Festo CP Factory User manual

Festo Didactic
CP Factory / CP Lab
02/2018
CP Factory / CP Lab
®
Manual
MR Buffer
and palletizing robot

2© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
Order number:
Status: 02/2018
Layout: 02/2018, Schober, Weiss
File Name: CP-F-BUFROB-B-RV4FL-GB-A002.doc
© Festo Didactic SE, 73770 Denkendorf, Germany, 2018
Internet: www.festo-didactic.com
E-Mail: [e-mail]
Intended use
This installation was developed and manufactured only for the use in basic and further training in
the fields of automation and communications. The training company and/or the training staff must
ensure that the trainees observe the safety precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations. It contains all
information and data required for commissioning, maintenance and operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training company and/or any
third parties which may occur when the installation is used beyond a genuine training situation,
except Festo Didactic has caused such injury or harm intentionally or by grossly negligence.
Experimenting on CP Factory / CP Lab systems with hazardous live voltage is not allowed.
This manual, all text and illustrations included, is protected by copyright. Any utilization outside the
limits of the copyright law and other than training purposes are not permissible without our definite
approval. This applies in particular to reproductions, operations, translations, micro filming and the
storing and processing into electronic systems. Distribution of this documentation, as well as
reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences
are liable to compensation. All rights reserved, especially the right to execute registrations
concerning patents, designs for use and patterns.
Intended use also comprises observing all instructions in the operating manual and carrying out the
inspection and maintenance works.

Content
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 3
Content
1 General safety instructions__________________________________________________________________ 6
1.1 Pictographs ___________________________________________________________________________ 7
1.2 Safety terminal sockets _________________________________________________________________ 8
1.3 Information for the electrical connection of the systems ______________________________________ 8
1.4 Handling the system ___________________________________________________________________ 9
1.4.1 Dangers when using the machine _____________________________________________________ 9
1.4.2 Safety precautions in normal operation ________________________________________________ 9
1.4.3 Dangers caused by electrical energy___________________________________________________ 9
1.4.4 Dangers caused by pneumatic energy _________________________________________________ 9
1.4.5 Maintenance and fault clearance______________________________________________________ 9
1.4.6 Organizational measures ____________________________________________________________ 9
1.5 Staff ________________________________________________________________________________ 10
1.5.1 Instructions regarding the staff ______________________________________________________ 10
1.5.2 Training operations________________________________________________________________ 10
1.5.3 Beyond training operations _________________________________________________________ 10
1.6 Commitment of the operator____________________________________________________________ 10
1.7 Commitment of the trainees ____________________________________________________________ 10
2 Introduction _____________________________________________________________________________ 11
2.1 Warranty and liability__________________________________________________________________ 11
2.2 Important information _________________________________________________________________ 11
2.3 Resources ___________________________________________________________________________ 12
3 Design and function_______________________________________________________________________ 15
3.1 Transport____________________________________________________________________________ 15
3.2 Set up ______________________________________________________________________________ 15
3.2.1 General notes ____________________________________________________________________ 15
3.3 MR Buffer module with palletizing robot __________________________________________________ 16
3.3.1 General Information _______________________________________________________________ 16
3.3.2 Interface to basic module bypass ____________________________________________________ 17
3.3.3 Supply of the MR Buffer with palletizing robot _________________________________________ 18
3.4 Electrical installation __________________________________________________________________ 19
3.4.1 RFID connections__________________________________________________________________ 23
3.4.2 Emergency-Stop structure __________________________________________________________ 24
3.4.3 Emergency-stop with central control__________________________________________________ 28
3.5 Commissioning _______________________________________________________________________ 29
3.5.1 Pneumatic commissioning __________________________________________________________ 29
3.5.2 Electrical commissioning ___________________________________________________________ 29
3.6 Adjusting the sensors _________________________________________________________________ 30
3.6.1 Fibre-optic (workpiece detection) ____________________________________________________ 30
3.6.2 Proximity Switch (transfer unit) ______________________________________________________ 32
3.6.3 Proximity switch (Indexing units) ____________________________________________________ 34
3.6.4 Proximity switch (transfer unit) ______________________________________________________ 36
3.7 Adjusting the one-way flow control valves_________________________________________________ 37
3.8 Visual inspection _____________________________________________________________________ 39
3.9 Commissioning _______________________________________________________________________ 39

Content
4© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
4 Operation _______________________________________________________________________________ 40
4.1 General operating instructions __________________________________________________________ 40
4.1.1 Conduct guidelines ________________________________________________________________ 40
4.1.2 Operating guidelines ______________________________________________________________ 40
4.2 The operation panel of the station _______________________________________________________ 41
4.2.1 Touch Panel ______________________________________________________________________ 42
4.3 Process description ___________________________________________________________________ 45
4.3.1 Process description box Stopper 1-4 _________________________________________________ 46
4.3.2 Process description transfer unit_____________________________________________________ 48
4.4 Switching on the MR Buffer with palletizing robot __________________________________________ 50
4.4.1 Switching on the robot _____________________________________________________________ 50
4.4.2 Process description Automatic Mode _________________________________________________ 50
4.4.3 Process description Cycle End _______________________________________________________ 50
4.5 Operating modes _____________________________________________________________________ 51
4.5.1 Automatic mode __________________________________________________________________ 51
4.5.2 Setting operation _________________________________________________________________ 51
4.6 Operating the HMI touch panel __________________________________________________________ 51
4.6.1 Menu structure of the operating panel ________________________________________________ 52
4.6.2 Menu navigation in general _________________________________________________________ 53
4.6.3 Operation Mode Home _____________________________________________________________ 55
4.6.4 Operation Mode Setup _____________________________________________________________ 59
4.7 Parameter ___________________________________________________________________________ 63
4.7.1 Operation Mode System____________________________________________________________ 63
4.7.2 Starting the Automatic Mode________________________________________________________ 64
4.7.3 Terminating the Automatic Mode ____________________________________________________ 66
4.8 Writing on the RFID tag manually _____________________________ Fehler! Textmarke nicht definiert.
4.8.1 MR buffer and palletizing robot parameters____________________________________________ 68
5 Components _____________________________________________________________________________ 69
5.1 Mitsubishi Robot RV-4FL _______________________________________________________________ 69
5.1.1 Drive Unit CR750-D ________________________________________________________________ 70
5.1.2 Teach pendant R32TB______________________________________________________________ 72
5.1.3 Teach pendant R56TB______________________________________________________________ 73
5.1.4 Set up___________________________________________________________________________ 74
5.1.5 Drive Unit Interface ________________________________________________________________ 77
5.1.6 Parameter _______________________________________________________________________ 80
5.1.7 Main tasks/programmes ___________________________________________________________ 81
5.1.8 Return messages__________________________________________________________________ 81
5.1.9 More information on the robot ______________________________________________________ 81
5.2 Robot positions ______________________________________________________________________ 82
5.3 Electrical components _________________________________________________________________ 83
5.3.1 2 Quadrant controller ______________________________________________________________ 83
5.3.2 Siemens Control __________________________________________________________________ 86
5.3.3 Scalance Ethernet Switch___________________________________________________________ 87
5.4 RFID ________________________________________________________________________________ 90
5.4.1 24 V Terminal Block _______________________________________________________________ 91
5.4.2 SYS link Interface _________________________________________________________________ 93
5.5 I/O terminal__________________________________________________________________________ 94

Content
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 5
5.6 Mechanic Components_________________________________________________________________ 96
5.6.1 Conveyor Motor___________________________________________________________________ 96

General Safety Instructions
6© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
1General safety instructions
The laboratory resp. the classroom must be equipped according to the rules of EN 50191:
•There must be Emergency Stop equipment in the training area and at least one Emergency Stop outside
the training area.
•The training area must be protected against any unauthorized switching-on, e.g. by key-operated
switches.
•The training area must be protected by fault current protective circuit (RCD).
– RCD circuit breaker with differential current ≤ 30 mA, type B.
•The training area must be protected by overcurrent protections -
– fuses or circuit breakers
•The training area must be supervised by a person who is responsible for the activities.
– This person must be a skilled electrician or a person instructed in electrical engineering with the
knowledge of all safety requirements and safety precautions on file.
•Any damaged device or faulty device may not be used.
– Any faulty or damaged device has to be blocked and removed from the training area.
General requirements regarding a safe operation of the devices:
•Do not lay cables over hot surfaces.
– Hot surfaces are marked with a corresponding warning symbol.
•The permitted power loads of cables and devices may not be exceeded.
– Do always compare the current values of the device, the cable and the fuse.
– In case of non-compliance, you have to use a separate upstream fuse as an appropriate overcurrent
protection.
•Any device with earth connection must always be grounded.
– If there is a ground connection (green-yellow laboratory socket) available, the connection to the
protective ground must always be effected. The protective ground must always be contacted first
(before voltage) and must only be separated last (after voltage separation).
•If not specified differently in the technical data, the device does not have an integrated fuse.

General Safety Instructions
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 7
1.1 Pictographs
This document and the described hardware contain information on possible dangers which may occur when
using the system improperly. The following pictographs are used:
Warning
This means that in case of disregarding the rules, serious personal injury or
material damage may occur.
Caution
This means that in case of disregarding the rules, personal injury or material
damage may occur.
Warning
This means that prior to any mounting, repair, maintenance or cleaning operations,
you have to switch off the device and to disconnect the power plug. Please
observe the manual, especially all information on safety. In case of disregarding,
serious personal injury or material damage may occur.
Warning
This means that you could burn yourself when touching hot surfaces
(temperatures up to 85 ° Celsius).
Important
Here you find important information for an appropriate handling of the machine.
Disregarding this symbol may lead to malfunctions at the machine or in its
surrounding area.
i
Information
This means that you obtain tips for the use and especially useful information.

General Safety Instructions
8© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
1.2 Safety terminal sockets
If not specified differently in the technical data, the following colour coding applies for the power and signal
supplies with components of the FESTO Didactic learning system automation and technics.
Colour Meaning Colour Meaning
Voltage bigger protective low voltage, e.g.
supply voltage 90 to 400 V AC conductor (grey)
24 V DC
(red)
neutral conductor
(grey/blue)
0 V DC
(blue)
protective earth conductor
(green-yellow)
protective low voltage
signal input/signal output
(black)
The specified protection categories and the safety can only been guaranteed when using Festo Didactic
safety laboratory cables.
Any damaged or faulty safety laboratory cables have to be blocked instantly and to
be removed from the training area.
1.3 Information for the electrical connection of the systems
For the supply of the CP-Factory/ CP-Lab systems, according to the regulations of the EN 60204-1 (VDE
0113-1) part 8.2.8, a supply cable with an additional protective earth conductor is required. Since a leakage
current of > 10mA may flow depending on the expansion, an additional protective earth conductor with
10mm² is required.
See also DIN EN 60204-1.

General Safety Instructions
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 9
1.4 Handling the system
1.4.1 Dangers when using the machine
The system has been constructed in accordance with the state of the art and the recognized safety rules.
Nevertheless, there might occur dangers to life and limb of the user or a third person when used, as well as
negative impact on the system or on other material assets.
You may only use the system:
•for the intended use
•in excellent condition concerning safety regulations
Any faults which might affect the safety must be eliminated instantly!
1.4.2 Safety precautions in normal operation
Please use the system only if all safety devices are fully functional.
Please inspect the system regarding externally discernible damages and the functionality of the safety
devices at least before starting the operation.
Do not touch the running station.
Before any circuit assembly, disassembly or modifications in a circuit:
Switch off the compressed air supply and the power supply.
Observe the general safety regulations: DIN 58126 and VDE 0100.
1.4.3 Dangers caused by electrical energy
After finishing the maintenance works you have to check the safety devices regarding their function.
Only an electrically or electronically trained person is allowed to execute operations on the electrical supply.
The terminal boxes have to be kept close all of the time. Any access is only allowed if supervised by a
training person.
Please do not operate electrical limit switches manually when searching for an error, but use the tools.
Please do only use low voltage 24 VDC.
1.4.4 Dangers caused by pneumatic energy
Tubes coming off due to compressed air may cause injuries. Take away the pressure instantly.
Caution! When switching on the compressed air, the cylinders may drive in or out automatically.
Do not uncouple the tubes when under pressure. Exception: Debugging. In this case, you have to hold the
tube end tight. Do not exceed the permitted working pressure. See also data sheets.
1.4.5 Maintenance and fault clearance
Carry out all prescribed setting and servicing work in due time (see data sheets).
Protect the compressed air and the electrics against an accidental commissioning.
During all maintenance, servicing or repair works, the machine must be disconnected from the power supply
and the compressed air supply, and it must be protected against an unintentional restart.
Please check that all screw connections which have been loosened during the maintenance, servicing or
repair works are firmly seated.
1.4.6 Organizational measures
All existing safety equipment has to be checked regularly.

General Safety Instructions
10 © Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
1.5 Staff
1.5.1 Instructions regarding the staff
Regarding the staff, there are basically two starting situations to be considered.
•activities during the training operation
•activities not connected with the training operations.
1.5.2 Training operations
The trainees are only allowed to work on the machine if supervised by a skilled person or the instructor.
Any activities concerning fault finding and elimination are controlled by the instructing person.
Safety regulations have to be observed here in particular.
1.5.3 Beyond training operations
All activities concerning maintenance, servicing and repair may only be executed by a person with
sufficiently professional qualifications.
1.6 Commitment of the operator
The operators commit themselves to only allowing the work at the CP-Factory/ CP-Lab to a person who:
•is familiar with the principle directions of work safety and accident prevention and has been instructed
in the handling of the CP-Factory / CP-Lab,
•has read and understood the safety chapter and the warnings in this manual.
The safety-conscious working of the staff should be checked at regular intervals.
1.7 Commitment of the trainees
Before they start work, all persons in charge of works at the system commit themselves to:
•read the safety chapter and the warnings in this manual,
•observe the basic principles about work safety and accident prevention.

Introduction
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 11
2Introduction
2.1 Warranty and liability
Basically, our “General Terms and Conditions“ apply, which have been made available for the user since the
conclusion of the contract at the latest.
Any warranty and liability claims for personal or material damage will be excluded, if they result from one or
more of the following causes:
•any non-intended use of the system
•any improper mounting, commissioning, operating and servicing of the system
•any operating of the system with faulty safety devices or safety and protective devices which have not
been mounted properly or are not functioning
•any disregarding of the information in the manual concerning transport, storage, mounting,
commissioning, operation, servicing and setting-up of the system
•any unauthorized constructional alterations on the system
•insufficient monitoring of installation parts which are subject to wear and tear
•any improperly executed repairs
•any major emergencies caused by external influence and force majeure.
Festo Didactic herewith rules out any legal responsibility for damages of the trainee, the training company
and/or a third party which might occur when using the system beyond a genuine training situation, unless
the damage has been caused by Festo Didactic intentionally or due to gross negligence.
2.2 Important information
Knowing the basic safety instructions and the safety rules is a basic prerequisite for the safe handling and
the trouble-free operation of the system.
This manual contains the most important information in order to operate the system in a way that meets the
safety demands.
The safety instructions in particular have to be observed by any person working with the system.
Furthermore all rules and instructions concerning accident prevention applying to the deployment location
have to be observed.

Introduction
12 © Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
2.3 Resources
The training equipment of the system consists of several resources. They are used depending on the
process selection.
The following resources are available:
Pallet carrier
These pallet carriers are available for transporting the pallets.
Pallet
These pallets are available for receiving always one workpiece.

Introduction
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 13
Box with retainer for 2 pallet carriers – Box Partnumber 20
Box with retainer for 15 raw turning pieces – Box Partnumber 26
Box with retainer for 10 PCB´s – Box Partnumber 27
Box with retainer for 10 front/backcovers or assembled workpieces – Box Partnumber 28

Introduction
14 © Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
External production parts
Workpieces Description
CP back cover
no 111
CP board
no 120
CP fuse
no 130
CP front cover
no 210 - if there is a CNC milling machine integrated in the system, the front cover can also be produced
there , thus becoming a production part.
Production parts
Workpieces Description Workpieces Description
CP no fuse
no 211
CP part no fuse
no 1211
CP fuse on the left
No. 212
CP part fuse on the left
No. 1212
CP fuse on the right
no 213
CP part fuse on the right
no 1213
CP fuses both
no 214
CP part both fuses
no 1214
CP part customer
no 1210 freely selectable

Design and function
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 15
3Design and function
3.1 Transport
On delivery of the stations, special attention must be payed on transporting them only by a suitable
industrial truck.
The weight of a station may amount up to 500 kg.
i
Warning
Before the transport, all supply roads must be cleared to be passable for the
industrial truck. If necessary, you have to install warning signs or barrier tapes.
When opening the transport boxes you have to be very careful because additional
components like computers may also be delivered with the box and have to be
protected against dropping out.
Caution
If the transport box is opened and the possibly additional components are taken
out, you can remove the station and bring it to its place of destination. Please
check the stability of all profile connectors with an Allen key size 4-6. It might
happen that the connectors are loosened during the transport due to inevitable
vibrations. Please pay special attention to any protruding components, sensors or
other small parts may easily be damaged during an improper transport. Do not
grab the station at or even under the pedestals – high risk of being crushed or
jammed!
3.2 Set up
3.2.1 General notes
You have to install the system in a frost-free room with a maximum relative humidity of 70 % and a
maximum ambient temperature of 25 ° Celsius. In countries with a higher humidity or higher temperatures,
you have to install air-conditioning systems for constant ambient conditions. You first have to check any
electrical disturbing sources like welding systems, big motors and contactors regarding their EMC and if
necessary to shield them in order to obtain the values permitted in the guidelines. A stable ground is
essential for a trouble-free operation in order to avoid subsidences. You have to see for an appropriate
distance between the system and the wall. Keep away any dust from the station resulting from construction
works (covering).

Design and function
16 © Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
3.3 MR Buffer module with palletizing robot
3.3.1 General Information
The module MR Buffer with palletizing robot is designed for supplying and removing workpieces into the
system. The module is directly located at a basic module bypass. For feeding the system, the boxes are
supplied manually or by a robotino into the module MR Buffer. The robot takes the workpieces from the
boxes and hands them over to the basic module bypass.
For removing workpieces from the system, the workpieces are picked up by the robot at the basic module
bypass. Any boxes requested before are first equipped with these workpieces and then output at the buffer.
Pos. Description
1 Touch panel
2 Conveyor output
3 Conveyor input
4 I/O module
5 Operating panel
6 Valve terminal
7 I/O terminal
8 robot RV-4FL
9 RFID sensor
10 shift unit

Design and function
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 17
3.3.2 Interface to basic module bypass
The interface of the module consists of 2 sensors which have been attached to the basic module bypass, but
are connected with the palletizing robot at the MR Buffer. The sensors are designed for checking if there is a
front or a back cover on the carrier.
Pos. Description
1 sensor BG5 – front cover
2 sensor BG6 – back cover

Design and function
18 © Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
3.3.3 Supply of the MR Buffer with palletizing robot
power supply
Position Station
1 power supply 110V / 230V / 400V
2 power supply to another station (optional)
3 power supply to another station (optional)

Design and function
© Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot 19
3.4 Electrical installation
The station MR Buffer with palletizing robot has got three electric boards.
Electric boards
Position Station
1 I/O board ET200SP 32IN/32OUT / +K1
2 board for power supply / +T1
3 board for power supply / +K4

Design and function
20 © Festo Didactic CP Factory / CP Lab ° MR Buffer and palletizing robot
Board for power supply / T1
Position Description Equipment identifier Name/Order number
1 Clamps XD1
2 Sitop power supply TB1 Sitop 85-550V – 24V / 10 A
3 Profinet interface for RFID KF1 + KF2 Turk BL20-GW-EN-PN / BL20-S4T-SBBS
4 24 V allocation FC1 MICO 4.6/24VDC/4*1/2/4/6A Murr.9000-41034-0100600
5 Ethernet Switch XF1 Siemens Scalance XB008 / 6GK5008-OBAOO-1AB2
6 Emergency Stop unit FZ1 Siemens Sirius / 3SK1111-2AB30
7 Switchboard 24V XZ1
8 Emergency stop board XZ2
9 Start-up current limiters QA1 Kaleja M-MZS-4-30 / 06.05.020
10 Start-up current limiters QA1 Kaleja M-MZS-4-30 / 06.05.020
11 Clamps XD2
12 I/O terminal XD11