Festo Checkbox Series User manual

Manual
Checkbox
Identbox
Countbox
Sortbox
Manual
526 373
[649 320]
en 0103c
The Checkbox family

Contents and general instructions
I
Festo P.BE-Checkbox-EN en 0103c
Author G. Neumann-Rasaei..........................
Editors H.-J. Drung, M. Holder........................
Original German text...............................
Translation transline Deutschland.....................
Layout Festo AG & Co., Dept. KG-GD...................
Layout Festo AG & Co., Dept. KI-DT...................
Edition en 0103c...................................
Title MANUAL-EN..................................
Designation P.BE-Checkbox-EN.......................
Order-no. 526 373.................................
E(Festo AG & Co., D-73726 Esslingen, Federal Republic of
Germany, 2001)
Internet: http://www.festo.com
E-Mail: [e-mail]
The copying, distribution and utilization of this document as
well as the communication of its contents to others without
expressed authorization is prohibited. Offenders will be held
liable for the payment of damages. All rights reserved, in par-
ticular the right to carry out patent, utility model or orna-
mental design registrations.

Contents and general instructions
II Festo P.BE-Checkbox-EN en 0103c

Contents and general instructions
III
Festo P.BE-Checkbox-EN en 0103c
Contents
Designated use VII........................................................
Operating requirements VII.................................................
Target group VIII..........................................................
Service VIII...............................................................
Scope of delivery VIII.......................................................
Important user instructions X..............................................
Notesonthismanual XIII...................................................
Documentation on the Checkbox family XIV....................................
Product-specific terms and abbreviations XIV...................................
1. System summary 1-1...............................................
1.1 The Checkbox family 1-3............................................
1.2 Software packages for the Checkbox 1-4...............................
1.3 Scope of functions of the Checkbox 1-5................................
1.4 Components of the Checkbox 1-6.....................................
1.5 Method of operation of the Checkbox 1-7...............................
1.6 Buffer zone 1-10....................................................
2. Fitting and Installation 2-1..........................................
2.1 Fitting the modules 2-3.............................................
2.2 Power supply connections of the controller 2-6..........................
2.2.1 Electrical connection 2-6............................................
2.2.2 Pneumatic connection 2-7...........................................
2.3 Operation without buffer zone sensors 2-9..............................
2.4 Operation with buffer zone sensors 2-11................................
2.4.1 Buffer zone sensors at the connection “Sensors” 2-11.....................
2.4.2 Buffer zone sensors at the connection “Controller” 2-13....................
2.4.3 Controlling the small parts conveyor 2-15...............................
2.5 Diagnostic interface 2-16.............................................

Contents and general instructions
IV Festo P.BE-Checkbox-EN en 0103c
3. The I/O module on the Checkbox 3-1.................................
3.1 I/O functions 3-3...................................................
3.2 Internal power supply of the I/O module 3-5............................
3.3 Connecting a higher-order controller 3-8...............................
3.4 Start/stop mode 3-10................................................
3.5 Counter reading check (Countbox, Sortbox) 3-13.........................
3.6 Displays at the transfer position 3-14...................................
3.7 Selecting the parts type/sorting program 3-17...........................
3.8 Error message 3-21..................................................
4. Commissioning 4-1................................................
4.1 Control panel of the Checkbox 4-3.....................................
4.2 Switching on and off 4-4.............................................
4.3 Operating modes of the Checkbox 4-6.................................
4.4 Error diagnosis 4-7.................................................
5. Teaching parts with the Checkbox 5-1.................................
5.1 Preparing the teach procedure 5-3....................................
5.1.1 Features and characteristics of the conveyed parts 5-3....................
5.1.2 Set operating mode TEACH 5-5.......................................
5.2 The teach procedure 5-6............................................
5.2.1 Addressing teach data 5-6...........................................
5.2.2 Scanning sample parts 5-7..........................................
5.2.3 Saving teach data 5-11...............................................
6. Testing parts with the Checkbox 6-1..................................
6.1 Preparing the test procedure 6-3.....................................
6.1.1 Set operating mode SELECT 6-3......................................
6.1.2 Load the teach data 6-4.............................................
6.1.3 Set the tolerance 6-6...............................................
6.1.4 Enable the orientations (Countbox, Sortbox) 6-7.........................
6.1.5 Set counter function (Countbox, Sortbox) 6-7...........................

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Festo P.BE-Checkbox-EN en 0103c
6.2 Test mode 6-10.....................................................
6.2.1 Proceed as follows 6-10..............................................
6.2.2 Visual check 6-12...................................................
6.2.3 Checking the features 6-12...........................................
6.2.4 Checking the orientation 6-13.........................................
6.2.5 Influence of tolerance on the test result 6-14.............................
6.3 Automatic mode 6-15................................................
6.3.1 Set operating mode SELECT 6-15......................................
6.3.2 Manual start/stop mode 6-16.........................................
6.3.3 Counter function (Countbox, Sortbox) 6-16..............................
6.3.4 Modifying operating parameters 6-18...................................
7. Maintenance 7-1..................................................
7.1 General 7-3.......................................................
7.2 Cleaning 7-3......................................................
A. Technical appendix A-1.............................................
A.1 Operating faults A-3................................................
A.1.1 General cause of faults A-3..........................................
A.1.2 Error messages A-5.................................................
A.2 Statusdisplaysonthecontrolpanel A-10................................
A.3 Calculation examples A-16............................................
A.3.1 Bandwidth and tolerance A-16.........................................
A.3.2 Scatter of characteristics A-18.........................................
A.3.3 Feature deviation A-19...............................................
0
A.4 Pin assignment A-21.................................................
A.5 Technical specifications A-24..........................................
A.6 Accessories A-27....................................................
B. Brief instructions B-1...............................................
C. Index C-1.........................................................

Contents and general instructions
VI Festo P.BE-Checkbox-EN en 0103c

Contents and general instructions
VII
Festo P.BE-Checkbox-EN en 0103c
Designated use
The Checkbox has been designed for use in manual and in-
dustrial applications in enclosed work rooms under normal
operating conditions.
The Checkbox described in this manual is intended exclus-
ively for use as follows:
– for sorting and rejecting small conveyed parts such as
e.g. screws, springs, bolts.
– for contact-free checking of the position and quality of the
parts.
Use the Checkbox only as follows:
– in accordance with designated use
– in faultless technical condition
– without any modifications by the user.
No guarantee claims can be accepted if the device is opened.
The specified limits for pressure, temperature, electrical con-
nections etc. must be observed.
Please observe the standards specified in the relevant
chapters and comply with technical regulations, as well as
with national and local regulations.
Operating requirements
– The features of the conveyed part which determine the
orientation or quality must be recognizable and distin-
guishable for the Checkbox.
– Itmustbepossibletointegratetheconveyorunitinthe
material flow.

Contents and general instructions
VIII Festo P.BE-Checkbox-EN en 0103c
Target group
This manual is intended exclusively for technicians trained in
control and automation technology, who have experience in
installing and commissioning electrical systems.
Service
Please consult your local Festo service centre if you have any
technical problems.
Scopeofdelivery
Checkbox Conveyor unit – with conveyor belt or tunnel variant and inte-
grated line camera control unit with operating panel and I/O
interfaces.
Documentation Description of the Checkbox
Software CheckKon (function: observe system) including diagnostic
cable
Accessories – Compressed air tubing with coupling plug and screw
connector
– Hybrid connecting cable for control unit/conveyor unit
with two Harting connectors
– 5-pin connector for the conveyor unit.

Contents and general instructions
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Festo P.BE-Checkbox-EN en 0103c
– 2 configurable (blanking) plugs:
– 4-pin round plug for connecting “sensors”
Wired at the factory:
Operation without buffer zone sensors i.e. sensor
inputs 1...2 wired with reference voltage
– 37-pin sub-D plug for connecting the “controller”
Wired at the factory:
Internal power supply of the I/O module.
Operation without buffer zone sensors i.e. sensor
inputs 3...6 wired with reference voltage (Sortbox).
A summary of additional accessories available can be found
in chapter A.6.

Contents and general instructions
XFesto P.BE-Checkbox-EN en 0103c
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 andmarked 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-Checkbox-EN en 0103c
Marking special information
The following pictograms mark passages in the text contain-
ing special information.
Pictograms
Information
Recommendations, tips and references to other sources of
information.
Accessories
Information about suitable accessories.
Environment
Sections dealing with environmetal aspects.
Identbox, Countbox, Sortbox
Information which only applies to a certain design of Check-
box (Identbox, Countbox or Sortbox).
Text markings
SThe bullet indicates activities which may be carried out in
any order.
1. Figures indicate activities which must be carried out in the
sequence shown from top to bottom.
– Hyphens indicate general activities.

Contents and general instructions
XII Festo P.BE-Checkbox-EN en 0103c
Conventions
– Operating and display components of the controller are
represented in the text in upper-case letters e.g. TYPE
SELECT, TOLERANCE. Supplementary details are shown in
square brackets.
Example: TYPE SELECT [1] indicates the luminous button 1
of the button group TYPE SELECT.
– Inputs and outputs of the plug connectors are specified
with the pin number as follows:
Input pin 1 I/1
Output pin 2 O/2
– Plug connectors are shown viewed towards the device.
This representation corresponds to the view (from the
cable side) of the connections to be wired.

Contents and general instructions
XIII
Festo P.BE-Checkbox-EN en 0103c
Notesonthismanual
This manual refers to the standard design of Identbox, Count-
box or Sortbox with operating system version 3.x.
When the Checkbox is switched on, the version number of the
operating system will be shown briefly on the TOLERANCE
display.
The options and parameters available depend on the operat-
ing system, the type of Checkbox connected and the pre-set-
tings made at the factory. Special customer-specific designs
may differ in technical data, parameter settings and function-
ality.
The pre-setting of the Checkbox can be modified if required
with the software packages CheckKon (function “Modify sys-
tem”) or CheckOpti available as options. Further information
on the software packages can be found in the manuals listed
under “Documentation on the Checkbox family.”

Contents and general instructions
XIV Festo P.BE-Checkbox-EN en 0103c
Documentation on the Checkbox family
Further information on using the Checkbox can be found in
the following manuals:
Manual Contents
User manual on the Checkbox family,
type P.BE-Checkbox...
Description of the functioning, commissioning,
operation and maintenance of the relevant Check-
box type: Identbox, Countbox and Sortbox
Description of the Checkbox configurator
software package, type P.SW-CB-KONF-...
Operation of the CheckKon software package
(Checkbox configurator)
Description of the Checkbox optimizer
software package, type P.SW-CB-OPTI-...
Operation of the CheckOpti software package
(Checkbox Optimizer)
Product-specific terms and abbreviations
Term/abbreviation Meaning
Bad part A test part on which at least one feature lies outside the tolerances.
C-value The C-value indicates the extent of the scatter of the features of the
sample parts.
Checkbox Any device from the Checkbox family (e.g. Identbox, Countbox,
Sortbox).
Feature Characteristic features are ascertained from the contour data of the
sample and test parts. These are, e.g. length, height etc., as well as a
feature for each configuration tool (CheckOpti).
Good part A test part on which all features lie within the tolerances.
Orientation The parts to be checked by the Checkbox may lie facing in different
directions on the conveyor belt. During the teach procedure, you de-
fine the orientations by showing the part in different directions.
Orientation 1 is the preferred orientation (nominal orientation).
Parts type Conveyed part defined by the teach data of the sample parts.
Sample parts Parts shown during the teach procedure.

Contents and general instructions
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Festo P.BE-Checkbox-EN en 0103c
Term/abbreviation Meaning
Scatter of features Thevaluerangeofafeatureascertainedfromseveralparts.
(System) parameter Checkbox settings (in some cases settings can only be made with
configuration software).
Teach data All features ascertained during teaching, in each case with min./max.
limits and average value.
Teach procedure During the teach process, sample parts on the conveyor belt are
shown to the Checkbox. This is also referred to as ”Teaching parts”.
Te s t d a t a Thetestdataarethedatausedforthetest.Thesecorrespondtothe
teach data plus the specified tolerances.
Te s t p a r t s Parts shown during the test process.
Test procedure During the test procedure, test parts on the conveyor belt are shown
to the Checkbox and classified according to their features with regard
to orientation and observance of tolerances. This is also referred to as
”Testing parts”.
To l e ra n c e Factor in percent related to the average values which has an effect on
the min./max. limits of all the features.

Contents and general instructions
XVI Festo P.BE-Checkbox-EN en 0103c

System summary
1-1Festo P.BE-Checkbox-EN en 0103c
Chapter 1

1. System summary
1-2 Festo P.BE-Checkbox-EN en 0103c
Contents
1. System summary 1-1...............................................
1.1 The Checkbox family 1-3............................................
1.2 Software packages for the Checkbox 1-4...............................
1.3 Scope of functions of the Checkbox 1-5................................
1.4 Components of the Checkbox 1-6.....................................
1.5 Method of operation of the Checkbox 1-7...............................
1.6 Buffer zone 1-10....................................................