Festo MPS 404-1 User manual

Festo Didactic
8150266 en/de/es/fr
12/2020
8150260
40
4-1 System
MPS
S
ystems
Ope
rating instructions
Betriebsanleitung
Instr
ucciones de
utilización
Notice d'utilis
ation

Order number: 8150266
Revision level: 12/2020
Authors: Festo Didactic
Layout: Festo Didactic
© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2020
[phone] www.festo-didactic.com
[phone] [email protected]
Translation of the original operating instructions
Reproduction, distribution and utilisation of this document, as well as the communication of its contents to
others without explicit authorisation, is prohibited. Offenders will be held liable for damages. All rights
reserved, in particular the right to file patent, utility model and registered design applications.
Originalbetriebsanleitung
Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts verboten,
soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten zu Schadenersatz. Alle Rechte
vorbehalten, insbesondere das Recht, Patent-, Gebrauchsmuster- oder Geschmacksmusteranmeldungen
durchzuführen.
Traducción de los Instrucciones de utilización originales
Sin nuestra expresa autorización, queda terminantemente prohibida la reproducción total o parcial de este
documento, así como su uso indebido y/o su exhibición o comunicación a terceros. De los infractores se
exigirá el correspondiente resarcimiento de daños y perjuicios. Reservados todos los derechos, en especial
los de patentes, de modelos registrados y estéticos.
Traduction du notice d'utilisation original
Toute communication ou reproduction de ce document, sous quelque forme que ce soit, et toute
exploitation ou communication de son contenu sont interdites, sauf autorisation écrite expresse. Tout
manquement à cette règle expose son auteur au versement de dommages et intérêts. Tous nos droits sont
réservés, notamment pour le cas de l'attribution d'un brevet ou celui de l'enregistrement d'un modèle
d'utilité.
404-1 System, Distributing Pro-Joining-Measuring Pro-Sorting Inline – Operating instructions_________ 5
System 404-1, Verteilen Pro-Fügen-Messen Pro-Sortieren Inline – Betriebsanleitung _______________ 55
Sistema 404-1, Distribución Pro-Unión-Medición Pro-Clasificación en línea – Manual de instrucciones 105
Système 404-1, Distribution Pro-Assemblage-Mesure Pro-Tri Inline – Notice d'utilisation___________ 155

© Festo Didactic 8150266 3
For the sake of readability
throughout these operating instructions, all gender-specific
terms are to be considered to refer to both the
feminine and the masculine form,
e
xcept when referring to a particular person.
CAUTION
These operating instructions must always be available to the user.
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.
Soweit in diese
r Betriebsanleitung nur von Lehrer, Schüler etc. die Rede ist, sind
selbstverständlich auch Lehreri
nnen, Schülerinnen etc. gemeint. Die Verwendung nur
ein
er Geschlechtsform soll keine geschlechtsspezifische Be
nachteiligung sein, sondern
dient nur der besseren Lesbarkeit und dem besseren Ver
ständnis der Formulierungen.
VORSICHT
Diese Betriebsanleitung muss dem Anwender ständig zur Verfügung stehen.
Vor Inbetriebnahme muss die Betriebsanleitung gelesen werden.
Die Sicherheitshinweise müssen beachtet werden.
Bei Missachten kann es zu schweren Personen- oder Sachschäden kommen.

4© Festo Didactic 8150266
Se sobreentiende que el uso de términos en género masculino incluye también los
correspondientes términos de género femenino. El uso de una sola forma de género no
supone
ninguna discriminación específica, sino que sirve para mejorar la lectura y la
compresión de los textos.
ATENCIÓN
Las presentes instrucciones de utilización deben estar a disposición del usuario en todo
momento.
Deben leerse estas instrucciones antes de la puesta en funcionamiento.
Deben respetarse las instrucciones de seguridad.
De no hacerlo, pueden producirse graves daños físicos y materiales.
Les termes enseignant, étudiant, etc. employés dans les présentes instructions de
service désignent aussi, bien entendu, les enseignantes
, étudiantes,
etc. L'emploi d'un
seul genre ne saurait constituer une discrimination sexuelle, mais a
simplement pour
but de faciliter la lecture et la compréhension de ce qui est dit.
ATTENTION
Les instructions de service doivent être constamment à la disposition de l'utilisateur.
Les instructions de service doivent avoir été lues avant la mise en service.
Se conformer aux consignes de sécurité.
Le non-respect peut entraîner de graves dommages corporels ou matériels.

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Table of contents
1 General requirements for operating the devices_________________________________________ 7
2 Safety instructions and pictograms ___________________________________________________ 8
2.1 Safety instructions _________________________________________________________________ 8
2.2 Pictograms _______________________________________________________________________ 9
3 Use for intended purpose __________________________________________________________ 10
4 For your safety ___________________________________________________________________ 11
4.1 Important information _____________________________________________________________ 11
4.2 Obligations of the operating company_________________________________________________ 12
4.3 Obligations of the trainees __________________________________________________________ 12
5 Work and safety instructions________________________________________________________ 13
5.1 General _________________________________________________________________________ 13
5.2 Mechanical safety _________________________________________________________________ 13
5.3 Electrical safety___________________________________________________________________ 14
5.4 Pneumatic safety__________________________________________________________________ 16
6 Safety Sockets ___________________________________________________________________ 18
7 Technical data ___________________________________________________________________ 20
7.1 General data _____________________________________________________________________ 20
7.2 Terminal assignment table for Distributing Pro station ___________________________________ 21
7.3 Terminal assignment table, Joining station _____________________________________________ 24
7.4 Pin allocation table for the Measuring Pro station _______________________________________ 26
7.5 Terminal assignment table for Sorting Inline____________________________________________ 30
7.6 Networking the system_____________________________________________________________ 30
8 Transport, unpacking, scope of delivery ______________________________________________ 32
8.1 Transport________________________________________________________________________ 32
8.2 Unpacking _______________________________________________________________________ 32
8.3 Scope of delivery__________________________________________________________________ 32
9 Configuration ____________________________________________________________________ 33
9.1 The MPS system 404-1 _____________________________________________________________ 33
9.2 The Distributing Pro station _________________________________________________________ 34
9.3 The Joining station ________________________________________________________________ 36
9.4 The Measuring Pro station __________________________________________________________ 38
9.5 The Sorting Inline station ___________________________________________________________ 40

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9.6 The Siemens TP700 HMI____________________________________________________________ 41
9.7 Web interface with Raspberry Pi _____________________________________________________ 42
9.8 MES ____________________________________________________________________________ 43
9.9 IO-Link sensors ___________________________________________________________________ 44
10 Function_________________________________________________________________________ 45
11 Sequence description______________________________________________________________ 45
11.1 Start-up prerequisites______________________________________________________________ 45
11.2 Initial position ____________________________________________________________________ 45
11.3 Resetting ________________________________________________________________________ 46
11.4 Starting the stations _______________________________________________________________ 46
11.5 Sequence________________________________________________________________________ 46
12 Commissioning___________________________________________________________________ 50
12.1 General information on using MPS systems and stations__________________________________ 50
12.2 Mechanical commissioning _________________________________________________________ 50
12.3 Pneumatic commissioning __________________________________________________________ 51
12.4 Electrical commissioning ___________________________________________________________ 51
12.5 Establishing 1-bit communication links________________________________________________ 52
12.6 Workstation______________________________________________________________________ 52
12.7 Power supply_____________________________________________________________________ 53
12.8 Loading PLC programs _____________________________________________________________ 53
13 Accessories______________________________________________________________________ 53
14 Maintenance and cleaning _________________________________________________________ 54
15 Further information and updates ____________________________________________________ 54
16 Disposal ________________________________________________________________________ 54

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1General requirements for operating the devices
General requirements for safe operation of the devices:
•National regulations for operating electrical systems and equipment must be observed in commercial
facilities.
•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 within, and one outside of the laboratory or the
classroom.
•The laboratory or classroom must be secured so that operating voltage and compressed air supply
cannot be activated by any unauthorized persons, for example with:
–A key switch
–Lockable on-off valves
•The laboratory or classroom must be protected by residual current devices (RCDs).
–Electrical devices (e.g. power supply units, compressors and hydraulic power units) may only be
operated in training rooms which are equipped with residual current devices.
–Type B residual current circuit breakers with a residual current of ≤ 30 mA must be used.
•The laboratory or classroom must be protected by overcurrent protection devices.
–Fuses or circuit breakers
•No damaged or defective devices may be used.
–Damaged devices must be banned 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.

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2Safety instructions and pictograms
2.1 Safety instructions
DANGER
... indicates an imminently hazardous situation which will result in death or severe
personal injury if not avoided.
WARNING
… indicates a possibly hazardous situation which may result in death or severe personal
injury if not avoided.
CAUTION
... indicates a possibly hazardous situation which may result in moderate or slight
personal injury or severe property damage if not avoided.
NOTICE
... indicates a possibly hazardous situation which may result in property damage or
loss of function if not avoided.

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2.2 Pictograms
Warning
regarding of a danger point
Warning regarding dangerou
s electric voltage
Warning regarding hand injuries
W
arning regarding entanglement hazard
Information and
/or references to other documentation

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3Use for intended purpose
Festo Didactic components and systems may only be used:
•For its intended use in teaching and training applications
•When its safety functions are in perfect condition
The components and systems are designed in accordance with the latest technology and recognized safety
rules. Nevertheless, incorrect use can lead to risk of severe or fatal injury for the user and third parties and
damage to the components.
The learning system from Festo Didactic 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
apprentices observe the safety precautions described in these operating instructions.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, 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.

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4For your safety
4.1 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 which 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 states. Do not
carry out any repairs or changes to the components and systems that are not described
in these operating instructions.

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4.2 Obligations of the operating company
The operating company undertakes to allow only those persons to work with the components and systems
who:
•Are familiar with the basic regulations regarding work safety and accident prevention and have been
instructed in the use of the components and systems.
•Have read and understood the safety chapter and warnings in these operating instructions.
Personnel should be tested at regular intervals for safety-conscious work habits.
4.3 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 work safety and accident prevention.

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5Work and safety instructions
5.1 General
CAUTION
•Trainees should only work with the circuits under the supervision of an instructor.
•Observe the specifications included in the technical data for the individual
components, and in particular all safety instructions!
•Wear personal safety equipment (safety glasses, safety shoes) when working on
circuits.
5.2 Mechanical safety
WARNING
•Switch off the power supply.
–Switch off the working and control power before working on the circuit.
–Only reach into the setup when it’s at a complete standstill.
–Be aware of potential overtravel times for the drives.
•Risk of injury during troubleshooting.
Use a tool such as a screwdriver to actuate limit switches.
CAUTION
•Mount all of the components securely on the profile plate.
•Make sure that limit valves are not actuated from the front.
•Set all components up so that it’s easy to activate the switches and interrupters.
•Follow the instructions about positioning the components.

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5.3 Electrical safety
DANGER
•Risk of death in case of interrupted protective earth conductor!
–The PE conductor (yellow-green) must not be interrupted, either inside or
outside of the device.
–The insulation of the protective conductor must never be damaged or removed.
•Risk of death from series connection of power supply units!
Contact voltages of > 25 V AC or > 60 V DC are not permissible. Coming into contact
with voltages of > 50 V AC or 120 V DC may be fatal.
–Do not connect voltage sources in series.
•Risk of death due to electric shock!
Protect the outputs of the power supply units (output sockets/terminals) and
connector cables connected to them from direct contact.
–Only use connector cables with adequate insulation and electric strength.
–Use safety sockets with fully shrouded contact points.
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 data sheets and operating
instructions included with the components.
–Caution!
Capacitors inside the device may still be charged even after being disconnected
from all sources of voltage.

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CAUTION
•Use safety extra-low voltage (SELV) only: max. 24 V DC.
•The power pack must only be operated using a power supply with a PE conductor.
•Establishing and disconnecting electrical connections
–Electrical connections may only be established in the absence of voltage.
–Electrical connections may only be disconnected in the absence of voltage.
–Always pull on the plug when disconnecting connecting cables; never pull the
cable.
•Maximum permissible current loads for cables and devices must not be exceeded.
–Always compare the current ratings of the device, the cable and the fuse.
–In the event that these are not the same, use a separate upstream fuse in order
to provide appropriate overcurrent protection.
•Use only connecting cables with safety plugs for electrical connections.
•When laying connecting cables, make sure they are not kinked or pinched.
•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 ground connection must always be grounded.
–If a grounding terminal (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 must always be
disconnected last (after voltage).
–Some devices have a high leakage current. These devices must be additionally
grounded with a PE conductor.
•When replacing fuses, use specified fuses only with the correct current ratings and
tripping characteristics.
•The device is not equipped with an integrated fuse unless otherwise specified in the
technical data.
•Hazard-free operation of the device is no longer possible in the case of:
–Visible damage
–Malfunction
–Incorrect storage
–Incorrect transport
–Switch off the power supply immediately.
–Protect the device against inadvertent restart.

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5.4 Pneumatic safety
WARNING
•Depressurize the system!
–Switch off the compressed air supply before working on the circuit.
–Check the system with pressure gauges to make sure that the entire circuit is
pressure-free.
–Please note that energy may be stored in pressure reservoirs.
Further information on this issue is available in the datasheets and operating
instructions included with the components.
•Risk of injury when switching compressed air on!
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 over the 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 possible tubing connections.
–If pneumatic tubing slips off:
Switch off the compressed air supply immediately.
•Do not exceed the maximum permissible pressure of 6 bar (600 kPa).
•Do not switch on the compressed air until all the tubing connections have been
established and secured.
•Do not disconnect pneumatic tubing while under pressure.
–Do not attempt to connect pneumatic tubing or push-in connectors with your
hands or fingers.

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CAUTION
•Setting up the pneumatic circuit
–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 the pneumatic circuit
–Switch off the compressed air supply before dismantling the circuit.
–Press the blue release ring down so that the pneumatic 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 pneumatic mufflers, or wear hearing protection if noise
cannot be avoided.
–All of the exhaust ports of the components included in the equipment sets are
equipped with mufflers. Do not remove these mufflers.

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6Safety Sockets
Unless otherwise indicated in the technical data, the following color coding applies for supply and signal
connections on components of the Festo Didactic Automation and Technology Learning System.
Color Function Color Function
Voltage greater than SELV
e.g. supply voltage of 90 to 400 V AC per conductor
external conductor L1
(grey-brown)
24 V DC
(red)
Voltage greater than SELV
e.g. supply voltage of 90 to 400 V AC per conductor
external conductor L2
(grey-black)
0 V DC
(blue)
Voltage greater than SELV
e.g. supply voltage of 90 to 400 V AC per conductor
external conductor L3
(grey-dark grey)
SELV
Signal input/signal output
(black)
Voltage greater than SELV
e.g. supply voltage of 90 to 400 V AC per conductor
external conductor
(grey)
Neutral conductor
(grey-blue)
PE conductor, configuration as 4 mm safety socket
(green-yellow)
Protective grounding terminal as PE+ contact,
delivery status
(green-yellow)
Depending on the type of
component, some of the safety sockets listed may not be
present.
The circuit design may contain additional safety sockets due to the use of
different components.
The specified protection class and safe use can only be assured if laboratory safety cables supplied by Festo
Didactic are used.

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The protective grounding terminal is designed as PE+ contact. This connection provides a low-impedance,
safe protective grounding conductor connection. The mechanically incompatible connection prevents a
connection error with a 4 mm laboratory safety cable.
The operator bears the responsibility for any removal of this adapter. The adapter can be unscrewed with a
1.5 mm socket head screw. The detent is located in the drilled hole of the adapter. Unscrew the screw in
clockwise direction.
WARNING
Danger of electric shock!
Damaged safety laboratory cables must be blocked immediately and removed from the
laboratory area!

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7Technical data
7.1 General data
Parameter Value
Operating pressure 600 kPa (6 bar)
Operating voltage 6x 230 V "IEC power cable"
Each station 24 V DC, 4 A, ≤ 100 W output power,
SELV/PELV limited power supply (LPS)
Digital inputs/outputs
Inputs: 42 (15+14+6+7)
Outputs: 23 (9+4+6+4)
Max. 24 V DC
Max. 2 A per output
Max. 4 A total
Analog inputs/outputs
Inputs: 2
Outputs: 1
0 … 10 V DC
or ±10 V DC
Digital input/outputs via IO-Link gateway (Distributing Pro station)
Inputs: 3
24 V DC
Max. 0.5 A per output
Max. 2 A total
Digital input/outputs via IO-Link DA interface (Joining station)
Inputs: 4
Outputs: 4
24 V DC
Max. 0.5 A per output
Max. 2 A total
Digital input/outputs via IO-Link gateway (Measuring Pro station)
Inputs: 1
Outputs: 6
24 V DC
Max. 0.5 A per output
Max. 2 A total
Digital inputs/outputs via RFID gateway (Sorting Inline station)
Inputs: 1
Outputs: 1
24 V DC
Max. 0.5 A per output
Max. 2 A total
Electrical connection Standard power plug
RJ-45 network connection
Pneumatic connection Plastic tubing with 6 mm outside diameter
Compressed air consumption at 600 kPa (continuous cycle) 10 l/min.
Dimensions 2100 x 700 x 1705 mm
Subject to change