Festo HSP AE Series User manual

Manual
Type HSP−Ū−AE−IO−Ū
Manual
541 946
en 0510NH
[691 172]
Handling module
HSP−...−AE

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States and/or other countries.

Contents and general instructions
I
Festo P.BE−HSP−AE−IO−EN en 0510NH
Original de. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Edition en 0510NH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Designation P.BE−HSP−AE−IO−EN. . . . . . . . . . . . . . . . . . . . . .
Order no. 541 946. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E(Festo AG&Co. KG, D73726 Esslingen, Federal Republic
of Germany, 2005)
Internet: http://www.festo.com
E−Mail: [e-mail]
The reproduction, distribution and utilization of this document
as well as the communicaton of its contents to others without
express authorization is prohibited. Offenders will be held
liable for the payment of damages. All rights reserved in the
event of the grant of a patent, utility module or design.

Contents and general instructions
II Festo P.BE−HSP−AE−IO−EN en 0510NH

Contents and general instructions
III
Festo P.BE−HSP−AE−IO−EN en 0510NH
Contents
Designated use VII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety instructions VIII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target group VIII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service IX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of delivery IX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important user instructions X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product−specific terms and abbreviations XII. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manuals on the handling module type HSP−...−AE XV. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Information on the version XVI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. System summary 1−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Handling with electric positioning motors 1−3. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1 Design and components 1−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.2 Method of operation 1−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Operating elements on the motor unit 1−15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Festo Configuration Tool (FCT) 1−16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Fitting 2−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Instructions on fitting 2−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Fitting the handling module 2−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1 Fastening options 2−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Attachment components 2−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Fitting the motor unit 2−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Turning the motor unit (only type HSP−...−GE) 2−10. . . . . . . . . . . . . . . . .
2.4.2 Swivelling the motor unit (only type HSP−...−GE) 2−11. . . . . . . . . . . . . . .
2.5 Static adjustment of the mechanical end positions 2−13. . . . . . . . . . . . . . . . . . . .
2.5.1 Setting the z−stroke 2−13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2 Setting the y−stroke 2−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.3 Replacing the silencers (rubber buffers) 2−17. . . . . . . . . . . . . . . . . . . . .

Contents and general instructions
IV Festo P.BE−HSP−AE−IO−EN en 0510NH
3. Installation 3−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Notes on installation 3−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Electrical connection of the motor unit 3−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Power supply 3−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Serial interface 3−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3 I/O control 3−12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Proximity switch (optional) 3−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. The control panel 4−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Composition and function of the control panel 4−4. . . . . . . . . . . . . . . . . . . . . . .
4.2 The menu system 4−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Accessing the main menu 4−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Selecting a menu command 4−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 [Diagnostic] menu 4−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 [Positioning] menu 4−10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 [Positioning] [Move positioning set] 4−11. . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 [Positioning] [Homing] 4−12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Menu [Settings] 4−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 [Settings] [HSP setup] [HSP mode] 4−14. . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 [Settings] [HSP setup] [Positioning set] 4−15. . . . . . . . . . . . . . . . . . . . . .
4.5.3 [Settings] [HSP setup] [Count direction] 4−17. . . . . . . . . . . . . . . . . . . . . .
4.5.4 [Settings] [HSP setup] [Delivery status] 4−19. . . . . . . . . . . . . . . . . . . . . .
4.5.5 [Settings] [HM type] 4−20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.6 [Settings] [Password edit] 4−21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Menu command [HMI control] 4−23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents and general instructions
V
Festo P.BE−HSP−AE−IO−EN en 0510NH
5. Commissioning with the control panel 5−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Preparing for commissioning 5−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Commissioning procedure 5−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Reference points and limits of the work range 5−8. . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Reference travel 5−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2 Limits of the work range in HSP mode 5−10. . . . . . . . . . . . . . . . . . . . . . .
5.4 Teaching typical Pick and place" positioning sets 5−13. . . . . . . . . . . . . . . . . . . .
5.4.1 HSP mode 5−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.3 Teach procedure 5−15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Parametrizing via the positioning set table 5−18. . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.1 Notes on parametrizing 5−19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.2 Creating new positioning sets (intermediate positions) 5−27. . . . . . . . .
5.5.3 Adapting existing positioning sets 5−28. . . . . . . . . . . . . . . . . . . . . . . . . .
5.5.4 Processing individual positioning sets (test run) 5−29. . . . . . . . . . . . . .
5.5.5 Delete positioning sets 5−30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Communication with the higher−order controller 5−31. . . . . . . . . . . . . . . . . . . . . .
5.6.1 I/O function check 5−31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.2 Description of the I/Os 5−32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6.3 Description of function (pulse−time diagram) 5−36. . . . . . . . . . . . . . . . .
6. Operation and maintenance 6−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Important user instructions 6−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Instructions on care and maintenance 6−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Replacing the spring clamping elements 6−8. . . . . . . . . . . . . . . . . . . . .
6.2.2 Replacing the rubber buffers 6−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Diagnosis 7−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 General diagnostic possibilities 7−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 LED status displays 7−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Fault messages on the display 7−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Mechanical fault 7−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents and general instructions
VI Festo P.BE−HSP−AE−IO−EN en 0510NH
A. Technical appendix A−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Technical specifications A−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Dimensions A−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.1 Through holes for attachment to the base plate A−8. . . . . . . . . . . . . . .
A.3 Characteristic curves A−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.1 Setting the speed via the positioning time A−9. . . . . . . . . . . . . . . . . . .
A.3.2 Setting the insert torque A−10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3.3 Positioning time t as a factor of the work load m A−11. . . . . . . . . . . . . .
A.4 Accessories A−12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.4.1 Accessories for tha handling module A−12. . . . . . . . . . . . . . . . . . . . . . . .
A.4.2 Cable for connecting the motor unit A−12. . . . . . . . . . . . . . . . . . . . . . . . .
A.4.3 User documentation A−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Index B−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents and general instructions
VII
Festo P.BE−HSP−AE−IO−EN en 0510NH
Designated use
Handling module type HSP−AE−... has been designed for use
in automated component assembly in handling and fitting
systems.
The handling module is particularly suitable for handling
small parts at high speed, e.g. when inserting or turning parts
in the automotive industry.
It is absolutely necessary to observe the Safety instructions"
as well as the designated use of the relevant components and
modules. Observe also the safety instructions in the operat
ing instructions for the electric components used.
Please observe the standards specified in the relevant
chapters and comply with technical regulations, as well as
with national and local regulations.
The handling module and the modules and cables which can
be connected are only to be used as follows:
inaccordance with designated use
 only in industrial applications
 without any modifications by the user. Only the conver
sions or modifications described in the documentation
supplied with the product are permitted.
infaultless technical condition.
If additional commercially−available components such as
sensors and actuators are connected, the specified limits for
temperatures, electrical data, pressures, torques, etc. must
be observed.

Contents and general instructions
VIII Festo P.BE−HSP−AE−IO−EN en 0510NH
Safety instructions
When commissioning and programming positioning systems,
you must observe the safety regulations in this manual as
well as those in the operating instructions for the other
components used.
The user must make sure that nobody is in the operating
range of the connected actuators or axis system. Access to
the possible danger area must be prevented by suitable
measures such as protective screens and warning signs.
Warning
Electric axes can move suddenly with high force and at
high speed. Collisions can lead to serious injury to human
beings and damage to components.
Make sure that nobody can gain access to the operating
range of the axes or other connected actuators and that no
objects lie in the positioning range while the system is still
connected to a power supply.
Warning
Faults in parametrization can cause injury to people and
damage to property.
Enable the controller only if the axis system is correctly
installed and parametrized.
Target group
This manual is intended exclusively for technicians trained in
control and automation technology, who have experience in
installing, commissioning, programming and diagnosing
positioning systems.

Contents and general instructions
IX
Festo P.BE−HSP−AE−IO−EN en 0510NH
Service
Please consult your local Festo repair service or write to the
following e−mail address if you have any technical problems:
[e-mail]
Scope of delivery
Included in scope of delivery:
 handling module and motor unit with integrated controller
 user documentation on CD ROM (in paper form can be
ordered as accessory).
Information on accessories for fitting and installation can be
found in chapter 1.1.1. Information on ordering and further
accessories can be found in appendix A.4.

Contents and general instructions
XFesto P.BE−HSP−AE−IO−EN en 0510NH
Important user instructions
Danger categories
This manual contains instructions on the possible dangers
which may occur if the product is not used correctly. These
instructions are marked (Warning, Caution, etc.), printed on a
shaded background and marked additionally with a picto
gram. A distinction is made between the following danger
warnings:
Warning
This means that failure to observe this instruction may
result in serious personal injury or damage to property.
Caution
This means that failure to observe this instruction may
result in personal injury or damage to property.
Please note
This means that failure to observe this instruction may
result in damage to property.
The following pictogram marks passages in the text which
describe activities with electrostatically sensitive compo
nents.
Electrostatically sensitive components may be damaged if
they are not handled correctly.

Contents and general instructions
XI
Festo P.BE−HSP−AE−IO−EN en 0510NH
Marking special information
The following pictograms mark passages in the text
containing special information.
Pictograms
Information:
Recommendations, tips and references to other sources of
information.
Accessories:
Information on necessary or sensible accessories for the
Festo product.
Environment:
Information on environment−friendly use of Festo products.
Text markings
·The bullet indicates activities which may be carried out in
any order.
1. Figures denote activities which must be carried out in the
numerical order specified.
 Hyphens indicate general activities.

Contents and general instructions
XII Festo P.BE−HSP−AE−IO−EN en 0510NH
Product−specific terms and abbreviations
The following product−specific terms and abbreviations are
used in this manual:
Term/abbreviation Meaning
0−signal 0 V at input or output (positive logic, corresponds to LOW)
1−signal 24 V at input or output (positive logic, corresponds to HIGH)
Controller Control electronics which evaluate the control signals and provide the
power supply for the motor via the power electronics.
Count direction The count direction is specified viewed down onto the motor shaft.
Positive count direction means:
Positive position specifications and torques have an effect from the
reference point in the clockwise direction.
Negative count direction means:
Negative position specifications and torques have an effect from the
reference point in the clockwise direction.
The factory pre−setting of the count direction is negative".
EMC Electromagnetic compatibility
Encoder Optical pulse generator (rotor position transducer). The electric signals
generated are sent to the controller, which then calculates the position
and speed on the basis of the signals received.
Festo Configuration Tool
(FCT)
Software with uniform project and data management for all supported
device types. The special wishes of a device type are supported by
PlugIns with the necessary descriptions and dialogues.
Handlingmodule Complete actuator, consisting of motor unit and moving mechanical
parts.
Homing mode Operating mode in which reference travel is carried out.
HSP mode Teach operation for referencing and automatic parametrizing of positiog
sets for pick and place standard applications (can be edited later via
positioning set table).
I
O
I/O
Input
Output
Input and/or output
Motor unit Integrated unit consisting of the controller, encoder and motor,
e.g. motor unit type MTR−DCI−...

Contents and general instructions
XIII
Festo P.BE−HSP−AE−IO−EN en 0510NH
Term/abbreviation Meaning
MTR−DCI−... Type designation of the motor unit
PLC Programmable logic controller; in brief: controller
Positioning set Positioning command defined in the positioning set table, consisting of:
 the number of the positioning set (0 ... 14)
 the absolute or relative reference of the nominal position
 Insert torque for reducing the torque when the nominal position is
reached
 nominal position of the positioning set
 positioning speed of the positioning set
Profile Position mode
(positioning mode)
Operating mode for position−controlled processing of a positioning set
Profile Torque mode
(positioning mode)
Operating mode for torque−controlled processing of a positioning set
Reference point Reference point for the incremental measuring system. The reference
point defines a known position/orientation within the positioning path of
the drive.
Reference travel The reference position and therefore the source of the measuring
reference system of the axis will be defined by the reference travel.
Use the following method to do this:
 Reference travel against a negative fixed stop
The drive moves at low speed in the direction of the pick position until
the fixed stop is reached.
Referencing Complete definition of the measuring reference system with reference
point and, if applicable, zero point
Referencing method Method for defining the reference position: against a fixed stop
(overcurrent/speed evaluation) or with reference switch.
On the HSP−...−AE−... referencing always takes place against the negative
fixed stop = pick position.
Slotted guide plate Mechanical component of the handling module which specifies the path
guide for the pick and place movement.
Software end position Stroke limitation, reference point = (axis) zero point
 Software end position, positive:
max. limit position of the stroke in the positive direction; must not be
exceeded during positioning.
 Software end position, negative:
min. limit position in the negative direction; must be reached during
positioning.

Contents and general instructions
XIV Festo P.BE−HSP−AE−IO−EN en 0510NH
Term/abbreviation Meaning
Swivel lever Mechanical component of the handling module which carries out the pick
and place movement and enables the work load to be mounted. The
movement takes place via the link and cross guide.
Teach mode Operating mode, e.g. for setting positions by moving to the target
position when creating positioning sets; see also HSP mode
Torque switching Reduction of the torque for moving to the end position. The transition
from position−controlled operation to torque−controlled operation takes
place when the nominal position is reached if M š0 Nmm. The torque is
specified either automatically in the HSP mode or if the positioning set is
parametrized.
Tab.0/1: Index of terms and abbreviations

Contents and general instructions
XV
Festo P.BE−HSP−AE−IO−EN en 0510NH
Manuals on the handling module type HSP−...−AE
This manual contains basic general information on operating,
fitting, installing and commissioning the I/O interface. It also
contains information on the functions of the I/O interface, as
well as on commissioning with the Festo Configuration Tool"
(FCT) software package.
Product variants are available for coupling to field bus sys
tems. Special information on this can be found in the manual
for the relevant product variant.
Information on components can be found in the operating
instructions supplied with the relevant product.
Version Designation Contents
Docu package with brief
description + manuals on
CD ROM
P.BE−HSP−AE−UDOK Brief description: Important
instructions on commissioning
and preliminary information.
Manuals: Contents as described
below
Manuals Handling module HSP−...−AE
P.BE−HSP−AE−IO−DE
P.BE−HSP−AE−IO−EN
P.BE−HSP−AE−IO−FR
P.BE−HSP−AE−IO−IT
P.BE−HSP−AE−IO−ES
P.BE−HSP−AE−IO−SV
 Installing, commissioning and
diagnosing handling modules
with electric servomotor
 Communication via the I/O
interface
Help system for software Festo Configuration Tool Help
(contained in the FCT software)
Function descriptions of the FCT
configuration software

Contents and general instructions
XVI Festo P.BE−HSP−AE−IO−EN en 0510NH
Information on the version
The hardware version specifies the version status of the
mechanical parts and electronics of the MTR−DCI.
The firmware version specifies the version status of the
operating system of the MTR−DCI.
You can find the specifications on the version status as
follows:
 Hardware version and firmware version in the FCT with
active device connection to the MTR−DCI under Device
data"
 Firmware version on the control panel under [Diagnostic]
[SW information]
Firmware version What is new? Which FCT PlugIn?
V−HM1.20 For handling modules with motor unit type
MTR−DCI−...−IO−HM including integrated controller
and I/O interface.
Supports type:
 HSP−12−AE−IO
 HSP−12−AE−IO−SD
 HSP−12−AE−IO−GE
 HSP−12−AE−IO−SD−GE
 HSP−16−AE−IO
 HSP−16−AE−IO−SD
 HSP−16−AE−IO−GE
 HSP−16−AE−IO−SD−GE
 HSP−25−AE−IO
 HSP−25−AE−IO−SD
 HSP−25−AE−IO−GE
 HSP−25−AE−IO−SD−GE
V1.0.0

Systemsummary
1−1Festo P.BE−HSP−AE−IO−EN en 0510NH
Chapter 1

1. System summary
1−2 Festo P.BE−HSP−AE−IO−EN en 0510NH
Contents
1. System summary 1−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Handling with electric positioning motors 1−3. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.1 Design and components 1−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1.2 Method of operation 1−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Operating elements on the motor unit 1−15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Festo Configuration Tool (FCT) 1−16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .