Festo CP Factory User manual

Festo Didactic
8152450 en
10/2022
8152450
Labeling
CP Factory/CP Lab
Original operating
instructions

Festo Didactic
8152450 en
10/2022
Order number: 8152450
Revision Level: 10/2022
Authors: Schober, Weiss
Layout: Frank Ebel
File Name: CP-AM-LABEL-GB-8152450-A001.doc
© Festo Didactic SE, Rechbergstr. 3, 73770 Denkendorf, Germany, 2022
[phone] www.festo-didactic.com
[phone] [email protected]
Original operating instructions
© 2022 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)

Contents
© Festo Didactic 8065842 en 3
Contents
1 Safety instructions ........................................................................................................................................5
1.1 Warning notice system...........................................................................................................................5
1.2 Pictograms .............................................................................................................................................6
1.3 General prerequisites for installing the product..................................................................................... 7
1.4 General prerequisites for operating the devices ....................................................................................7
2 Intended use ................................................................................................................................................. 8
3 For your safety ..............................................................................................................................................9
3.1 Important information ............................................................................................................................ 9
3.2 Qualified persons................................................................................................................................. 10
3.3 Obligations of the operating company ................................................................................................. 10
3.4 Obligations of the trainees...................................................................................................................10
4 Basic safety instructions .............................................................................................................................11
4.1 General information .............................................................................................................................11
4.2 Mechanical components ...................................................................................................................... 11
4.3 Electrical components ..........................................................................................................................12
4.4 Pneumatic components........................................................................................................................14
4.5 Guarantee and liability for application examples .................................................................................16
4.6 Cyber security ...................................................................................................................................... 16
4.7 Additional safety instructions ..............................................................................................................17
4.8 Guarantee and liability ......................................................................................................................... 18
4.9 Transport.............................................................................................................................................. 19
4.10 Name plates ....................................................................................................................................... 20
4.11 CE Declaration of Conformity .............................................................................................................21
4.12 General product safety.......................................................................................................................24
4.13 Protective devices ..............................................................................................................................25
4.13.1 Emergency stop...........................................................................................................................25
4.13.2 Additional protective devices ...................................................................................................... 25
5 Technical Data ............................................................................................................................................26
6 Design and Function ................................................................................................................................... 28
6.1 Transport..............................................................................................................................................28
6.2 Overview of the System........................................................................................................................ 30
6.3 The application module labeling .......................................................................................................... 31
6.3.1 Electrics.........................................................................................................................................32
6.3.2 Pneumatic .....................................................................................................................................35
6.4 Function ...............................................................................................................................................38
6.5 Sequence description........................................................................................................................... 38
6.6 Electrical Connections ..........................................................................................................................40
6.6.1 Overview .......................................................................................................................................40
6.6.2 I/O Box XD1...................................................................................................................................41
7 Commissioning ...........................................................................................................................................42
7.1 Workplace ............................................................................................................................................42
7.2 Visual Inspection..................................................................................................................................43
7.3 Safety Regulations ............................................................................................................................... 43
7.4 Assembly..............................................................................................................................................44

Contents
4© Festo Didactic 8065842 en
7.4.1 Assembly of an CP application module to basic module CP Lab Conveyor ....................................45
7.4.2 Connecting the CP application module electrically to basic module CP Lab Conveyor ..................48
7.4.3 Pneumatic connection from application modules to basic module CP Lab Conveyor (option –not
available at all application modules)......................................................................................................50
7.4.4 Assembly of an CP application module to a CP Factory basic module ...........................................51
7.4.5 Connecting the CP application module electrically to the CP Factory basic module ......................54
7.4.6 Pneumatic connection from application modules to CP Factory basic module ..............................55
7.5 Adjusting the sensors........................................................................................................................... 56
7.5.1 Through-beam sensor (Workpiece detection) ...............................................................................56
7.5.2 Proximity Switch (Z and X-axis cylinder) ........................................................................................ 58
7.5.3 Vacuum suction nozzle..................................................................................................................60
7.6 Adjusting the one-way flow control valves ...........................................................................................62
7.7 Adjusting the pressure regulator..........................................................................................................64
8 Operation....................................................................................................................................................66
8.1 Setting the application module labeling at HMI ...................................................................................66
8.2 Transitions of the application module..................................................................................................72
8.3 Process of the application module .......................................................................................................73
8.4 Flow chart.............................................................................................................................................74
8.5 Parameter (LABEL) ...............................................................................................................................80
9 Message texts and interactive error messages at the HMI..........................................................................82
9.1 Message texts ...................................................................................................................................... 83
9.1.1 Message texts of the application module labeling ........................................................................ 83
9.2 Interactive error messages...................................................................................................................84
9.2.1 Default operation ..........................................................................................................................84
9.2.2 MES Operation ..............................................................................................................................85
9.2.3 General.......................................................................................................................................... 85
9.2.4 Application module labeling.......................................................................................................... 85
10 Spare part list ...........................................................................................................................................86
10.1 Electric parts ......................................................................................................................................86
10.2 Pneumatic parts .................................................................................................................................86
11 Service and cleaning .................................................................................................................................87
12 Further information and updating .............................................................................................................88
13 Disposal .................................................................................................................................................... 89

Safety instructions
© Festo Didactic 8065842 en 5
1Safety 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".

Safety instructions
6© Festo Didactic 8065842 en
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 –hand injuries
Warning –lifting heavy loads
Information and/or references to other documentation

Safety instructions
© Festo Didactic 8065842 en 7
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.

Intended use
8© Festo Didactic 8065842 en
2Intended 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.

For your safety
© Festo Didactic 8065842 en 9
3For 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.

For your safety
10 © Festo Didactic 8065842 en
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

Fundamental safety instructions
© Festo Didactic 8065842 en 11
4Basic 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 safety gloves.

Fundamental safety instructions
12 © Festo Didactic 8065842 en
4.3 Electrical components
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.

Fundamental safety instructions
© Festo Didactic 8065842 en 13
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.

Fundamental safety instructions
14 © Festo Didactic 8065842 en
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.

Fundamental safety instructions
© Festo Didactic 8065842 en 15
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.

Fundamental safety instructions
16 © Festo Didactic 8065842 en
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.

Fundamental safety instructions
© Festo Didactic 8065842 en 17
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.

Fundamental safety instructions
18 © Festo Didactic 8065842 en
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.

Fundamental safety instructions
© Festo Didactic 8065842 en 19
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.
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.

Fundamental safety instructions
20 © Festo Didactic 8065842 en
4.10 Name plates
Name plate example
Position
Description
1
Type code
2
Material number
3
Production code
4
Technical data
5
Technical data
6
Technical data
7
Safety note
8
Manufacturer address
9
UK importer address
10
Country of origin
11
Internet address service portal
12
CE Mark
13
UKCA mark
14
Warning mark
15
Symbol read manual
16
WEEE Marking
17
QR Code (Type-and serial number)