi the emergency stop situation.

Design and function


3.5.4 Connection of application module

The mounting of an application module is very easy. At first, 2 slot nuts M5 are put into the front slot of the

front cross profile. Then two other slot nuts are put into the back slot of the profile. Afterwards the slot nuts

have to be adjusted to the distance of the application module profiles. The following example is exemplary

for all application modules, these are all mounted in the same way.

Put in slot nuts

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

that the screws can be fixed.

Design and function


Mounting of the application module

With fillister-head screws M5x8, the mounting brackets of the application module are now connected to the

cross profiles, but not fastened yet. When all screws are placed, the application module can still be moved

to the position required. Please make sure that the workpieces can be transferred correctly like here at the

application module magazine. Once the position has been fixed, you only have to tighten the screws and to

put the covers on the mounting brackets.

Design and function


3.5.5 Pneumatic port of application module

Pneumatic port is done on the principle of the following sketch. The application module is connected from

the valve terminal to the on-off valve at the conveyor. You only have to plug the tube (nominal size 4) into

the QS plug.

Pneumatic connection of the application module

Design and function


3.5.6 Electrical connections from application modules

Connection with syslink plugs

The application module is connected to the electrical board of the module via I/O. The I/O box (1) of the

application module is connected to the I/O terminal (2) on the module's electrical board.

The example refers to the connection to a basic module linear, it is possible that the terminal names of the

I/O terminal differ when connected to another module.

If an application module has more than 8 I / O, the second I / O box cable is connected to the I / O terminal

XMB on the electrical board.

Electrical connection by I/O example

Design and function


3.6 Commissioning

The basic module linear has got several components which have to be attached when starting up. The

procedure will be described on the following pages.

3.6.1 Pneumatic commissioning

The mechanic mounting must be finished and completed. At first you have to connect the basic module

linear 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.

3.6.2 Electrical commissioning

Now the basic module linear has to be supplied with electric voltage (400 V). The voltage has to be provided

by the customer. Professional installation must be guaranteed as well.

Design and function


3.7 Adjusting the sensors

3.7.1 Proximity switch (stopper Identsensor)


1

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

1 position (BG21/BG31/BG41)




2 Screw to clamp the sensor

The proximity switches are used for controlling the carrier.

Design and function


Requirements – Stopper unit is attached to the conveyor.

– Electrical connection of the proximity switches is set up.

– Power supply is available.

Procedure 1. The stopper is in upper position, a carrier is stopped at the stopper.

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

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

display disappears.

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

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

6. Check the position of the proximity switch by repeated removing the carrier.

Documents • Data sheets / operating instructions

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

Design and function


3.7.2 Proximity switch (stopper cylinder)


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

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

The proximity switches are used for controlling the end position of the cylinder for the stopper. The

proximity switches react to a permanent magnet on the piston of the cylinder.

Design and function


Requirements – Cylinder stopper is attached to the conveyor.

– Pneumatic port of the cylinder is set up.

– Compressed air supply is switched on.

– Electrical connection of the proximity switches is set up.

– Power supply is available.

Procedure 1. The cylinder is in its end position to be queried.

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

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

display disappears.

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

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

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

Documents • Data sheets / operating instructions

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

Design and function


3.8 Adjusting the one-way flow control valves

One-way flow control valves

Pos Description

1 One-way flow control valves GRLA for stopper cylinder

2 One-way flow control valves GRLA for stopper cylinder

Design and function


One-way flow control valves are used for the regulation of the exhaust air volume of double-acting drive

units. In the opposite direction the air flows through the flow control valve having a full cross-sectional flow.

The piston is clamped between air cushions by free supply air and throttled exhaust air (improvement of the

operating behaviour even if the load changes). Requirements – Pneumatic port of the cylinders is set up.

– Compressed air supply is switched on.

Procedure 1. At first, turn off both one-way control valves completely. Then turn them on by about one rotation.

2. Start a test run.

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

Documents • Data sheets

One-way flow control valve (193138)

3.9 Visual inspection

Visual inspection must always be done before starting up!

Before starting the station, please check:

• the electrical connections

• the correct fit and condition of the supply ports

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

• the function of the Emergency Stop

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

3.10 Starting up

For the basic module, an „initial start-up“ has already been conducted.

In order to be able to work with the basic modules and the applications, you have to carry out the following

measures:

1. You have to provide the mains supply 400 V AC for the basic module.

2. The basic module/the application is supplied by about 6 bar compressed air. On initial start-up, please

pay attention to slowly increasing the pressure (herewith unpredictable events are prevented).

3. Now you can work with the basic module/the application.

Operation


4 Operation The chapter operation describes the control units required for operating and their connections. The

functions of the control units are freely programmable for the user and have not been assigned yet in

delivery state.

The following operating instructions must therefore be considered universal.

4.1 General operating instructions

Operating the system requires some rules that have to be strictly observed. Any offence against these rules

may cause errors in the process. Damage to physical health may also not be excluded. Users are strongly

advised to stick to the following rules.

4.1.1 Conduct guidelines

• Manual interference during the operation is prohibited.

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

• It is prohibited to pull off any live cables.

• Keep away from water of any kind.

4.1.2 Operating guidelines

• The systems may only be operated by instructed persons.

• Operation has to be effected according to the manual.

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

Operation


4.2 The control units of the basic module linear

CP Factory control panel


1 Main switch -QB1

2 Manometer

3 Touch Panel – PH1 / Festo panel or Siemens panel possible

4 Emergency- stop switch – F2-FQ1

5 Network socket- XPN3

6 Controller on pushbutton – F2-SF1

Operation


4.2.1 Touch Panel

Siemens TP 700 Comfort

Supply voltage

Type of supply voltage DC

Rated value (DC) 24 V

permissible range, lower limit (DC) 19.2 V

permissible range, upper limit (DC) 28.8 V

Input current

Current consumption (rated value) 0.5 A

Starting current inrush I²t 0.5 A²·s

Power

Power consumption, typ. 12 W

Processor

Processor type X86

Memory

Flash Yes

RAM Yes

Memory available for user data 12 Mbyte

Operation


Festo CDPX Panel

Operation


Feature values

Recipe memory 32 Kilobyte

Events per event buffer 2,048

Alarms 2,000

Java script file size per page 8 Kilobyte

Supported PLC protocol

CODESYS 2.3

CODESYS 3.X

ModbusRTU Client

ModbusRTU Server

ModbusTCP Client

ModbusTCP Server

Real-time clock deviation 130 s / month

Number of colours 64 k

Number of system LEDs 1

Display TFT colour

Display property Touchscreen

Display size 7"

Backup battery Li battery, rechargeable

Operating voltage range DC 18 ... 30 V

Display resolution WVGA, 800x480 Pixel

Nominal operating voltage DC 24 V

Current consumption at nominal operating voltage 0,7 A

CE mark (see declaration of conformity) to EU directive for EMC

Storage temperature -20 ... 70 °C

Relative air humidity 5 - 85 %

non-condensing

Protection class IP65 front, IP20 back

Ambient temperature 0 ... 50 °C

Authorisation C-Tick

c UL us - Listed (OL)

PLC interface Ethernet

RS485

USB interface Yes

Ethernet interface RJ45 10/100 MBd

Mounting type Front panel installation

Materials note Conforms to RoHS

Programming software Designer Studio

Operation


4.3 Sequence description stopper of the basic module linear


1 Stopper front side

2 Stopper back side

The sequence description is for the stopper of the basic module. The sequence is equal for both sides.

Operation


Operation


4.4 Switching on the station

1. All EMERGENCY STOP signal transmitters (push buttons, door contact, light barriers, etc.) are not

activated or activated and unlocked.

2. Check the possibly installed application for optical damage and correct if necessary

3. Remove the workpieces

4. Switch on the main switch

5. Reset button lights up blue, HMI is started

4.4.1 Sequence Description Automatic

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

2. Stoppers are retracted

3. Workpiece is transported in circulation mode

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

5. If a carrier moves into the module / application module, this will execute your automatic process. The

operation of the module / application module is, however, only started if the operation in MES is

intended for this resource and the resource can also carry out this operation.

6. The Busy displays become active.

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

8. The next resource and operation are written to the RFID chip

9. When the module / application module is ready, the display changes back to the original state and the

stopper is retracted

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

4.4.2 Process description Cycle End

1. An automatic run is active.

2. Press the button Cycle End.

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

End has got a red background.

4. The stoppers are extended.

5. The conveyors are stopped.

Operation


4.5 Operating modes

4.5.1 Automatic mode

• MES mode

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

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

• Default Mode

The automatic sequence is not centrally controlled in the default mode, all information from the

transition tables (see chapter "Schematic process flow") is read and processed separately at each

station.

4.5.2 Setting operation

In the setting operation, all sensors can be displayed and actuators can be controlled from the HMI. This is

used in fault finding or on commissioning.

4.6 Operating the HMI touch panel

Operating the basic modules is always the same procedure. A basic module with the application module

drilling serves as an example here. Any additional operating possibilities are described separately in the

corresponding manuals. The operation is not depending on the type of the operating panel, Festo and

Siemens Panels have got the same functions.

Operation


4.6.1 Menu architecture from operation panel

This description serves as an example; it is made with a base module and a drilling application. Some of the

functions are not available if there is no application mounted.


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

announcement

2

Main menu (always shown the same)

Operating mode Home:

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

be operated.

Operating mode Setup:

Here, the application can be operated manually in setup mode

Operating mode Parameter:

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

can be set

System type:

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

3 Submenu in the main menu

Changing content, depending on the main menu

4 Changing content, depending on the main or submenu

5 Announcement of operation mode automatic or set up

6 Announcement of default or MES Mode

Operation


4.6.2 Menu navigation

General operation notice

• White buttons with blue letters – function is active

• White buttons with black letters – function is not active

• Blue buttons – function is active – waiting for insert

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

• Grey buttons with blue letters – function can be executed

• Green advice – Sensor/function is active

• Orange device – announce an actor


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

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

Operation


4.6.3 Display operation modus (MES/Default)

In the Home operating mode on the Overview page, different states can be displayed depending on the

mode (MES or Default).

In the upper right-hand area, the order data of the workpiece carrier are displayed in the MES mode, while

the RFID status code is displayed in the default mode.

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

Operation


4.6.4 Operation mode Home

Submenu operating mode

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


1 Reset Button

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

3 Setup button: Here the application module can be controlled manually and sensors can be displayed. To put an application

module into operation or suitable for troubleshooting.

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

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

5 Select the mode:

Default - Automatic sequence is executed with the stored transitions

MES software is fully controlled by MES software

Operation


Submenu overview MES Mode


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

Carrier ID: Carrier number

ONo: Order number

OPos: Order position

PNo: Part number

OpNo: Operation number

Resc: Resource

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

Start: Green when started

Ready: Green when ready

Init Pos .: Green when the basic position is reached

Reset: Green when the application is directed

Busy: Green when the application processes an order

RFID Busy: green when an RFID code is read or written

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

Parameter1: The parameters are displayed or entered here

Operation


Submenu overview Default Mode


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

Carrier ID: Carrier number

ONo: Order number

OPos: Order position

PNo: Part number

OpNo: Operation number

Resc: Resource

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

Start: Green when started

Ready: Green when ready

Init Pos .: Green when the basic position is reached

Reset: Green when the application is directed

Busy: Green when the application processes an order

RFID Busy: green when an RFID code is read or written

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

Parameter1: The parameters are displayed or entered here

Operation


Submenu user

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

default)

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

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

Operation


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

Operation


4.6.5 Operating mode Setup

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

the application module.

The operation of the belts and stoppers are the same and described here.

Position number description

1 Run the conveyor left / right

Left: conveyor moves counter clockwise to the left

Drive: Display conveyor belt

Right: conveyor moves clockwise to the right

2 To left: Move the tape to the left (actuator QA1_A2 is activated, lights up blue when active)

Pre-selection slow: Slowly set the tape speed

Slow: Move the tape slowly (actuator QA1_A3 is activated, lights up blue when active)

To right: Move the tape to the right (actuator QA1_A1 is activated, lights up blue when active)

3 Sensor BG26 Indicator tape inlet (lights up green when active)

Sensor BG27 Indicator Disc spout (lit green when active)

Operation



1 Move down the stopper

Down: Move stopper down (actuator G1_MB20 is activated, lights up blue when active)

G1_BG20: Sensor G1_BG20 Stopper at bottom (lit green when active)

Stopper: Indicator stopper

2 RFID area

MES Mode: Displays the job data

Default Mode: Displays the RFID status

3 Write and read RFID area

Initialize: Set RFID data to zero

read: Read RFID data

write: Write current data on RFID

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

4 Range Display of the active sensors (lit green when active) and actuators (lit orange when active) at the stopper

5 Display of RFID reading status

Operation


4.6.6 Operation mode Parameters

Set parameters of the application module on the HMI

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

1. On the Start screen, click Setup

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

Operation



1 Here the application module can be activated (tick set). If no application module is activated, the carrier is

stopped at the stopper and released again without processing.

2 Here a simulation of the application module can be selected (tick set). This function is helpful if the application

module is not available, but the function should be integrated into a process. See chapter operator assistance

and simulate application on free AP

3 Here it can be determined in simulation mode whether a operator assistance or the application module should

be simulated. See chapter operator assistance and simulate application on free AP

4 If the processing end is to be confirmed, a check mark must be set here. The process is only continued if this has

been confirmed at the HMI, otherwise the process is automatically continued after the end of processing.

5 The desired return value can be entered here

6 Here you can enter the time required for the simulation.

7 If the check box is set when activating as an I-device, an i-application module must also be located at the

working position. This means that the application module has its own intelligence. This intelligence is then

responsible for controlling the application. In the case of an application without its own intelligence, this is

adopted by the controller of the basic module and no check is to be made.

Operation


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

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

application modules.

Operation


The parameters of the belt drive can be set here.


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

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

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

carrier passing by

3 Belt energy saving mode with sensors:

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

4 Stopper: Check the jam at the belt outlet:

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

Operation


4.6.7 Operation mode System - settings

The system can be set in this operation mode

Position number Description

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

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

unintentional operation is excluded

3 Daylight time set – activate summer time

4 Daylight time reset – activate winter time

5 Send test mail – send test mail to eMailserver (all error messages are sent from the hmi to a eMailserver on

the MES4 PC – this function is to test if the configuration is ok.)

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

7 Button system control: Windows system control is opened

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

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

10 Button switch language: here the language can be changed

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

12 Display date and time of the PLC

13 Display date and time of the HMI touch panel

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

PW: festo)

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

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

Operation


4.7 Operator assistance and simulate application on free AP

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

example on the basic module Linear.

Selection of the mode via the touch panel

Each free application position, which is not equipped with an application module, can provide a simple

operator assistance and a simulate application.

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

1. Generic sequence simulation

2. Operator assictance

The application function is added with a fitted application module

1. Process simulation of the application

2. Operator assictance

3. Application Function

Operation


4.7.1 Generic sequence simulation

1. If the mode is simulate application and a carrier moves into the application, it is stopped. The

application procedure is simulated, this is indicated by the following screen.

2. The processing time in this case is 10 sec. This can be set in the parameters. The current time is

indicated by the bar in progress. At the end of the simulation, the return value is transferred to MES.

3. The carrier is released from the application position.

Operation


4.7.2 Operator assistance with display of pictures

1. If the mode is set to operator assistance (application mode must be set to Standard) and a carrier

moves into the application, it will be stopped.

2. The worker now has to complete the specified work task. This is specified in the transition table and

consists of the element (parameter 1) and the action (parameter 2).

Parameter 1 / Element Parameter 2 / Aktion

0 No element 0 No action

1 Front cover 1 Check

2 Back cover 2 Extract

3 Printed circuit board 3 Assemble

4 Front fuse (in direction of transport) 4 Insert

5 Rear fuse (in direction of transport) 5 Apply

6 Both fuses 6 Rework

7 Workpiece 7 Reserve_7

8 Reserve_8 8 Reserve_8



Operation


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

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

is transmitted to MES

5. The carrier is released from the application position.

Operation


4.7.3 Operator assistance with call of htm-page

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

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

2. The worker now has to complete the specified work task. This is described on a html page, which must

be created by the customer. The URL of this page, which must be present on the MES PC, can be

specified in the work plan of the MES. This worker guide (depending on the html page content) is

started if the OpNo 510 is selected for the AP in the work plan and the URL points to this URL link in the

work step

3. In this case, the html page was designed so that a work instruction for mounting the front fuse appears

in the worker's guidance.

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

is transmitted to MES

5. The carrier is released from the working position.

Operation


4.8 Automatic operation

4.8.1 Start automatic

The operation is the same for all application modules and modules, for the description the basic module is

used with an application module Drilling.

The general rule:

A blinking button is a prompt to start an action.

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

executed.

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

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

2. Press Setup button

Operation


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

4. Press the automatic button

5. Automatic is active

Operation


4.8.2 Stop automatic

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

Operation


4.9 Manually describe the RFID tag

In order to describe a goods carrier with a specific ID, or to get information on which data is stored on the

goods carrier, it is possible to read this data or to describe the tag.

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

station is switched on.

1. Activate the default mode.

2. Select the Setup mode

3. Select the stopper from the setup menu on the left

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

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

6. Press the Delete Data button

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

Operation


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

MES Mode

Carrier ID - displays or enter the carrier number

ONo - the order number is displayed or entered here

OPos - the order position is displayed or entered here

PNo - the part number is displayed or entered here

Resource - here the resource is displayed or entered

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

DefaultMode

State code - here the state code for the start condition is entered, if these match the transition tables,

the parameters are read out and the automatic sequence of the application is started.

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

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

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

Parameters 2 - 4 - not used in this example

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

Components


5 Components 5.1 Electrical components

5.1.1 2 Quadrant Controller

Description

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

The module M-MZ-4-30 is a two-quadrant motor control for DC motors with anti-clockwise and clockwise

rotation. It guarantees a safe starting and stopping as well as the control of the rotational direction of

motors. In off-state, the load is short-circuited which results in a dynamic braking. By the inlet SLOW, you

can switch over from slow speed (adjustment at Tr1) to high speed. At the inlet STOP a limit switch can be

installed.

Use:

Motor controls for brushed motors

Electronic load relay for solenoid valves and various loads

Characteristics • Anti-clockwise and clockwise rotation • Switch-over from high speed to the speed adjusted at the TR.1 • Port for limit switch for stop • Short-circuit proof and temperature protected • Limitation for starting circuit

Components


Technical Data

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

Technical Data

Control

circuit

Input A1/A2

A1=Start clockwise

A2=Start

anticlockwise

Start wave 8 (V)

Stop wave 5 (V)

Allowed range 0-35 (V)

Input A3/A4

A3=slow drive

A4=Stop

Shift wave 8 (V)

Allowed range 0-35 (V)

Adjustment range for turning speed with trimmer at front

plate (typical)

0 to max. turning speed

Start delay at A1 and A2 to 24V < 2 (ms)

Load circle Nominal voltage (power supply) Ub/range 24 (19-30) (VDC)

Load current/constant load 3/5 depends on switching

frequency

(A)

Input current at Un /without load circle T 10 mA (mA)

Loading current Imax. T=1 sec. 20 (A)

Current detection at short 95 Typ. (45-140) A

De-energize time at short 80-400 µs

Other data Current entry at stop <20 (mA)

Allowed surrounding temperature -20 to +40 (C°)

DIN VDE-regulations 0110, 0160 in parts

Any assembly position / DIN-rail assembly No / Yes

Housing Plastic housing light grey

Dimensions 59x77x50 mm

Weight Approx. 100 G

Temperature / short guard Yes / Yes

Connection type

screw connection

4mm², 2,5mm²

Yes

Components


Connection Diagramm

Input/Output Starting Current Limiter Description

Control – K5-KF1 / Q0.4 / 0x+4:4 QA1 / X1:re Transport direction to the right

Control – K5-KF1 / Q0.5 / 0x+5:5 QA1 / X1:li Transport direction to the left

Control – K5-KF1 / Q0.6 / 0x+6:6 QA1 / X1:sl Transport slow speed

Conveyor motor DC / -XJM1:4 QA1 / X2:M1 Conveyor motor connection

Conveyor motor DC / -XJM1:3 QA1 / X2:M2 Conveyor motor connection

Components


5.2 PLC Siemens

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

For detailed information see electrical circuit diagram.

Components


5.3 PLC Festo CECC

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

Festo CECC

Position Description Comment

1 USB interface For external memory

2 Ethernet interface RJ 45 For external PC (for programming with CodeSys) or for external operation panel

CDPX

3 CanOpen interface To connect CanOpen slaves

Components


5.4 Turck Interface

Turck interface

For detailed information see electrical circuit diagram.

Components


5.5 Scalance Ethernet Switch

Siemens Scalance Ethernet switch

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

Components


Product properties

SCALANCE X-208

Operating Instructions, 12/2011, A5E00349864-19

TP ports / Connector pinout

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

Dependent Interface–Autocrossover) of a network component.

RJ-45 jack

Pin number

Assignment

Pin 8 n. c.

Pin 7 n. c.

Pin 6 TD-

Pin 5 n. c.

Pin 4 n. c.

Pin 3 TD+

Pin 2 RD-

Pin 1 RD+

NOTICE

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

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

between two devices depending on the cable type.

Autonegotiation

Autonegotiation means the automatic detection of the functionality of the port at the opposite end. Using

autonegotiation, repeaters or end devices can detect the functionality available at the port of a partner

device allowing automatic configuration of different types of device. With autonegotiation, two components

connected to a link segment can exchange parameters and set themselves to match the supported

communication functionality.

Note

If an IE switch port operating in autonegotiation mode is connected to a partner device that is not operating

in autonegotiation mode, the partner device must be set permanently to half duplex mode. If an IE switch

port is set permanently to full duplex, the connected partner device must also be set to full duplex. If the

autonegotiation function is disabled, the MDI/MDI-X auto crossover function is also inactive. This means it

may be necessary to use a crossover cable.

Components


Note

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

MDI /MDIX autocrossover function

The advantage of the MDI /MDIX autocrossover function is that straight-through cables can be used

throughout and crossover Ethernet cables are unnecessary. This prevents malfunctions resulting from

mismatching send and receive wires. This makes installation much easier for the user. IE Switches X-200

support the MDI / MDIX autocrossover function.

NOTICE

Please note that the direct connection of two ports on the switch or accidental connection over several

switches causes an illegal loop. Such a loop can lead to network overload and network failures.

Auto polarity exchange

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

automatically.

Components


5.6 RFID with Ethernet

Turck - BLCEN-2M12MT-2RFID-A

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

Position Order Number 6811484

1 Ethernet connection RSSD-RSSD 441-2M

2 Ethernet connection RSSD-RSSD 441-2M

3 Rotary coding switch for addressing

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

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

6 Power supply

7 Power supply

Components


I/O data mapping

The BLident RFID-a interface modules cannot be controlled by the process data only. In any case, there is a

software functional module required in the control. The functional module has been standardized for the

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

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

Chanel 0 0 Status word channel 0- low byte

1 Status word channel 0- high byte

Chanel 1 2 Status word channel 1- low byte

3 Status word channel 1- high byte

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

Chanel 0 0 Control word channel 0- low byte

1 Control word channel 0- high byte

Chanel 1 2 Control word channel 1- low byte

3 Control word channel 1- high byte

Components


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

Pos Name

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

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

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

4 Ethernet cable from Turck module to controller (via Scalance)

5 Turck cable from Turck read-write head to Turck module

6 Turck cable from Turck read-write head to Turck module

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

Components


RFID read-write head

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

Its designation is TB-M18-H1147.

Name

Operating voltage 10…30 VDC

DC rated operating current 0-80 mA

Operating voltage DC

Data transfer Inductive coupling

Working frequency 13,56 MHz

Read-write distance max. 30 mm

Components


5.7 RFID with CanBus

Read/write head

Metal thread M18 x 1

Application Detection of objects on transport equipment and in mobile applications

Switching output CANopen interface

Operating voltage [V] 9...32 DC

Current consumption [mA] < 50 (24 V) / < 80 (12 V)

Protection class III

Operating frequency [MHz] 13.56

standard ISO 15693

Distance to the ID tag * [mm] ≤ 18

Distance between read/write heads [mm] ≥ 50 side

≥ 100 front

Ambient temperature [°C] -40...85

Storage temperature [°C] Protection

-40...85

IP 67 / IP 69K

Displays / operating elements

1 LED green continuous light Preoperational mode

1 LED green flashing light Operational mode

1 LED Red flashing light Error

1 LED yellow continuous light tag communication

Connection M12 connector

Wiring

1 Not used

2 U+

3 GND

4 CAN_H

5 CAN_L

Components


5.7.1 Mini Terminal

Multi-pin plug distributor

The multi-pin plug distributor is designed for the inputs and outputs of the station. You can connect PNP

sensors and two-pole actuators there. The connection is effected by three-pole M8x1 plugs, and the bus

terminal by a 15pole sub-D plug connector. The operating status is displayed on yellow LEDs.

Pin allocation on the multi pin plug distributor

Pin allocation 15pole sub-D plug connector

• Signal lines Pin 1 to Pin 12

• DC 24V Pin 13

• 0V Pin 14 and Pin 15

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

• slots 0 to 11

• Signal line socket 4

• DC 24V socket 1

• 0V socket 3

Components


XD20 – Multi pin distributor MPV1 / front side

15-pole D-Sub Pin Bit Name

1 Bit 0 Stopper 1 down / -BG20

2 Bit 1 Stopper 1 lower / -MB20

3 Bit 2 Pallet available identity sensor 1 / -BG21

4 Bit 3 Reserve

5 Bit 4 Identity sensor 2 / -BG22

6 Bit 5 Reserve


8 Bit 7 Reserve


10 Bit 9 Reserve

11 Bit 10 Option / downstream station free 1

12 Bit 11 Reserve / Option station occupied 1

13 +24 V

14 and 15 0V

Components


Pos Designation Pos Designation

1 Mounting hole 12 Inscription label

2 15 pole sub-D plug 13 PIN 8

3 PIN 1 14 PIN 15

4 PIN 9 15 Inscription label

5 Mounting hole M3 16 OUT 0

6 IN 0 17 OUT 1

7 IN 1 18 OUT 2

8 IN 2 19 OUT 3

9 IN 3 20 OUT 4

10 IN 4 21 OUT 5

11 IN 5

Components


5.7.2 SYS link interface

Syslink allocation

SYSlink PIN Bit Description Syslink PIN Bit Function

01 0 Output AX.0 13 0 Input EX.0




05 4 Output AX.4 17 4 InputEX.4


07 6 Output AX.6 19 6 InputEX.6


09 24V Power Supply 21 24V Power Supply




Components


5.8 Mechanic components

5.8.1 Motor of Conveyor

Motor type 403438

The motor has got the equipment identifier / 3M1

Name

Nominal voltage UN /Volt 36

Idling speed n0 [min-1] 120

Rated torque MN [Nm] 2

Starting torque MA [Nm] 16

Gear ratio i 53/2

Connection resistance 2 vanes R [m ] 3400

Connection resistance 4 vanes R [m ] 3000

Protection class IP 30 30

Weight [kg] 1

Components


5.8.2 The stopper unit

CP Factory Stopper Unit


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

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



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

6 Stopping unit

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

8 Sensor Stopper lowered / Ordernumber 574334 / SMT-8M-A-PS-24V-E-0,3-M8D

9 one-way flow control valve / Ordernumber. 193967 / GR-QS-4

Components


Diagram of pneumatics, Stopper Unit

Components


5.8.3 Transportation of the Basic Module

CP Factory Transportation methode

With the help of mechanically adjustable feet, you can lower the Basic Module ByPass and then put it on the

rollers. In this way, an easy transport is possible. If you wind up the machine mounts, you can move the

Basic Module ByPass easily to another place.


1 Star knob for adjusting the height of the machine mount

2 Roller

3 Lock nut for locking the machine mount in the position required

Components


Festo Didactic SE

Rechbergstraße 3

73770 Denkendorf

Germany

Internet: www.festo-didactic.com

E-mail: [email protected]

Date post:	07-Nov-2021
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