8043916

Basic module linear

CP Factory

Translation of the
original operating
instructions

Festo Didactic
8043916 en
10/2021
Order number: 8043916
Date: 10/2021
Authors: Schober
Layout: Frank Ebel
File Name: CP-F-LINEAR-GB-A004.doc

© Festo Didactic SE, Rechbergstr. 3, 73770 Denkendorf, Germany, 2021

+49 711 3467-0 www.festo-didactic.com

+49 711 34754-88500 [email protected]

Translation of the original instructions

© 2021 all rights reserved to Festo Didactic SE.

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

CAUTION
These operating instructions must be available to the user at all times.
The operating instructions must be read before commissioning.
The safety instructions must be observed.
Non-observance may result in severe personal injury or damage to property.

Main document
Associated documents attached:

Safety instructions concerning transport (print/electronic)

Component datasheets (print/electronic)
Circuit diagram (print/electronic)

Festo Didactic
8043916 en
10/2021
 Contents

Contents

1 Safety instructions ........................................................................................................................................ 6

1.1 Warning notice system ........................................................................................................................... 6
1.2 Pictograms ............................................................................................................................................. 7
1.3 General prerequisites for installing the product ..................................................................................... 8
1.4 General prerequisites for operating the devices .................................................................................... 8
2 Intended use ................................................................................................................................................. 9
3 For your safety ............................................................................................................................................ 10
3.1 Important information .......................................................................................................................... 10
3.2 Qualified persons ................................................................................................................................. 11
3.3 Obligations of the operating company ................................................................................................. 11
3.4 Obligations of the trainees ................................................................................................................... 11
4 Basic safety instructions ............................................................................................................................. 12
4.1 General information ............................................................................................................................. 12
4.2 Mechanical components ...................................................................................................................... 12
4.3 Electrical components .......................................................................................................................... 13
4.4 Pneumatic components ........................................................................................................................ 16
4.5 Guarantee and liability for application examples ................................................................................. 18
4.6 Cyber security ...................................................................................................................................... 18
4.7 Additional safety instructions .............................................................................................................. 19
4.8 Guarantee and liability ......................................................................................................................... 20
4.9 Transport.............................................................................................................................................. 21
4.10 Name plates stations ......................................................................................................................... 22
4.11 General machine safety ...................................................................................................................... 23
4.12 Protective devices .............................................................................................................................. 24
4.12.1 Panel doors on underground control cabinet .............................................................................. 24
4.12.2 Emergency stop ........................................................................................................................... 25
4.12.3 Additional protective devices ...................................................................................................... 25
5 Technical data ............................................................................................................................................. 26
5.1 Setup.................................................................................................................................................... 27
6 Introduction ................................................................................................................................................ 30
6.1 General information about CP Factory .................................................................................................. 30
6.2 Resources ............................................................................................................................................ 31
7 Design and Function ................................................................................................................................... 35
7.1 Transport .............................................................................................................................................. 35
7.2 Overview of the System ........................................................................................................................ 37
7.3 Basic module linear .............................................................................................................................. 38
7.4 Mechanical setup ................................................................................................................................. 40
7.4.1 Supply of the Basic Module ........................................................................................................... 44
7.5 Electrical installation ............................................................................................................................ 46
7.5.1 Cabling chart ................................................................................................................................. 51
7.5.2 Emergency-stop structure ............................................................................................................. 54
7.6 Function extension by application modules ......................................................................................... 57
7.6.1 Assembly of an CP application module to a CP Factory basic module ........................................... 57
7.6.2 Connecting the CP application module electrically to the CP Factory basic module ...................... 60

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Contents

7.6.3 Pneumatic connection from application modules.......................................................................... 61

7.7 Commissioning ..................................................................................................................................... 62
7.7.1 Pneumatic commissioning ............................................................................................................. 62
7.7.2 Electrical commissioning ............................................................................................................... 62
7.8 Visual inspection .................................................................................................................................. 62
7.9 Adjusting the sensors ........................................................................................................................... 63
7.9.1 Proximity switch (stopper Identsensor) ......................................................................................... 63
7.9.2 Proximity switch (stopper cylinder) ............................................................................................... 65
7.10 Adjusting the one-way flow control valves ......................................................................................... 67
8 Operation .................................................................................................................................................... 69
8.1 Starting the station .............................................................................................................................. 69
8.2 The control units of the basic module linear ........................................................................................ 69
8.3 Sequence description stopper of the basic module linear.................................................................... 70
8.4 Menu architecture from operation panel .............................................................................................. 72
8.5 Operation modes ................................................................................................................................. 75
8.5.1 Mode ............................................................................................................................................. 75
8.5.2 Operation mode Reset ................................................................................................................... 78
8.5.3 Operation mode Setup .................................................................................................................. 79
8.5.4 Operation mode automatic ........................................................................................................... 92
8.5.5 Main menu - Home ........................................................................................................................ 93
8.5.6 Main menu - Setup ........................................................................................................................ 98
8.5.7 Main menu – Parameter ................................................................................................................ 98
8.5.8 Main menu – System ................................................................................................................... 101
8.6 Switching on the station..................................................................................................................... 109
8.6.1 Start automatic............................................................................................................................ 110
8.6.2 Sequence Description Automatic ................................................................................................ 113
8.6.3 Process description Cycle End ..................................................................................................... 114
8.7 Operator assistance and simulate application on free AP .................................................................. 115
8.7.1 Generic sequence simulation ...................................................................................................... 116
8.7.2 Operator assistance with display of pictures ............................................................................... 117
8.7.3 Operator assistance with call of htm-page .................................................................................. 119
8.8 Writing on the RFID tag manually ....................................................................................................... 120
8.8.1 Pallet carriers .............................................................................................................................. 120
9 Components .............................................................................................................................................. 122
9.1 Electrical components ........................................................................................................................ 122
9.1.1 2 Quadrant Controller .................................................................................................................. 122
9.2 PLC Siemens ....................................................................................................................................... 125
9.3 PLC Festo CECC................................................................................................................................... 126
9.4 Turck Interface ................................................................................................................................... 127
9.5 PLC FESTO CPX-E ................................................................................................................................ 128
9.5.1 Touch Panel ................................................................................................................................. 129
9.6 Scalance Ethernet Switch ................................................................................................................... 132
9.7 RFID with Ethernet .............................................................................................................................. 135
9.7.1 Electronic circuit protection ......................................................................................................... 138
9.7.2 Power supply unit ........................................................................................................................ 140
9.7.3 SAFETY RELAY ............................................................................................................................. 142
9.7.4 Mini Terminal .............................................................................................................................. 143

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9.7.5 SYS link interface ........................................................................................................................ 146

9.8 Mechanic components ....................................................................................................................... 147
9.8.1 Motor of Conveyor ....................................................................................................................... 147
9.8.2 The stopper unit .......................................................................................................................... 148
9.8.3 Transportation of the station ....................................................................................................... 150
9.8.4 Operation panel working position ............................................................................................... 151
10 Message texts and interactive error messages at the HMI ...................................................................... 153
10.1 Message texts .................................................................................................................................. 153
10.2 Interactive error messages ............................................................................................................... 154
10.2.1 Default operation ...................................................................................................................... 154
10.2.2 MES Operation .......................................................................................................................... 155
10.2.3 General ...................................................................................................................................... 155
11 Service and cleaning ............................................................................................................................... 156
12 Further information and updating ........................................................................................................... 157
13 Disposal .................................................................................................................................................. 158

© Festo Didactic 8043916 en 5

Safety instructions

1 Safety instructions
1.1 Warning notice system
These operating instructions contain notes that must be observed for your personal safety and in order to
prevent property damage. The notes concerning your personal safety are indicated by a safety symbol.
Notes that only concern property damage are not indicated by a safety symbol.
The notes below are listed in order of hazard level.

DANGER
... indicates an imminently hazardous situation that will result in fatal or severe personal
injury if not avoided.

WARNING
… indicates a potentially hazardous situation which may result in fatal or severe
personal injury if not avoided.

CAUTION
... indicates a potentially hazardous situation that may result in moderate or slight
personal injury or severe property damage if not avoided.

NOTE
... indicates a potentially hazardous situation that may result in property damage or loss
of function if not avoided.

In cases where more than one hazard level applies, the safety note with the highest hazard level will be
shown. A safety note may concern both personal injury and property damage.
Hazards that will only result in property damage are indicated with the word "Note".

6 © Festo Didactic 8043916 en

 Safety instructions

1.2 Pictograms
This document and the hardware described in it include warnings concerning possible hazards which may
arise if the system is used incorrectly.
The following pictograms are used:

Hazard warning

Warning - dangerous electric voltage

Read and observe the operating and safety instructions prior to commissioning.

Switch off the device and unplug the connection for power supply from the plug socket
before commencing installation, repair, maintenance or cleaning work.

Warning – hot surface

Warning – hand injuries

Warning – risk of entanglement

Warning – lifting heavy loads

Electrostatically sensitive devices

Information and/or references to other documentation

© Festo Didactic 8043916 en 7

Safety instructions

1.3 General prerequisites for installing the product

• Festo Didactic products must only be used for the applications specified in their respective operating
instructions. Products or components supplied by other manufacturers must only be used if
recommended or approved by Festo.
• The products must be transported, stored, installed, assembled, commissioned, operated and
maintained properly in order to ensure their safe operation.
• The approved ambient conditions must be observed. The specifications in the relevant operating
instructions must be observed.
• The safety equipment must be tested every working day.
• Connecting cables must be checked for damage before each use. In case of damage, they must be
replaced.

Connecting cables must correspond to the minimum specifications.

1.4 General prerequisites for operating the devices

General requirements for safe operation of the system:
• In industrial facilities, the national accident prevention regulations must be observed.
• The laboratory or classroom must be overseen by a supervisor.
– A supervisor is a qualified electrician or a person who has been trained in electrical engineering,
knows the respective safety requirements and safety regulations, and whose training has been
documented accordingly.

The laboratory or the classroom must be equipped with the following devices:
• An emergency-off device must be provided.
– At least one emergency-off device must be located inside the laboratory or the classroom, and at
least one outside it.
• The laboratory or classroom must be secured so that the operating voltage and compressed air supply
cannot be activated by any unauthorized persons, for example by means of:
– e.g. a keyswitch
– e.g. lockable shut off valves
• The laboratory or classroom must be protected by residual current devices (RCDs).
– RCDs with a differential current of ≤ 30 mA, Type B. When operating machinery with unavoidable
leakage current, suitable measures must be implemented and documented in the corresponding
workplace risk assessment.
• The laboratory or classroom must be protected by overcurrent protection devices.
– Fuses or circuit breakers
• Devices must not be used if they are damaged or defective.
– Damaged devices must be barred from further use and removed from the laboratory or classroom.
– Damaged connecting cables, pneumatic tubing and hydraulic hoses represent a
safety risk and must be removed from the laboratory or classroom.
• Safety devices must be checked every working day to ensure that they are fully functional.
• Connecting cables and accessories must be checked for damage before each use.

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 Basic safety instructions

2 Intended use
Festo Didactic systems and components must only be used:
• For their intended use in teaching and training applications
• When their safety functions are in perfect condition

The components and systems are designed in accordance with the latest technology and recognized safety
rules. However, life and limb of the user and third parties may be endangered and the components may be
impaired if they are used incorrectly.

The Festo Didactic learning system has been developed and produced exclusively for education and training
in the field of automation technology. The training company and/or trainers must ensure that all trainees
observe the safety precautions described in these operating instructions.

Training with complex machinery is a highly hazardous activity. The operating company must draw up and
document a workplace risk assessment. The trainees must be briefed on all the relevant safety aspects
before work commences.

Festo Didactic hereby excludes any and all liability for damages suffered by apprentices, the training
company and/or any third parties, which occur during use of the device in situations which serve any
purpose other than training and/or vocational education, unless such damages have been caused by
Festo Didactic due to malicious intent or gross negligence.

All extensions and accessories must be approved by Festo Didactic, and are only permitted for use for their
intended purpose.

The machine fulfils the requirements of the European directives that applied when it was commissioned. Any
modification to the machine shall render the manufacturer's CE Declaration of Conformity null and void. The
CE Declaration of Conformity must be renewed following each major modification.

© Festo Didactic 8043916 en 9

For your safety

3 For your safety

3.1 Important information
Knowledge of the basic safety instructions and safety regulations is a fundamental prerequisite for safe
handling and trouble-free operation of Festo Didactic components and systems.

These operating instructions include the most important instructions for safe use of the components and
systems. In particular, the safety instructions must be adhered to by all persons who work with these
components and systems. Furthermore, all pertinent accident prevention rules and regulations that are
applicable at the respective place of use must be adhered to.

WARNING
• Malfunctions which could impair safety must be eliminated immediately!

CAUTION
• Improper repairs or modifications may result in unforeseeable operating statuses.
Do not carry out any repair or alternation work on components or systems that is
not described in these operating instructions.

10 © Festo Didactic 8043916 en

 For your safety

3.2 Qualified persons

• The product described in these operating instructions is only permitted for operation by persons who
are qualified for the task in question in accordance with the operating instructions, especially the safety
instructions.
• Qualified persons are defined as persons whose training and experience enables them to recognize
risks and avoid potential dangers when working with this product.

3.3 Obligations of the operating company

It is the responsibility of the operating company to ensure that the station is operated safely.

The operating company undertakes to allow only those persons to work with the components and systems
who:
• Are familiar with the basic regulations regarding occupational safety, with the safety instructions, and
with the accident prevention regulations, and who have been instructed in the use of the components
and systems
• Have read and understood the safety chapter and warnings in these operating instructions
• Are qualified to operate the components and systems in question
• Are governed by and trained in suitable organizational measures to ensure safe training

Personnel should be tested at regular intervals to ensure that they are safety-conscious in their work habits.

3.4 Obligations of the trainees

All persons who have been entrusted to work with the components and systems undertake to complete the
following steps before beginning work:
• Read the chapter concerning safety and the warnings in these operating instructions
• Familiarize themselves with the basic regulations regarding occupational safety and accident prevention

© Festo Didactic 8043916 en 11

Basic safety instructions

4 Basic safety instructions

4.1 General information

CAUTION
• Trainees must be supervised by an instructor at all times when working with the
components and systems.
• Observe the specifications included in the technical data for the individual
components and in particular all the safety instructions!
• Wear your personal protective equipment (safety goggles, safety shoes).
• Never leave objects lying on the top of protective enclosures. Vibrations could
cause such objects to fall off.

4.2 Mechanical components

WARNING
• Switch off the power supply!
– Switch off both the operating power and the control power before commencing
work on the circuit.
– Never reach into the setup unless it is at a complete standstill.
– Be aware of potential overtravel times for the actuators.
• Risk of injury during troubleshooting!
– Use a tool such as a screwdriver for actuating sensors.

CAUTION
• Risk of burns due to hot surfaces
– Devices can reach high temperatures during operation, as a result of which they
can cause burns if touched.
• Measures to take when maintenance is required.
– Allow the device to cool off before commencing work.
– Use suitable personal protective clothing, e.g. safety gloves.

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 Basic safety instructions

4.3 Electrical components

DANGER
• Risk of fatal injury in case of interrupted protective grounding conductor!
– The protective grounding conductor (yellow-green) must not be interrupted,
either inside or outside of the device.
– The insulation of the protective grounding conductor must never be damaged or
removed.
• Risk of death from connecting power supply units in series!
Contact voltages of greater than 25 V AC or 60 V DC are not permissible.
Contact with voltages of greater than 50 V AC or 120 V DC may be fatal.
– Do not connect power supplies in series.
• Risk of death due to electric shock!
Protect the outputs of the power supplies (output sockets/terminals) and cables
connected to them from direct contact.
– Always use connector cables with adequate insulation and electric strength.
– Use safety sockets with fully shrouded contact points.

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Basic safety instructions

WARNING
• Disconnect from all sources of electrical power!
– Switch off the power supply before working on the circuit.
– Please note that electrical energy may be stored in individual components.
Further information on this issue is available in the datasheets and operating
instructions included with the components.
– Warning!
Capacitors inside the device may still be charged even after being disconnected
from all sources of voltage.
• Danger due to malfunction
– Never place or leave liquids (e.g. drinks) on the station in open containers.
– The machine must not be switched on if there is condensation (moisture) on its
surface.
– Never lay pipes/hoses designed to carry liquid media near the machine.
• Electric shock due to connection to unsuitable power supply!
– When devices are connected to an unsuitable power supply, exposed
components can cause dangerous electrical voltage that can lead to severe or
fatal injury.
– Always use power supplies that provide SELV (safety extra-low voltage) or PELV
(protective extra-low voltage) output voltages for all the connections and
terminals on the electronics modules.
• Electric shock when there is no protective grounding in place
– If there is no protective grounding terminal in place for a Protection Class I
device, or if the protective grounding terminal has not been installed correctly,
exposed, conductive parts may carry high voltages, thus causing severe or fatal
injury if touched.
– Ground the device in accordance with the applicable regulations.

WARNING
• Risk of fire due to use of unsuitable power supply
– If a device i connected to an unsuitable power supply, this can cause
components to overheat, leading to a breakout of fire.
– Always use limited power supplies (LPSs) for all the connections and terminals
on the electronics modules.

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 Basic safety instructions

CAUTION
• Always ensure that your connecting cables are designed for use with the electrical
connections in question.
• When laying connecting cables, make sure they are not kinked, sheared or
pinched. Cables laid on the floor must be covered with a cable bridge to protect
them.
• Do not lay cables over hot surfaces.
– Hot surfaces are identified with a corresponding warning symbol.
• Make sure that connecting cables are not subjected to continuous tensile loads.
• Devices with a grounding terminal must always be grounded.
– If a ground connection (green-yellow laboratory socket) is available, it must
always be connected to the protective grounding. The protective grounding
must always be connected first (before voltage) and disconnected last (after
disconnecting the voltage).
– Some devices have high leakage current. These devices must be fitted with a
grounding conductor for additional grounding.
• When replacing fuses, always use specified fuses with the correct current rating
and tripping characteristics.
• The device is not equipped with a built-in fuse unless otherwise specified in the
technical data.
• Safe operation of the device is not possible in the event of any of the following
circumstances:
– Visible damage
– Malfunction
– Inappropriate storage
– Incorrect transport
• Switch off the power supply immediately.
• Protect the device to prevent it from being restarted accidentally.

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Basic safety instructions

4.4 Pneumatic components

WARNING
• Depressurize the system!
– Switch off the compressed air supply before working on the circuit.
– Check the system using pressure gauges to make sure that the entire circuit is
fully depressurized.
– Please note that energy may be stored in reservoirs. Further information on this
issue is available in the datasheets and operating instructions included with the
components.
• Risk of injury when switching on compressed air!
– Cylinders may advance and retract automatically.
• Risk of accident due to advancing cylinders!
– Always position pneumatic cylinders so that the piston rod’s working space is
unobstructed along its entire stroke range.
– Make sure that the piston rod cannot collide with any of the rigid components in
the setup.
• Risk of accident due to pneumatic tubing slipping off!
– Use shortest barbed tubing connectors possible.
– If pneumatic tubing slips off, switch off the compressed air supply immediately.
• Do not exceed the maximum permissible pressure of 600 kPa (6 bar).
• Do not switch on the compressed air until all the barbed tubing connectors have
been connected and secured.
• Do not disconnect pneumatic tubing while it is under pressure.
– Do not attempt to seal or plug pneumatic tubing or plug connectors with your
hands or fingers.
• Check the condition of the condensate in the service unit regularly. If necessary,
drain the condensate and dispose of it properly.

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 Basic safety instructions

CAUTION
• Setting up pneumatic circuits
– Connect the devices with plastic tubing with an outside diameter of 4 or 6 mm.
– Push the pneumatic tubing into the push-in connector as far as it will go.
• Dismantling pneumatic circuits
– Switch off the compressed air supply before dismantling the circuit.
– Press the blue release ring down so that the tubing can be pulled out.
• Noise due to escaping compressed air
– Noise caused by escaping compressed air may damage your hearing. Reduce
noise by using mufflers, or wear hearing protection if the noise cannot be
avoided.
– All of the exhaust ports on the components included in the equipment set are
equipped with mufflers. Do not remove these mufflers.

© Festo Didactic 8043916 en 17

Basic safety instructions

4.5 Guarantee and liability for application examples

The application examples are not legally binding, and we cannot guarantee their completeness in terms of
their configuration, their equipment or any events that may occur. The application examples are not
representations of any specific customer solution; they are merely intended to illustrate typical tasks for
which the product in question could be used. You bear the responsibility for ensuring that the products
described here are operated properly. These application examples do not in any way relieve you of your
responsibility to ensure that the system is handled safely when it is being used, installed, operated or
maintained.

4.6 Cyber security

Note
Festo Didactic offers products with industrial security functions that aid the safe operation of plants,
systems, machines and networks. In order to protect plants, systems, machines and networks from cyber
threats, a comprehensive industrial security concept must be implemented and continuously updated.
Festo's products and services only constitute one part of such a concept.
The customer is responsible for preventing unauthorized access to their plants, systems, machines and
networks. Systems, machines and components should only be connected to a company's network or the
Internet if and as necessary, and only when the suitable security measures (e.g. firewalls and network
segmentation) are in place. Furthermore, Festo's guidelines on suitable security measures should be
observed. Festo products and solutions are constantly being developed further in order to make them more
secure. Festo strongly recommends that customers install product updates as soon as they become
available and always use the latest versions of its products. Any use of product versions that are no longer
supported or any failure to install the latest updates may render the customer vulnerable to cyber attacks.

WARNING
• Unsecure operating conditions due to software tampering
– Forms of software tampering (e.g. viruses, Trojans, malware and worms) can
lead to unsecure operating conditions in your system, which may in turn lead to
severe or fatal injury or property damage.
– Keep your software up to date.
– Integrate the automation and actuator components into an overarching and
comprehensive industrial security concept for the installation or machine in
question that is in line with the latest technological developments.
– Make sure that all the products you have installed are incorporated into your
overarching industrial security concept.
– Use suitable measures, such as a virus scanner, to protect files save on
exchangeable storage media from malware.

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 Basic safety instructions

4.7 Additional safety instructions

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 connector cables and devices must not be exceeded.
– Always compare the current ratings of the device, the cable and the fuse to ensure that they match.
– If they do not match, use a separate upstream fuse in order to provide appropriate overcurrent
protection.
• Devices with a grounding terminal must always be grounded.
– If a ground terminal (green-yellow laboratory socket) is available, it must always be
connected to protective ground. The protective grounding must always be connected first (before
voltage) and disconnected last (after disconnecting the voltage).
• The device is not equipped with a built-in circuit unless otherwise specified in the technical data.

WARNING
• This product is designed for use in industrial environments, and may cause
malfunctions if used in domestic or small commercial environments.

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Basic safety instructions

4.8 Guarantee and liability

Our General Terms and Conditions of Sale and Delivery shall apply at all times. These shall be made
available to the operating company no later than upon conclusion of the sales contract. Guarantee and
liability claims resulting from personal injury and/or property damage are excluded if they can be traced
back to one or more of the following causes:
• Use of the equipment for purposes other than its intended use
• Improper installation, commissioning, operation or maintenance of the system
• Operation of the system with defective safety equipment, or with improperly attached or non-functional
safety equipment and protective guards
• Non-compliance with directions included in the operating instructions with regard to transport, storage,
installation, commissioning, operation, maintenance and setup of the system
• Unauthorized modifications to the system
• Improperly executed repairs
• Disasters resulting from the influence of foreign bodies and acts of God
• Dust generated during construction work must be kept away from the system (use coverings).
See the Environmental Requirements section (contamination level) for more details.

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 Basic safety instructions

4.9 Transport

WARNING
• Danger due to tipping over
– Suitable packaging and transport equipment must be used when transporting
the station. The station can be lifted from underneath using a forklift truck.
Please note that eccentric centers of gravity can cause the station to tip over.
– Stations with attachments at height will have a high center of gravity.
– Take care to avoid tipping over during transportation.

CAUTION
• Danger due to broken castors!
The castors on the device are not designed to be used for transportation.
The castors are designed merely for positioning the station. The screw feet must
relieve the castors of all the station's weight before commissioning begins.
The screw feet must be set so that the station is horizontal and aligned at the same
height as its neighboring station.
– Safety shoes must be worn when transporting the station!

NOTE
• Station contains delicate components!
– Take care not to shake during transportation
– The station is only permitted for installation on solid, non-vibrating surfaces.
– Make sure that the ground underneath the station has sufficient load-bearing
capacity.

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Basic safety instructions

4.10 Name plates stations

Name plate example

Position Description

1 Description / Configuration

2 Intern material number

3 Order number, charge code, year of construction

4 Data electrical connection

5 Current consumption, short-circuits strength, input pressure compressed air (bar / psi)

6 Unique-ID, unique machine identification

7 Manufacturer's address

8 Data matrix code of a link to the website of the product

9 CE Identification

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 Basic safety instructions

4.11 General machine safety

WARNING
• General machine safety, CE conformity
– The individual modules of this system contain control programs for which the
safety of the machine has been evaluated.
– The safety-related parameters and checksums of the safety function are listed
in the operating instructions for the respective stations.
– Changes to programs may impair the safety of the machine. A modified control
program may constitute a major change to the machine.
– In such cases, the manufacturer's CE Declaration of Conformity shall be
rendered null and void. The operating company will need to re-evaluate the
safety of the machine and confirm its CE conformity.

© Festo Didactic 8043916 en 23

Basic safety instructions

4.12 Protective devices

In order to reduce risks, this machine contains guards to prevent access to dangerous areas. These guards
must not be removed or tampered with.

WARNING
• Damage to the safety window
– Windows must not be cleaned using aggressive or alcoholic cleaning agents.
Risk of brittleness and breakage!
– This protective device must be replaced if it shows any signs of damage. Please
contact our Service department to arrange this.

4.12.1 Panel doors on underground control cabinet

Transparent, impact-resistant, polycarbonate plate with lock.
Can only be accessed with tool (control cabinet key); tool must be kept in a secure place!
Access reserved for qualified electricians.
The safety door is not monitored! Make sure the safety door is always closed.

Illustration similar

The hinges of the control cabinet doors are provided with spring steel sheets (1). If the switch cabinet locks
(2) are not locked, the door is automatically opened a crack and reminds the user to firmly lock the door
with the switch cabinet locks.

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 Basic safety instructions

4.12.2 Emergency stop

Every station contains an emergency stop mushroom actuator. All the emergency stop actuators in the
system are interconnected. The emergency stop signal shuts off all the actuators. Operator confirmation is
required to restart the system; there is no automatic restart.

4.12.3 Additional protective devices

The individual components, such as the power supplies and the controllers, possess built-in safety functions
such as short-circuit protection, overcurrent protection, overvoltage protection and thermal monitoring. If
necessary, consult the instruction manual for the device in question for more information.

© Festo Didactic 8043916 en 25

Technical data

5 Technical data
Parameter Value

Electrics

Operating voltage 3-phase 400 V AC±10%, 50 Hz

Power supply system TNC-S, mains conductor L1, L2, L3, neutral conductor N, protective grounding PE

Full load power 1A

Control voltage, 24 V DC
Voltage for small actuators Protective extra-low voltage (PELV)

Power supply connection IEC 60309, CEE 16 A

Max. backup fuse for installation 16 A

Leakage current <= 18 mA

Connecting cable between stations System plug

Protection class I, Operation with protective grounding only.

Second protective grounding conductor required due to high leakage current

Overvoltage category CAT II, Operation in building installation only

Short circuit current rating (SCCR) 10 kA

Compressed air

Supply pressure 6 bar, 90 psi

Supply rate >= 40 l/min

Compressed air quality EN ISO 8573-1

Pressure dew point (Class 4) <= +3°C

Ambient conditions

Operating environment Use inside building only

Ambient temperature 5°C … 40°C

Rel. air humidity 80% up to 31°C

Pollution degree 2, Dry, non-conductive contamination

Operating height Up to 2000 m above NN (sea level)

Noise emission level LpA < 70 dB

Certification

CE marking in accordance with: Machinery Directive

EMC Directive
RoHS Directive

EMC environment Industrial environment, Class A (in acc. with EN 55011)

Subject to change

26 © Festo Didactic 8043916 en

 Technical data

5.1 Setup

Drawing with closed doors / illustration similar

© Festo Didactic 8043916 en 27

Technical data

Drawing with open doors 90° / illustration similar

28 © Festo Didactic 8043916 en

 Technical data

Drawing with open doors 180° / illustration similar

Recommended minimum distance from the spatial boundary is 1.2 m

© Festo Didactic 8043916 en 29

Introduction

6 Introduction
6.1 General information about CP Factory
The CP Factory has been developed in close co-operation with teachers and instructors. The result is a
training system meeting all demands on modularity, mobility, flexibility and openness due to its completely
new characteristics.
The station provides an appropriate system for practice-orientated tuition of the following key qualifications
• Social competence,
• Professional competence and
• Methodological competence,

Which are required in today's complex world of employment. This is much easier now with use of the
CP Factory.
The two-sided symmetrical basic modules with accompanying control board and control unit are identical.
With their technical system „transfer line with drive unit and stopper unit“, they are ideal for the training in
SPS programming and drive technology from basics to medium level.
Due to the patented passive pallet return systems, the continuous working process „pallet circulation“ is
already possible when using one single basic module.
The industrial-relevant basic process „pallet circulation“ already contains a large number of important
course contents such as:
• drive technology with DC geared motor
• drive technology with asynchronous motor and converter (optional)
• drive technology with servo motor and servo converter (optional)
• pallet-stop setting
• pallet-stroke setting and pallet-indexing (optional)
• pallet identification by binary coding
• pallet identification by RFID
• speed and position recording by pulse generating disc (optional)
• basics on electro pneumatics (stop-cylinder model)
• basics on SPS programming
• SPS programming in steps
• SPS programming operating modes
• SPS programming binary coding
• SPS programming communication by frequency converter (optional)
• SPS programming communication by RFID (optional)
• SPS programming/visualization by touch panel (optional)

The basic module becomes a station by adding technology-specific application modules like magazines,
handling or machining units. The standardized mechanical and electrical interface of application and basic
module allows an unproblematic starting-up.
The CP Factory is a perfect platform for nearly all course contents. It helps to improve the co-operation of
different teams and to extend the ability of understanding processes.
On this system, especially the topics about networking, communication and data acquisition can be shown
in an easily comprehensible way and can be further trained.

30 © Festo Didactic 8043916 en

 Introduction

6.2 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 / illustration similar

These pallet carriers are available for transporting the pallets.

Partnumber in MES - 31

Pallet / illustration similar

These pallets are available for receiving always one workpiece.

Partnumber in MES - 25

© Festo Didactic 8043916 en 31

Introduction

Illustration similar

Box with retainer for 10 PCB´s

Partnumber in MES – 27

Illustration similar

Box with retainer for 8 front/backcovers or assembled workpieces

Partnumber in MES – 28

32 © Festo Didactic 8043916 en

 Introduction

Workpieces
The workpieces are differentiated according to the project into production parts and external production
parts.
Workpieces Description Workpieces Description

CP raw material black CP back cover blue

No. 101 No. 113

CP raw material grey CP back cover red

No. 102 No. 114

CP raw material blue CP – board

No. 103 No. 120

CP raw material red CP fuse

No. 103 No. 130

CP front cover black

No. 210 – if there is a CNC milling
CP front cover red
machine integrated in the system, the
No. 107 front cover can also be produced there ,
thus becoming a production part.

CP front cover blue CP front cover black without fuses

No. 108 No. 211

CP front cover grey CP front cover black with fuse left

No. 109 No. 212

CP front cover black CP front cover black with fuse right

No. 110 No. 213

CP back cover black CP front cover black with both fuses

No. 111 No. 214

CP back cover grey

No. 112

© Festo Didactic 8043916 en 33

Introduction

Workpieces Description Workpieces Description

CP front cover grey CP front cover red

No. 310 – if there is a CNC milling No. 510 – if there is a CNC milling
machine integrated in the system, the machine integrated in the system, the
front cover can also be produced there , front cover can also be produced there ,
thus becoming a production part. thus becoming a production part.

CP front cover grey without fuses CP front cover red without fuses
No. 311 No. 511

CP front cover grey with fuse left CP front cover red with fuse left
No. 312 No. 512

CP front cover grey with fuse right CP front cover red with fuse right
No. 313 No. 513

CP front cover grey with both fuses CP front cover red with both fuses
No. 314 No. 514

CP front cover blue

No. 410 – if there is a CNC milling CP black complete without board
machine integrated in the system, the
No. 1200
front cover can also be produced there ,
thus becoming a production part.

CP front cover blue without fuses CP part customer

No. 411 No. 1210 freely selectable

CP front cover blue with fuse left CP part black with no fuse
No. 412 No. 1211

CP front cover blue with fuse right CP part black with fuse on the left
No. 413 No. 1212

CP front cover blue with both fuses CP part black with fuse on the right
No. 414 No. 1213

CP part black with both fuses

No. 1214

34 © Festo Didactic 8043916 en

 Design and function

7 Design and Function

7.1 Transport

WARNING
• Damage to transport equipment when moving heavy machines/machine sections
– When the stations are shipped out, extra care must be taken to ensure that
heavy machines/machine sections are always transported using a suitable fork-
lift truck. A single station can weigh up to 500 kg.
– Always use suitable transport equipment.
– Always use the lifting points provided to move the machine/machine sections.
– Always use the designated load take-up point.

WARNING
• Securing transit routes
– The supply routes must be cleared prior to transport, and must be suitable for
the forklift truck to pass through. If necessary, warning signs or barrier tape
must be set up to keep the routes clear.
• Caution
– When opening transport boxes, care must be taken to ensure that any
additional components delivered in the same box, such as computers, do not
fall out.

WARNING
• Danger of crushing for hands/feet
– It is not permitted to grip onto or under the feet when handling the machine, as
there is an increased risk of hands or feet getting crushed or trapped in these
areas.
– When setting down the station, make sure no persons have their feet under the
machine's feet.

© Festo Didactic 8043916 en 35

Design and function

NOTE
– When opening the transport box, any additional components must be secured
to prevent them from falling out, and removed first.
– Once this is done, the transport box can be removed/opened up fully, and the
station can be taken out and moved to its intended location.
– Care must be taken with all components projecting from the machine, as
sensors and similar small parts can easily be damaged if the machine is not
transported correctly.
– Check that all the profile connectors are seated correctly using a size 4 – 6 Allen
key. Unavoidable vibrations can loosen the connectors during transport.

36 © Festo Didactic 8043916 en

 Design and function

7.2 Overview of the System

CP Lab Conveyor, CP Factory Linear, CP Factory Shunt and CP Factory Bypass are called basic modules. If an
application module, e.g. the CP Application Module muscle press is attached to a basic module, it becomes
a station.

Example

+ =

basic module, e.g. CP Lab Conveyor application module, e.g. station muscle press
muscle press

If several stations are put in a row one behind the other, this will form a production line.

+ +

carrier pallet workpiece

Carriers are transported on the conveyors of the basic modules. And on the carriers, there are pallets with a
fixed workpiece reception placed. The workpieces are placed on the workpiece reception or taken from it.
Pallets can also be placed on a carrier in some stations or gripped from there.

The typical workpiece of a CP Factory/Lab System is the roughly simplified version of a mobile phone. The
workpiece consists of a front cover, of a back cover, of a board and of a maximum of two fuses.

front cover board back cover

© Festo Didactic 8043916 en 37

Design and function

7.3 Basic module linear

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 / illustration similar

38 © Festo Didactic 8043916 en

 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

Touch panel
6 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

© Festo Didactic 8043916 en 39

Design and function

7.4 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 / illustration similar

Position Description

1 Operating side 1 (independent from side 2)

2 Operating side 2 (independent from side 1)

40 © Festo Didactic 8043916 en

 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 / illustration similar

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.

Position Description

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

© Festo Didactic 8043916 en 41

Design and function

Installation as independent basic module / illustration similar

Position Description

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

42 © Festo Didactic 8043916 en

 Design and function

Installation in combination with another Basic Module / illustration similar

Position Description

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

© Festo Didactic 8043916 en 43

Design and function

7.4.1 Supply of the Basic Module

CP Factory supply/ illustration similar

Position Description

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

2 Connection plug K2-XZ1

3 Connection plug K2-XZ2

4 Outlet port for the connection tube of a further module

WARNING
• Electric shock when grip inside the in/outlet ports
– the in/outlet ports are secured against engaging with a metal sheet.

44 © Festo Didactic 8043916 en

 Design and function

Illustration similar

Position Description

1 Emergency chain linking

2 Pressure

3 Network

4 400 V

© Festo Didactic 8043916 en 45

Design and function

7.5 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 / illustration similar

46 © Festo Didactic 8043916 en

 Design and function

Electric board front side with Siemens controller / illustration similar

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

© Festo Didactic 8043916 en 47

Design and function

Electric board front side with Festo controller / illustration similar

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

48 © Festo Didactic 8043916 en

 Design and function

Electric board front side with Festo controller / illustration similar

Position Designation BMK Description / Ordernumber

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

2 CPU Festo CPX-E K1-K5- CPX-E-CEC-C1-PN / 4252741

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

© Festo Didactic 8043916 en 49

Design and function

E-board front side / illustration similar

Position Description BMK Description / order number

1 Supply plug K2-XZ1

2 Supply plug K2-XZ2

3 Supply plug K2-XJ1

4 Supply plug K2-XJ2

5 RFID K2-KF80 Turck TBEN-S2-2RFID-4DXP / 6814029

50 © Festo Didactic 8043916 en

 Design and function

7.5.1 Cabling chart

Cabling chart frontside siemens controller / illustration similar

© Festo Didactic 8043916 en 51

Design and function

Cabling chart frontside Festo CECC controller / illustration similar

52 © Festo Didactic 8043916 en

 Design and function

Cabling chart frontside festo CPX-E controller

© Festo Didactic 8043916 en 53

Design and function

7.5.2 Emergency-stop structure

Structure of the emergency-stop system / illustration similar

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

54 © Festo Didactic 8043916 en

 Design and function

Setup emergency stop system / illustration similar

The emergency stop system affects the whole line, so if an emergency stop is pressed, all stations in the line
stop.

The emergency stop boards which are used in each station are used to connect one station to the next.
These are connected with 10-pin cables and route all emergency stop information from one station to the
next.
Starting at the power cabinet, a 10-pin cable is plugged into the X1 interface of the emergency stop board at
the first station, from there it goes from the X2 of the emergency stop board to the X1 interface of the
Emergency stop board from the next station. If no other station is connected, a jumper plug must be plugged
into X2 of the emergency stop board at the last station.
The information is processed internally by X4 on the emergency stop board.

© Festo Didactic 8043916 en 55

Design and function

Illustration similar

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

56 © Festo Didactic 8043916 en

 Design and function

7.6 Function extension by application modules

7.6.1 Assembly of an CP application module to a CP Factory basic module

NOTE
The procedure for installing a CP application module on a basic module is identical for
all basic modules. The following example is an example for all basic modules and
applications.

Positioning slot nuts in the cross profiles of the CP Factory basic module
Mounting the CP application module is very easy:
• Two M5-slot nuts (1) have to be put into the inner front slot of the cross profile (4) of the
CP Factory basic module.
• Then put two additional M5-slot nuts (1) into the inner back slot of the cross profile (2) of the basic
module.
• Then you have to position the slot nuts (1) approximately to the distance of the vertical cross profiles of
the CP application module.

Positioning slot nuts / illustration similar

Position Description

1 slot nut

2 back cross profile

3 Inner slot (front cross profile)

4 front cross profile

© Festo Didactic 8043916 en 57

Design and function

Attaching the application module to the CP Factory basic module

• Put the CP application module on the CP Factory basic module.
• Position the slot nuts (2) underneath the mounting brackets (1) of the CP application module so that the
internal threads of the slot nuts are visible underneath the elongated holes of the mounting brackets.

NOTE
Use Allen keys for lateral adjustment of the slot nuts.

How to put on the CP application module / illustration similar

Position Description

1 CP application module: mounting bracket

2 slot nut

58 © Festo Didactic 8043916 en

 Design and function

Adjusting the CP application module and fixing it on the CP Factor basic module
• Use raised head screws M5x8, in order to connect the mounting brackets (1) of the CP application
module Measuring, at first loosely, with the cross profiles (2) of the CP Factory basic module.
• After setting all raised head screws, you can still move the CP application module to the position
required.
• Push a carrier with pallet and front cover to the stopper position. The front cover points with its inside
upwards. The drilled hole of the front cover is on the left side.
• Have a visual inspection to make sure that the two distance sensors are capable of registering the front
cover more or less in medium range.
• Now tighten the raised head screws.
• Then put the black covers onto the mounting brackets.

Tightening the CP application module / illustration similar

Position Description

1 CP application module: mounting bracket with cover

2 CP Factory basic module: cross profile

© Festo Didactic 8043916 en 59

Design and function

7.6.2 Connecting the CP application module electrically to the CP Factory basic module
SysLink-interface for digital signals
The CP application module exchanges digital input and output signals with the basic module via the
SysLink interface:
• Connect the I/O terminal (1) of the CP application module with the I/O terminal (6) on the electric board
of the CP Factory basic module. Therefore use the provided connecting cable with SysLink plugs (5).

D-Sub-interface for analogue signals (option – not available at all CP application modules)
The CP application module produces two analogue output signals with the distance sensors. These are set
on the analogue terminal and have to be connected with the analogue inputs of the CP Factory basic
module:
• Connect the analogue terminal (2) of the CP application module with the analogue terminal (4) on the
electric board of the CP Factory basic module. Therefore use the provided connecting cable (3) with
standard D-Sub plugs: 15-pin, two-rowed.

Electrical connections / illustration similar

Position Description

1 CP application module: I/O terminal (+BG-XD1)

2 CP application module: analogue terminal (+BG-XD2A)

3 connecting cable with 15-pin D-Sub-plugs

4 electric board CP Factory basic module: analogue terminal (+K1-XD16A)

5 connecting cable with SysLink-plugs (SysLink-cable)

6 electric board CP Factory basic module: I/O terminal (+K1-XD15)

60 © Festo Didactic 8043916 en

 Design and function

7.6.3 Pneumatic connection from application modules

The pneumatic connection is based on the principle of the following sketch. The application module is
connected from the valve (terminal) to the shut-off valve (3) on the conveyor belt. The hose (nominal width
4) is simply inserted into the QS connector.
The supply line (2) is plugged into the shut off-valve (3).

Pneumatically connect application module / illustration similar

© Festo Didactic 8043916 en 61

Design and function

7.7 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.

7.7.1 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.

7.7.2 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.

7.8 Visual inspection

The visual inspection must be carried out before each start-up!
Before starting the station, check:
• the electrical connections
• the correct fit and the condition of the compressed air connections
• the mechanical components for visible defects
(Cracks, loose connections, etc.)
• the emergency stop devices are working

Eliminate any damage found before starting the station!

62 © Festo Didactic 8043916 en

 Design and function

7.9 Adjusting the sensors

7.9.1 Proximity switch (stopper Identsensor)

Illustration similar

Position Description

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

1 position (BG21/BG31/BG41)
1 2 position (BG22/BG32/BG42)
3 position (BG23/BG33/BG43)
4 position (BG24/BG34/BG44)

2 Screw to clamp the sensor

The proximity switches are used for controlling the carrier.

© Festo Didactic 8043916 en 63

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 millimeters 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)

64 © Festo Didactic 8043916 en

 Design and function

7.9.2 Proximity switch (stopper cylinder)

Illustration similar

Position Description

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

1
(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.

© Festo Didactic 8043916 en 65

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 millimeters 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)

66 © Festo Didactic 8043916 en

 Design and function

7.10 Adjusting the one-way flow control valves

One-way flow control valves / illustration similar

Pos Description

1 One-way flow control valves GRLA for stopper cylinder

2 One-way flow control valves GRLA for stopper cylinder

© Festo Didactic 8043916 en 67

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 behavior 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)

68 © Festo Didactic 8043916 en

 Operation

8 Operation
8.1 Starting the station
An initial commissioning has already been carried out ex works for the station.
Follow these steps to work with the station and the applications:
1. Establish mains supply 400 V AC for basic module.
2. The basic module is supplied with approx. 6 bar compressed air. When commissioning for the first time,
make sure to increase the pressure slowly. (Prevents unpredictable events).
3. Now you can work with the station.

8.2 The control units of the basic module linear

CP Factory control panel / illustration similar

Position Description

1 Main switch - QB1

2 Manometer

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

4 Network socket- XPN3

5 Emergency- stop switch – F2-FQ1

6 Reset pushbutton – F2-SF1

7 Switch operation mode (option)

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8.3 Sequence description stopper of the basic module linear

Illustration similar

Position Description

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.

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8.4 Menu architecture from operation panel

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

Position Description

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

Main menu (always shown the same)

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.

Setup:
2 Here, the application can be operated manually in setup 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:
Here the system parameters such as language, time, etc. are set

Submenu
3
Changing content, depending on the main menu

4 Changing content, depending on the main or submenu

5 Announcement of operation mode or mode (MES or default)

6 Announcement of actual date and time

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Log in as an administrator
There are 2 functions in the operation of the HMI that are only available when the operator logs on to the
HMI. These functions are the I/O test in the setup mode and the user area.
If one of the functions has been logged in, the other function is also available without the user having to log
in again.
The process is explained using the user function as an example.

1. With a click on the User Dialog button the following window is opened.

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

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3. The user data can be entered here. The entry is confirmed with the Return key.
User: festo
Password: festo

4. The user is now logged in as "Administrator" and the functions User and I / O test are available.

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8.5 Operation modes

The following operation modes are available
• Reset
The station is moved to its home position
• Setup
The station runs in set-up mode, actuators can be controlled and monitored
• Automatic
The station runs in automatic mode, all processes run automatically, no actuators can be controlled.
There are two modes in the automatic mode: the default mode and the MES mode.

8.5.1 Mode
The mode can be set between MES and default, there are two ways to set it.
1. Clicking on the blue marked area opens a pop-up window in which the operating mode can be selected.
Other functions are also integrated in the pop-up.
2. The mode can also be set on the Home / Operating mode page.

Possibilities of mode
• MES mode
In the MES mode, all processes are centrally started, executed and monitored by the MES software. All
stations must be set to MES mode and automatic start.
• 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.

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Display MES Mode

Various states are displayed in the Home operating mode on the Overview page.

Position Description

1 Change to sub menu Overview

2 Display operation state MES is active

3 Display of the order data of the current carrier

4 Display of various functions (marked green if active)

5 Display of various information about the station and its parameters

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Display Default mode

Various states are displayed in the Home operating mode on the Overview page.

Position Description

1 Change to sub menu Overview

2 Display default mode is active

3 Display of RFID statecode

4 Display of various functions (marked green if active)

5 Display of various information about the station and its parameters

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8.5.2 Operation mode Reset

In the operation mode Reset, the station is moved to its home position.

1. After switching on the station, the Reset button flashes, press this to move the station into its home
position.
2. The operating mode Reset is displayed here during the process.

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8.5.3 Operation mode Setup

In operation mode Setup, all sensors can be displayed and actuators can be controlled from the HMI. This is
used for troubleshooting or during commissioning.

1. Automatic mode is not active and the Setup button is not greyed out - press the Setup button to
activate the Setup mode.
2. The current operation mode is displayed here

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Set up application
1. Click on the Setup button
2. Select application - the currently installed application is always displayed here. In the example this
would be the magazine application. The content of this page changes depending on the installed
application module. The description of the functions is described in the operating instructions for the
application modules. The magazine is used here as an example.
3. n the setup menu under application, the functions can be activated by clicking the buttons.

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The functions can be activated in the Setup menu under Application by clicking the buttons.

Position Description

1 Move lifting cylinder (Z-axis)

Lift: Move the Z axis up (actuator CL_MB1 is activated, lights up blue when active)
CL_BG1: Sensor CL_BG1 Indicator (lights up green when Z axis is up)
Lifting cyl: Z axis display
CL_BG2: Sensor CL_BG2 indicator (lights up green when Z axis is down)
lower: Move the Z axis down (actuator CL_MB2 is activated, lights up blue when active)

2 Separator
open: open the separator (actuator CL_MB3 is activated, lights up blue when active)
CL_BG3: Sensor CL_BG3 Indicator (lights up green when separator is opened)
Separate: Display separator
CL_BG4: Sensor CL_BG4 Indicator (lights up green when separator is closed)
Close: close separator (actuator CL_MB4 is activated, lights up blue when active)

3 Release the clamp

Unlock: Unlocking the clamp (actuator CL_MB5 is activated, lights up blue when active)
CL_MB5: Indicator (lights up green when clamp is declamped)
Clamp: Display Clamp

4 0 = Magazine empty: Sensor CL_BG5 Display (lights up green when the magazine is empty)

5 Palette / front cover available: Sensor CL_BG7 Indicator (lights up green when a pallet with front cover is
installed)

6 Front / back cover available: Sensor CL_BG8 Indicator (lights up green when front / back cover is present)

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Setup Belt
1. Click the Setup mode button
2. Select belt - the functions of the conveyor belt are displayed and / or controlled here.

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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 Backward: Move the conveyor to the left (actuator QA1_A2 is activated, lights up blue when active)
Preselection slow: Slowly set the conveyor speed
Creep feed: Move the conveyor slowly (actuator QA1_A3 is activated, lights up blue when active)
Forward: Move the conveyor to the right (actuator QA1_A1 is activated, lights up blue when active)

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

4 Sensor BG27 Indicator conveyor outlet (lights up green when active)

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Setup Stopper
1. Click the Setup mode button
2. Select stopper - the functions of the stopper position are displayed and / or controlled here.

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Position number description

1 Move down the stopper

Lower: Move stopper down (actuator G1_MB20 is activated, lights up blue when active)
G1_BG20: Sensor G1_BG20 Stopper lowered (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

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Set up application parameters

1. Click on the Parameter button
2. Select application - the parameters of the application can now be set up here.

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Position number description

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 you can specify whether the station should be operated without an application module. If a check is placed
here, the application module is not used. In this case there are two options, operator guidance or a simulation of
the application.
This function is helpful if the application module is not available, but the function is to be integrated into a
process. See chapter operator assistance and process simulation on a 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.

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1. Choice between
Simulate application - no application is activated, an automatic process is simulated. The processing
time for the simulation can be specified in this window.

and worker guidance. (See chapter worker guidance)

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I/O Test

Position number Description

1 Setup mode must be active

2 Choose Home

3 Choose I/O Test

4 By clicking in this area, the outputs are enabled and can be activated.
A login as "Administrator" is required.

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Position number Description

1 By clicking in a field, this digital output is activated (orange if active)

2 By clicking again in this field, the outputs are blocked again

3 These controllers can be used to set values for the analog outputs (blue when active, the value is displayed
above the controller.

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Exit operation mode setup

1. Setup mode is active, button lights up blue

2. Press the cycle end button to end the operation mode setup.

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8.5.4 Operation mode automatic

In automatic mode, the chosen automatic processes can be processed at the station. Depending on the
selection of the mode, the processes are controlled via the transition tables (default) or via MES.

1. Automatic button flashing blue – Press Button to activate operation mode automatic

2. Operation mode automatic is active, button lights up blue

3. Announcement of active operation mode automatic

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8.5.5 Main menu - Home

Sub menu operation mode

In the operation mode Home, the operating mode and the mode (MES or default) can be selected and
started.

Position Description

1 Reset button: Start reset sequence

2 Automatic button: the automatic sequence in dependent from the mode (Default/MES) is started here

Setup button: Here the application module can be controlled manually and sensors can be displayed. Suitable for
3 commissioning an application module or for troubleshooting.
There is no difference in mode - setup mode is independent of default or MES mode.

4 Cycle end button: The currently active operating mode is stopped here.

5 Selection of the mode:

Default - automatic sequence is processed with the stored transitions
MES - automatic process is completely controlled by MES software

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Submenu overview
Various states are displayed in the operation mode home on the Overview page.
(changing content depending on the selected operating mode)

Position Description

1 Display of the order data of the current carrier

2 Display of various functions (marked green if active)

3 Display of various information about the station and its parameters

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Error messages are also displayed in the overview window.

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Sub menu user

Different users can be created here. The function is independent of the selected mode (MES - or default)

Display / editing of all users, a login as "Administrator" is required.

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Sub menu I/O Test

The inputs / outputs are displayed here. The outputs can also be activated in setup mode.

Sub menu process

Here the process from the application module (if available) is announced.

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8.5.6 Main menu - Setup

See chapter operation mode setup.

8.5.7 Main menu – Parameter

Submenu application
See chapter operation mode setup.

Sub menu transitions

If the sub menu transitions is selected, the transitions of the installed application module are displayed.
The transitions of all other application modules can be found in the associated manuals for the application
modules.

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Sub menu belt, stopper

Position number description

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 Reduce belt speed:

Here the belt speed is reduced to save energy

5 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.

6 Stopper 1: Switch stopper without MES connection

Function active

MES in – workpiece carriers run through / MES out - workpiece carriers run through constantly
Function not active
MES in - workpiece carriers run continuously / MES out - workpiece carriers stop

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If the belt energy saving by sensors function is activated and the belts stop when there are no workpiece
carriers on the belt, this is displayed in the upper message window.

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8.5.8 Main menu – System

Sub menu - Settings

1. To get to the system settings, the System button must be selected

2. Click on Settings

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The system can be set in this operating mode.

Position number Description

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

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

3 Button 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.)

4 Display of the MES IP address additionally the IP of the MES can be set here. (Password protected) User: festo,
PW: festo)
Input fields for your own resource number, query port and status port of the MES connection

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

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

7 Button switch language: here the language can be changed

8 Button system control: Windows system control is opened

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

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Sub menu diagnostics

Position number Description

1 Announcement overview plant

2 Send diagnostic message via mail

3 Next diagnostic message

4 Previous diagnostic message

5 Home Button

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Sub menu software versions

Display of the current library version.

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Sub menu Backup

Position number Description

1 Save parameters button: all parameters are saved, for this it is necessary to press the button for at least 2
seconds.
The display shows the date of the last storage.

2 Restore parameters button: all parameters are loaded, for this it is necessary to press the button for at least 2
seconds
The display shows the date on which the parameters were last loaded.

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Submenu operating hours counter

Display of the operating times with allocation to the respective operating mode.

In the "Operation times" area, the time since the control was switched on is counted.
In the "Actual record" area, the time until the next time the "Reset current record" button is pressed is
counted. The times are divided into the categories “Total”, “Automatic mode”, Setup mode and “Other
operating modes”. The times are counted under the heading “Other operating modes” while the station is in
the operating mode “Automatic preselection”, “Setup” and “No operating mode”. The value in the "Total"
line represents the total of the operating times differentiated according to the operating mode. The
percentage refers to the proportion of the operating mode in the total time.

With the button (1) "Reset current record", the current recording is set to 0 and the operating times
contained therein are added to the "Previous recordings accumulated" area. The current recording can thus
be used, for example, for daily recordings.

All counter values are saved in a retentive data block. These are lost when the controller is booted. If they
are to be retained, the values must be saved beforehand.

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Time zone submenu in the PLC

The time and time zone of the PLC can be set in this menu. The default settings of the PLC are overwritten
when you click the "Apply" button.

Position number Description

1 Select TimeZone

2 Checkmark set - the daylight saving time changeover is automatically changed at the times "Beginning of
daylight saving time" and "End of daylight saving time"

Checkmark not set - there is no daylight saving time changeover

3 Setting the start of daylight saving time

4 Setting the end of summer time

5 Set time & date: When this button is pressed, a pop-up window opens for setting the time of the PLC

6 Display of the current time zone of the controller

(Only valid if the time zone of the PLC has been set once using the "Apply" button)

7 Display of whether daylight saving time changeover is active in the PLC.

(Only valid if the time zone of the PLC has been set once using the "Apply" button)

8 Display of the current start of daylight saving time in the control

(Only valid if the time zone of the PLC has been set once using the "Apply" button)

9 Display of the current end of daylight saving time in the control

(Only valid if the time zone of the PLC has been set once using the "Apply" button)

10 Enter the time difference between summer and winter time in minutes.

11 Accept the selected settings for the time zone and time change by pressing the button.

12 Display of the time difference between summer and winter time in minutes.
(Only valid if the time zone of the PLC has been set once using the "Apply" button)

13 Display of whether daylight saving time is currently active.

(Only valid if the time zone of the PLC has been set once using the "Apply" button)

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Time zone submenu in the HMI

The time and time zone of the HMI can be set in this menu. The default settings of the HMI are overwritten. It
is important to set the time zone in the HMI the same as it is set in the PLC, otherwise certain functions will
get a different time stamp. (e.g. sending emails)

Position number Description

1 System pop-up window of the HMI for selecting the time zone. The selected time zone in the Time Zone drop-
down field is transferred to the HMI by pressing the "Apply" button.
Before exiting the menu item, close the system pop-up window by pressing the X at the top right.

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8.6 Switching on the station

Illustration similar

1. The station is supplied with voltage.

2. The station is supplied with 6 bar air pressure.
3. All EMERGENCY STOP signal transmitters (pushbuttons, door contacts, light barriers, etc.) are not
actuated and unlocked.
4. Turn on the main switch
5. Press the RESET button, the RESET button lights up blue, the HMI starts and starts up.
6. Wait till HMI is ready

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8.6.1 Start automatic

The following procedure is exemplarily explained for the basic module linear. The emergency stop is
released in the same way at all other stations of the CP Factory system.

WARNING
• Danger of being pulled in at the conveyors
– When the automatic mode starts, the belts of the conveyor belts start to move,
creating a risk of being pulled in.
– When starting, do not stand directly at the ends of the belt or hold on to them,
keep enough distance.
– Failure to heed the information given can lead to injuries.

1. Pull out the emergency stop button

2. Press the blue reset button
3. Remove any existing workpieces
4. Acknowledge errors on the HMI by clicking on the error message.

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5. The error message is displayed in the main window. After the error situation has been remedied, it can
be acknowledged by pressing the RESET button.

6. Press Home Button

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7. Press the flashing RESET Button. Station/application moves in home position.

8. Press the flashing AUTOMATIC Button

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9. AUTOMATIC Button lights up

10. Automatic mode is active

8.6.2 Sequence Description Automatic

If the automatic sequence was started,
1. The automatic button lights up blue
2. Stoppers are retracted
3. The workpiece is transported in circulation mode
4. 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.
5. The busy displays become active.
6. During this time, the automatic sequence is executed in the application.
7. The next resource and operation are written to the RFID chip
8. When the module / application module is ready, the display changes back to the original state and the
stopper is retracted
9. The carrier moves out of the working position and is available to further modules / application modules.

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8.6.3 Process description Cycle End

1. An automatic cycle 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.

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8.7 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

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8.7.1 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.

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8.7.2 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

9 Reserve_9 9 Reserve_9

10 Reserve_10 10 Reserve_10

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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.

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8.7.3 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.

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8.8 Writing on the RFID tag manually

8.8.1 Pallet carriers
In order to describe a pallet carrier with a specific ID, or to get information on which data is stored on the
pallet carrier, it is possible to read this data or to describe the tag.
For this, it is necessary that a pallet carrier with a functioning tag is at one of the stopper positions and the
station is switched on.
The following example is guilty for all read out positions where pallet carriers can be read out.

1. Select the Setup mode

2. Select the stopper from the setup menu on the left
3. If an RFID is detected, this is indicated by "tag present". (TF80 and button "tag present" are green)
4. The data of the RFID tag can be read out and displayed by pressing the "read" button.
5. Press the Delete Data button
For easier input, all data is only deleted in the input mask, the data remains on the tag itself.

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6. 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 = Input of parameter value (e.g., 1 / left side drilling)
Input of parameter value (e.g., 2 / right side drilling)
Input of parameter value (e.g., 3 / both sides drilling)
Parameters 2 - 4 - not used in this example
7. Press the "Write" button to write the changes made to the tag.

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Components

9 Components
9.1 Electrical components
9.1.1 2 Quadrant Controller

Illustration similar

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

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Technical Data
Type: M-MZS-4-30
Item No. 06.05.020

Technical Data

Control Input A1/A2 Start wave 8 (V)

circuit A1=Start clockwise
Stop wave 5 (V)
A2=Start
anticlockwise Allowed range 0-35 (V)

Input A3/A4 Shift wave 8 (V)

A3=slow drive
Allowed range 0-35 (V)
A4=Stop

Adjustment range for turning speed with trimmer at front 0 to max. turning speed
plate (typical)

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 (A)

frequency

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 4mm², 2,5mm²

screw connection Yes

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Connection diagram

Illustration similar

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

124 © Festo Didactic 8043916 en

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9.2 PLC Siemens

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

For detailed information see electrical circuit diagram.

© Festo Didactic 8043916 en 125

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9.3 PLC Festo CECC

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

Festo CECC / illustration similar

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

126 © Festo Didactic 8043916 en

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9.4 Turck Interface

Turck interface / illustration similar

For detailed information see electrical circuit diagram.

© Festo Didactic 8043916 en 127

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9.5 PLC FESTO CPX-E

FESTO CPX-E / illustration similar

For detailed information see electrical circuit diagram.

128 © Festo Didactic 8043916 en

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9.5.1 Touch Panel

Siemens TP 700 Comfort / illustration similar

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

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Festo CDPX Panel / illustration similar

130 © Festo Didactic 8043916 en

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Feature values

Recipe memory 32 Kilobyte

Events per event buffer 2,048

Alarms 2,000

Java script file size per page 8 Kilobyte

CODESYS 2.3
CODESYS 3.X
ModbusRTU Client
Supported PLC protocol
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

5 - 85 %
Relative air humidity
non-condensing

Protection class IP65 front, IP20 back

Ambient temperature 0 ... 50 °C

C-Tick
Authorisation
c UL us - Listed (OL)

Ethernet
PLC interface
RS485

USB interface Yes

Ethernet interface RJ45 10/100 MBd

Mounting type Front panel installation

Materials note Conforms to RoHS

Programming software Designer Studio

© Festo Didactic 8043916 en 131

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9.6 Scalance Ethernet Switch

Siemens Scalance Ethernet switch / illustration similar

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

132 © Festo Didactic 8043916 en

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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.

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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.

134 © Festo Didactic 8043916 en

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9.7 RFID with Ethernet

Turck – TBEN-S2-2RFID-4DXP / 6814029 / illustration similar

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

0 Status word channel 0- low byte

Chanel 0
1 Status word channel 0- high byte

2 Status word channel 1- low byte

Chanel 1
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

0 Control word channel 0- low byte

Chanel 0
1 Control word channel 0- high byte

2 Control word channel 1- low byte

Chanel 1
3 Control word channel 1- high byte

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Wiring of the RFid module to the RFID interface / illustration similar

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 Ethernet cable from Turck module to controller (via Scalance)

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

136 © Festo Didactic 8043916 en

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RFID read-write head / illustration similar

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

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9.7.1 Electronic circuit protection

Murr Mico electronic circuit protection 2-channels / illustration similar

138 © Festo Didactic 8043916 en

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Description

Input

Operating voltage 24 V DC (18...30 V DC)

Control inputs

Input voltage (ON) 10...30 V DC

Impulse length (ON) min. 20 ms

Control outputs

Group alarm output Potential free 30 V AC/DC, 100 mA

General data

Connection Spring clamp terminals

Input terminals 1× 16 mm²

Output terminals Per output 1× 4 mm²

Alarm terminals 2.5 mm²

Bridging concept Two sides, with spring clamp terminals or bridge set (max. 40 A)

Mounting method DIN-rail mountable TH35 (EN 60715)

Dimensions H×B×T 90×36×80 mm

Temperature range 0...+55 °C ( storage temperature -40...+80 °C)

Output

Current adjustment 1 A, 2 A, 4 A, 6 A, by counters inked rotary switch, sealed

Inrush capacity max. 20 mF (per channel)

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9.7.2 Power supply unit

Power supply unit Festo CACN-3A-1-10 / illustration similar

140 © Festo Didactic 8043916 en

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Description Value

Width 60 mm

Height 130 mm

Length 152,5 mm

Assembly position Free convection

Primary supply Single-phase

Input current 1,5 - 3,0 A

Nominal output voltage DC 24 V

Nominal output current 10 A

Input voltage range AC 100 ... 240 V

Power failure buffering 24 ms

Line frequency 45 ... 65 Hz

Authorisation C-Tick /c UL us - Listed (OL)

CE mark (see declaration of conformity) to EU directive for EMC to EU directive low-voltage devices

Storage temperature -40 ... 85 °C

Relative air humidity 95 %

Protection class IP20

Ambient temperature -25 ... 70 °C

Product weight 1.554 g

Mounting type with top-hat rail

Materials note PWIS substances/Conforms to RoHS

© Festo Didactic 8043916 en 141

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9.7.3 SAFETY RELAY

Siemens Sirius safety relay / illustration similar

Description 24 V DC/AC

Mounting type Span on mounting

Part number 3SK1111-2AB30

Type SIRIUS 3SK11

Depth 121.6 mm

Height 100 mm

Width 22.5 mm

Current 5A

Power supply 24 V/DC; 24 V/AC

Max. temperature 60 °C

Min. temperature -25 °C

Product-type Safety relay

142 © Festo Didactic 8043916 en

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9.7.4 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

© Festo Didactic 8043916 en 143

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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

7 Bit 6 Identity sensor 3 / -BG23

8 Bit 7 Reserve

9 Bit 8 Identity sensor 4 / -BG24

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

144 © Festo Didactic 8043916 en

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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

© Festo Didactic 8043916 en 145

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9.7.5 SYS link interface

Syslink allocation

SYSlink PIN Bit Description 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 InputEX.4

06 5 Output AX.5 18 5 Input EX.5

07 6 Output AX.6 19 6 InputEX.6

08 7 Output AX.7 20 7 Input EX.7

09 24V Power Supply 21 24V Power Supply

10 24V Power Supply 22 24V Power Supply

11 0V Power Supply 23 0V Power Supply

12 0V Power Supply 24 0V Power Supply

146 © Festo Didactic 8043916 en

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9.8 Mechanic components

9.8.1 Motor of Conveyor

Motor type 403438 / illustration similar

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

© Festo Didactic 8043916 en 147

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9.8.2 The stopper unit

CP Factory Stopper Unit / illustration similar

Position Description

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

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

4 Pallet available Ident sensor 3 / 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

148 © Festo Didactic 8043916 en

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Diagram of pneumatics, Stopper Unit

© Festo Didactic 8043916 en 149

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9.8.3 Transportation of the station

CP Factory Transportation method / illustration similar

With the help of mechanically adjustable feet, you can lower the basic module 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 easily to another place.

Position Description

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

WARNING
• Danger of crushing for hands/feet
– It is not permitted to grip onto or under the feet when handling the machine, as
there is an increased risk of hands or feet getting crushed or trapped in these
areas.
– When setting down the station, make sure no persons have their feet under the
machine's feet.

150 © Festo Didactic 8043916 en

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9.8.4 Operation panel working position

So that the components in the base frame of the module are more easily accessible, the entire control panel
can be folded up.
The panel is gripped at the bottom and folded up. When the panel is completely raised, the springs stand
vertically and support the panel against folding down.

WARNING
• Risk of crushing
– - Make sure that the springs are vertical and that the panel is secured against
folding down.
– - It is also important to ensure that no third person can fold the panel down.
– - Failure to heed the information given can lead to injuries.

Illustration similar

1. Grip the panel at the bottom and fold it up

© Festo Didactic 8043916 en 151

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Illustration similar

2. Push the springs back in the middle and fold down the control panel

152 © Festo Didactic 8043916 en

 Message texts and interactive error messages at the HMI

10 Message texts and interactive error messages at the HMI

In general, there are three different reporting classes. These are designed as follows
• Message class 0 (displayed red in the message line)
- the program is immediately stopped and the automatic mode is terminated
- the cause of the error has to be fixed
- Then acknowledge the fault and restart the station
• Message class 1 (displayed red in the message line)
- the program and the automatic mode are stopped at the end of the cycle
- the cause of the error has to be fixed
- Then acknowledge the fault and restart the station
• Message class 2 (displayed yellow in the message line)
- the program and the automatic mode are executed further
- If the cause of the fault is fixed, the error is automatically acknowledged
• Note
- Displayed on the HMI but not processed in MES

10.1 Message texts

Actual there are no message texts available.

© Festo Didactic 8043916 en 153

Message texts and interacrive error messages at the HMI

10.2 Interactive error messages

10.2.1 Default operation
Interactive messages are displayed via a pop-up window at HMI
The Pop Up has three buttons.

Example application module output - interactive error message in default mode

Position Note

1 Repeat - An attempt is made to run the application again.

2 Ignore – The error status is ignored; the workpiece carrier receives the status code as indicated in the transition
table in the "Initial status" column. The application is no longer executed.

3 Abort – The error status is ignored; the workpiece carrier receives the status code as shown in the input / output
field next to the value displayed. This can be changed in this interactive error message window.

154 © Festo Didactic 8043916 en

 Message texts and interactive error messages at the HMI

10.2.2 MES Operation

Interactive messages are displayed via a pop-up window at HMI
The Pop Up has four buttons.

Example application module output - interactive error message in default mode

Position Note

1 Repeat - An attempt is made to run the application again with the same parameters.

2 Ignore – The application is not executed, but is treated in the MES as if the order step had been executed without
errors.

3 Abort – The application is no longer executed. In the MES, this order position is terminated with an error and
canceled, depending on whether an error step has been defined or not.

4 Reject order - the application will not be executed. In the MES, the step of this order position is reset and restarted
the next time the workpiece carrier arrives.

10.2.3 General
Value Text Fix error

100 Order aborted with errors! Start order again

© Festo Didactic 8043916 en 155

Service and cleaning

11 Service and cleaning

The components and systems from Festo Didactic are maintenance-free.
At regular intervals you should have checked:
• the lenses of the optical sensors, fibre optics and reflectors
• the active surface of the proximity switch
• the entire station

can be cleaned with a soft, lint-free cloth or brush.

NOTE
Do not use aggressive or abrasive cleaners.

Protective covers must not be cleaned with alcoholic cleaning agents, there is a risk of embrittlement.

156 © Festo Didactic 8043916 en

 Further information and updating

12 Further information and updating

Further information and updates on the technical documentation of Festo Didactic components and systems
can be found on the Internet at:
www.ip.festo-didactic.com

© Festo Didactic 8043916 en 157

Further information and updating

13 Disposal

NOTE
Electronic waste contains recyclable materials and must not be disposed of with the
domestic waste. Bring electronic waste to a designated municipal collection point.

158 © Festo Didactic 8043916 en

 Disposal

Festo Didactic SE
Rechbergstraße 3
73770 Denkendorf
Germany

+49 711 3467-0 www.festo-didactic.com

+49 711 34754-88500 [email protected]

© Festo Didactic 8043916 en 159