Festo CP-AM-MEAS Original Operating Instructions

Cp factory/cp lab

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8154245

Measuring

CP Factory/CP Lab

Original operating

instructions

Festo Didactic

8154245 en

03/2022

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Summary of Contents for Festo CP-AM-MEAS

Page 1 8154245 Measuring CP Factory/CP Lab Original operating instructions Festo Didactic 8154245 en 03/2022...
Page 2 Authors: Schober, Weiss, Hatalcik Layout: Frank Ebel File Name: CP-AM-MEAS-GB-8154245-A001.doc © Festo Didactic SE, Rechbergstr. 3, 73770 Denkendorf, Germany, 2022 +49 711 3467-0 www.festo-didactic.com +49 711 34754-88500 did@festo.com Original operating instructions © 2022 all rights reserved to Festo Didactic SE.
Page 3: Table Of Contents
7.3 Safety Regulations ..........................42 7.4 Assembly .............................. 43 7.4.1 Assembly of an CP application module to basic module CP Lab Conveyor ........44 7.4.2 Connecting the CP application module electrically to basic module CP Lab Conveyor ....47 © Festo Didactic 8154245 en...
Page 4 9.2.3 General ............................89 9.2.4 Application module measuring ...................... 89 10 Spare part list ............................90 10.1 Electric parts ............................90 11 Service and cleaning ..........................91 12 Further information and updating ......................92 13 Disposal ..............................93 © Festo Didactic 8154245 en...
Page 5: Safety Instructions
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". © Festo Didactic 8154245 en...
Page 6: Pictograms
Switch off the device and unplug the connection for power supply from the plug socket before commencing installation, repair, maintenance or cleaning work. Warning of laser beam Laser Warning – optical radiation Warning – lifting heavy loads Information and/or references to other documentation © Festo Didactic 8154245 en...
Page 7: General Prerequisites For Installing The Product
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.
Page 8: Intended Use
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.
Page 9: For Your Safety
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.
Page 10: Qualified Persons
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 8154245 en...
Page 11: Basic Safety Instructions
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 safety gloves. © Festo Didactic 8154245 en...
Page 12: Electrical Components
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. © Festo Didactic 8154245 en...
Page 13 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. © Festo Didactic 8154245 en...
Page 14: Guarantee And Liability For Application Examples
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.
Page 15: Additional Safety Instructions
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. © Festo Didactic 8154245 en...
Page 16: Safety Instructions For Laser Class 2
- Avoid reflections of the laser beam on reflective surfaces. Pay particular attention to this during assembly and alignment work. – - Do not open the housing. Opening the housing can increase the risk. – - Observe the valid national regulations for laser protection © Festo Didactic 8154245 en...
Page 17: Guarantee And Liability
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. © Festo Didactic 8154245 en...
Page 18: Transport
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. © Festo Didactic 8154245 en...
Page 19: Name Plates
Technical data Technical data Technical data Safety note Manufacturer address UK importer address Country of origin Internet address service portal CE Mark UKCA mark Warning mark Symbol read manual WEEE Marking QR Code (Type-and serial number) © Festo Didactic 8154245 en...
Page 20: Ce Declaration Of Conformity
Basic safety instructions 4.11 CE Declaration of Conformity © Festo Didactic 8154245 en...
Page 23: General Product Safety
– Product safety can no longer be guaranteed by the operator. – In this case, the manufacturer's CE declaration of conformity expires. The operator must re-evaluate the safety and determine the CE conformity. © Festo Didactic 8154245 en...
Page 24: 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 8154245 en...
Page 25: Technical Data
CE marking in accordance with: Machinery Directive EMC Directive RoHS Directive EMC environment Industrial environment, Class A (in acc. with EN 55011) Measurements Length 273 mm Width 240 mm Height 558 mm Weight Approx 4,0 kg Subject to change © Festo Didactic 8154245 en...
Page 27: Design And Function
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 8154245 en...
Page 28 – Check that all the profile connectors are seated correctly using a size 4 – 6 Allen key. Unavoidable vibrations can loosen the connectors during transport. © Festo Didactic 8154245 en...
Page 29: Overview Of The System
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 8154245 en...
Page 30: Components Of The Cp Application Module Measuring
CP application module Measuring / illustration similar Position Description analogue terminal height measurement 1 / distance sensor height measurement 2 / distance sensor workpiece request / light guide signal lamp I/O module workpiece request / lightguide © Festo Didactic 8154245 en...
Page 31: Terminal Allocation Of The Digital And Analogue Interfaces
OUT0 to OUT7 visualizes the actuator status with an orange LED. If one of the LEDs is flashing orange, the actuator connected with the output will be energized. Digital Inputs (PLC): Digital Inputs Reference Identifier Description True = workpiece available Reserve Reserve Reserve Reserve Reserve Reserve Reserve © Festo Didactic 8154245 en...
Page 32 BG2 Multi function OUT5 BG3-MF BG3 Multi function OUT6 reserve OUT7 reserve Display LED lamp Color Display color • • • • PF1: red • • • • PF2: green • • • • PF3: blue © Festo Didactic 8154245 en...
Page 33 Design and function Analogue-Terminal (XD2A) Analogue-Terminal (XD2A) Multimeter and Analogue-Terminal Position Description Multimeter Measuring line with probe (U Measuring line with probe (GND) Analogue-Terminal © Festo Didactic 8154245 en...
Page 34 Therefore, the measurement and testing of the input voltage for the A/D converter can be performed at these pairs of terminals. • pair of terminals 6/8: distance sensor BG2 • pair of terminals 6/7: distance sensor BG3 © Festo Didactic 8154245 en...
Page 35: Assignment
40 mm. The station Measuring reads the two analogue signals and calculates the actual measured value of difference (characteristic value) from that. © Festo Didactic 8154245 en...
Page 36 Differential measurement / illustration similar Position Description distance sensor (BG2) workpiece distance sensor (BG3) maximum height of object h = 40 mm reference area: topside of the workpiece reception h = 0 mm difference Δh = 40 mm © Festo Didactic 8154245 en...
Page 38 IO link master by means of a IO-Link point-to-point connection and afterwards forwarded to the CPU. In the CPU, the basic value is scaled to the height h = 0...40 mm with the function Scale_xBit_1_10V (FC105). © Festo Didactic 8154245 en...
Page 40 0 V - 361,7 µV* underamplify range* -4864* -17,593 %* -1,759 V* -32768* <-17,593 %* <-1,759 V* underflow* *negative values are only possible if the module (6ES7134-6GD01-0BA1) is projected with firmware status from V2.0.0 on. © Festo Didactic 8154245 en...
Page 41: Commissioning
Ethernet cable for the connection of the motor controller (option) • an on-site electrical connection in the room, see data sheet basic module • an on-site pneumatically connection in the room, see data sheet basic module © Festo Didactic 8154245 en...
Page 42: Visual Inspection
The technical condition – mechanically and electrically – of the CP Application Module is perfect. • The CP Application Module is used in accordance with the regulations. • The operating instructions have been read and understood. • All safety devices are available and active. © Festo Didactic 8154245 en...
Page 43: Assembly
The assembly process is explained in the following chapter as an example. The displayed dimension is an approximation, it is possible that a fine adjustment is necessary for error-free processing. Example distance between application module and stopper / illustration similar © Festo Didactic 8154245 en...
Page 44: Assembly Of An Cp Application Module To Basic Module Cp Lab Conveyor
Then you have to position the slot nuts (2) approximately to the distance of the vertical cross profiles of the CP application module. Positioning slot nuts / illustration similar Position Description back cross profile slot nut Inner slot (back cross profile) Inner slot (front cross profile) front cross profile © Festo Didactic 8154245 en...
Page 45 NOTE Use Allen keys for lateral adjustment of the slot nuts. How to put on the CP application module / illustration similar Position Description CP application module: mounting bracket slot nut © Festo Didactic 8154245 en...
Page 46 Now tighten the raised head screws. • Then put the black covers onto the mounting brackets. Tightening the CP application module / illustration similar Position Description CP application module: mounting bracket with cover basic module CP Lab Conveyor: cross profile © Festo Didactic 8154245 en...
Page 47: Connecting The Cp Application Module Electrically To Basic Module Cp Lab Conveyor
CP Lab Conveyor: control or decentralized periphery CP application module: I/O terminal (+BG-XD1) CP application module: analogue terminal (+BG-XD2A) connecting cable with a SysLink-plug (SysLink-cable) basic module CP Lab Conveyor: board at the back (+G1-XZ2) © Festo Didactic 8154245 en...
Page 48 CP Lab Conveyor: control or decentralized periphery CP application module: I/O terminal (+BG-XD1) CP application module: analogue terminal (+BG-XD2A) connecting cable with a SysLink-plug (SysLink-cable) basic module CP Lab Conveyor: board at the back (+G1-XZ2) © Festo Didactic 8154245 en...
Page 49: Assembly Of An Cp Application Module To A Cp Factory 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 slot nut back cross profile Inner slot (front cross profile) front cross profile © Festo Didactic 8154245 en...
Page 50 NOTE Use Allen keys for lateral adjustment of the slot nuts. How to put on the CP application module / illustration similar Position Description CP application module: mounting bracket slot nut © Festo Didactic 8154245 en...
Page 51 Now tighten the raised head screws. • Then put the black covers onto the mounting brackets. Tightening the CP application module / illustration similar Position Description CP application module: mounting bracket with cover CP Factory basic module: cross profile © Festo Didactic 8154245 en...
Page 52: Connecting The Cp Application Module Electrically To The Cp Factory Basic Module
CP application module: I/O terminal (+BG-XD1) CP application module: analogue terminal (+BG-XD2A) connecting cable with 15-pin D-Sub-plugs electric board CP Factory basic module: analogue terminal (+K1-XD16A) connecting cable with SysLink-plugs (SysLink-cable) electric board CP Factory basic module: I/O terminal (+K1-XD15) © Festo Didactic 8154245 en...
Page 53: Hardware Configuration Of Sensor Sick Od1-B100H50U14
Press “+”, several times until display shows “n_P” • Press “Set” • Press “+”, once until display shows “PnP” • Press “Set” • Press “Zero Run” to go back to the main display and leave the settings. © Festo Didactic 8154245 en...
Page 54: Mechanical Adjustment Of Sensors
(100 mm) in mm. If the distance between the sensor and the surface of the measurement object is 110 mm, it therefore shows 10 mm. This display cannot be changed and is also not influenced by the scaling. © Festo Didactic 8154245 en...
Page 55: Workpiece Variants
When you have adjusted the sensors using the lab stands as above, remove the workpiece. • Place the measuring body in the round cutout of the pallet. • Adjust the limit values as described in the next section "Adjustment of limit values". © Festo Didactic 8154245 en...
Page 56: Alignment Of The Sensors To The Injection Molded Workpiece (Abs)
When you have adjusted the sensors using the lab stands as above, remove the workpiece. • Go to the menu item "Setup" > "Stopper" on the HMI and switch the stopper down via the "Lower" button, select the Setup operating mode for this. © Festo Didactic 8154245 en...
Page 57 • Place the measuring body in the round cutout of the pallet. • Adjust the limit values as described in the next section "Adjustment of limit values". © Festo Didactic 8154245 en...
Page 58: Adjustment Of Limit Values
1. On the HMI, go to the menu item "Setup" > "Application” 2. Place the measuring body in the circular cutout of the pallet so that the light beam of the BG 2 sensor hits the deep spot of the measuring body. © Festo Didactic 8154245 en...
Page 59 The buttons are password protected. User: festo Password: festo (First the analog output of the sensor is calibrated to 0V and then the converted analog value is taken over in the PLC as minimum value). © Festo Didactic 8154245 en...
Page 60 5. Press the "Scale 40mm" button on the HMI and wait a few seconds until the yellow warning disappears. (First the analog output of the sensor is calibrated to 10V and then the converted analog value is taken over in the PLC as maximum value). © Festo Didactic 8154245 en...
Page 61 (2) and load the data block into the PLC. Press Button (3) Upload. Confirm the loading into the data block of the PLC with the button (4) Load. NOTE This step 7 is not mandatory © Festo Didactic 8154245 en...
Page 62: Operation
– current test result is incorrect, the recorded measured value is beyond the defined limits. Yellow – application is busy, measurement is being taken. Green – measurement was successful, test result is within the defined limits. © Festo Didactic 8154245 en...
Page 63: Process Description
On this website, any order-specific operating instructions can be displayed at the HMI by the MES system, e.g. for the worker guidance at the manual workplace. © Festo Didactic 8154245 en...
Page 64 23. If no carrier blockade has been recognized in front of the station and if there is no other order for the station, the carrier will be released by the stopper and transferred to the next station. © Festo Didactic 8154245 en...
Page 65: Default-Mode
HMI. If it has not been released, the CP application module Measuring will not start, and the carrier will be released by the stopper (you will find further information on that in the operating instructions of the basic module). © Festo Didactic 8154245 en...
Page 66 RFID read-write head as the new status code on the transponder of the carrier. 10. If no carrier blockade has been recognized in front of the station, the carrier will be released by the stopper and transferred to the next station. © Festo Didactic 8154245 en...
Page 67: Setup Mode
A carrier with pallet and front cover is at the stopper position. The front cover’s inside points upwards, its drill hole is on the left side. Sequence description You will find a detailed sequence description in the chapter “Measurement taken in Setup Mode”. © Festo Didactic 8154245 en...
Page 68: Setting The Application Module Measuring At Hmi
1. If the application module has not yet started, click on the Setup button under Operating mode on the home screen. The application module moves into its basic position Then click on Setup, setup mode is active. © Festo Didactic 8154245 en...
Page 70 The background of the button is blue, if the button is active. output field „0s“: indicates the time how long the actuator has been activated.. output field „26“: indicates how often the actuator has been activated.. © Festo Didactic 8154245 en...
Page 71 If this value is within the .limit values, it is highlighted in green If it goes below the lower limit value, it is highlighted in orange . If it exceeds the upper limit value, it is highlighted in red. © Festo Didactic 8154245 en...
Page 72 Measurement result = measured value of difference: Here the last measured actual measured value of difference is displayed. button „Application“: action: releasing the button result: The HMI switches to the menu page „Setup - Application“. © Festo Didactic 8154245 en...
Page 73: Measurement Is Performed Via The Mes-Mode
(3) is displayed in green color, and the result (2) is also displayed in green color as “good”. The signal lamp on the CP application module Measuring is flashing green. © Festo Didactic 8154245 en...
Page 74 Since another measurement has already been performed, the example explained here is displayed in the area „Differential Measurement last order“. 2. If you click the button „Application“ (4), you will return to the menu page “Setup - Application”. © Festo Didactic 8154245 en...
Page 75 Since another measurement has already been performed, the example explained here is displayed in the area „Differential Measurement last order“. 4. If you click the button „Application“ (4), you will return to the menu page “Setup – Application”. © Festo Didactic 8154245 en...
Page 76 Since another measurement has already been performed, the example explained here is displayed in the area „Differential Measurement last order“. 2. If you click the button „Application“ (4), you will return to the menu page “Setup - Application”. © Festo Didactic 8154245 en...
Page 77: Measurement Performed With Default-Mode
“upper limit value” in the area „Application Parameters“ (1). Now a screen keyboard will appear. Enter the upper limit value on the screen keyboard and confirm. Repeat this procedure for the lower limit value. Now all parameters required for the measurement have been entered. © Festo Didactic 8154245 en...
Page 78 You can operate it manually, however, with the buttons “BadPart”,”Busy” and “GoodPart”. 5. By pressing the „Process button (3), you will switch to the menu page „Home - Process“. There you can have the measuring result displayed graphically. © Festo Didactic 8154245 en...
Page 79 Operation 6. By pressing the „Application“ button (6), you return to the menu page „Setup - Application“. © Festo Didactic 8154245 en...
Page 80 A screen keyboard will appear. You only have to enter the suitable value for the measuring scale, so that the measured value of difference can be displayed correspondingly. You can also modify the measuring scale upwards. Therefore you have to change the upper value (1). © Festo Didactic 8154245 en...
Page 81: Default-Mode: Transitions Of The Cp Application Module Measuring
With the table of transitions, it is defined at CP Factory/Lab-Stations in Default Mode whether an operation shall take place at this station, and if so, with which parameters. In order to switch to the sub menu “Parameters - Transitions“, you have to set the HMI to the Setup Mode. © Festo Didactic 8154245 en...
Page 82 “Upper limit value”/”Upper limit” and “Lower limit value”/”Lower limit” are transferred to the CP application module Measuring. NOTE – Operating the table of transitions is described in the operating instructions of the basic modules. © Festo Didactic 8154245 en...
Page 83 Operation workpiece (limit values) Position Description distance sensor BG3 distance sensor BG2 workpiece upper limit for distance sensor BG3 lower limit for distance sensor BG3 © Festo Didactic 8154245 en...
Page 84: Flow Chart
If #AppProc.rDiffAct >= #rMinVal AND #AppProc.rDiffAct <= #rMaxVal, then Good Part = true Ret code = 0 else Bad Part = true,Ret code = ISTB Message "Actual value outside limits" 110: Finish Order go back to step 10 © Festo Didactic 8154245 en...
Page 85: Parameter (Meas)
Operation 8.6 Parameter (MEAS) Illustration similar Default: Parameter-No. Description Program number Setpoint Limitation: No limit to the value in the transition table Upper limit Lower limit Measure value © Festo Didactic 8154245 en...
Page 86 Type: changeable Upper limit [0,1 mm] Low Limit: 0 High Limit:-300 Value: 26 Type: changeable Upper limit [0,1 mm] Low Limit: 0 High Limit:-300 Value: 14 Type: changeable Meassured [0,1mm] Value: 0 Type: on runtime © Festo Didactic 8154245 en...
Page 87: Message Texts And Interactive Error Messages At The Hmi
- If the cause of the fault is fixed, the error is automatically acknowledged • Note - Displayed on the HMI but not processed in MES 9.1 Message texts Actual there are no message texts available. © Festo Didactic 8154245 en...
Page 88: Interactive Error Messages
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. © Festo Didactic 8154245 en...
Page 89: Mes Operation
Fix error Order aborted with errors! Start order again 9.2.4 Application module measuring Value Text Fix error 5040 Measured value is out of defined range! Check workpiece and measurement unit / check parameter for limit value © Festo Didactic 8154245 en...
Page 90: Spare Part List
1 / distance sensor Sick 6050513 workpiece request / light guide 552812 signal lamp / Turck / BAN.K50L2RGB7Q 802145 I/O module 537823 height measurement 2 / distance sensor Sick 6050513 workpiece request / lightguide 8027412 © Festo Didactic 8154245 en...
Page 91: Service And Cleaning
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 •...
Page 92: Further Information And Updating
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 8154245 en...
Page 93: Disposal
Disposal 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. © Festo Didactic 8154245 en...
Page 94 Disposal Festo Didactic SE Rechbergstraße 3 73770 Denkendorf Germany +49 711 3467-0 www.festo-didactic.com +49 711 34754-88500 did@festo.com © Festo Didactic 8154245 en...

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