Checkbox Compact

Manual Checkbox Compact

Type CHB-C-X

Manual 533412 en 1102d [757659] Festo Checkbox ® is a registered trademark of Festo SE & Co. KG, D-73726 Esslingen, Germany Contents and general instructions

Original ...... de

Edition ...... en 1102d

Designation ...... P.BE-CB-COMP-EN

Order no...... 533412

E (Festo SE & Co. KG, D-73726 Esslingen, Germany, 2011) Internet: http://www.festo.com E-mail: [email protected]

The reproduction of this document and disclosure to third parties and the utilisation or communication of its contents without explicit authorization is prohibited. Offenders will be held liable for compensation of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registrations.

Festo P.BE-CB-COMP-EN en 1102d I Contents and general instructions

II Festo P.BE-CB-COMP-EN en 1102d Contents and general instructions

Contents

Intended use...... VI Operating requirements...... VIII Target group...... VIII Service ...... VIII Scope of delivery...... VIII Important user instructions...... IX Notes on the use of this manual...... XII DocumentationontheCheckbox...... XII Product-specific terms and abbreviations...... XIII

1. System summary...... 1-1

1.1 The Festo Checkbox...... 1-3 1.2 Software packages for the Checkbox...... 1-4 1.3 Functional range...... 1-5 1.4 Operating principle...... 1-6 1.5 Buffer zone...... 1-9

2. Fitting and commissioning...... 2-1

2.1 General instructions...... 2-3 2.2 Mounting...... 2-4 2.3 Electrical connection...... 2-7 2.3.1 Selection of the power supply unit...... 2-10 2.3.2 Connection of the operating voltage...... 2-11 2.3.3 Power supply for external components...... 2-12 2.4 Adapting system parameters with CheckKon...... 2-13 2.5 Commissioning the Checkbox...... 2-15 2.6 Error diagnostics...... 2-20

Festo P.BE-CB-COMP-EN en 1102d III Contents and general instructions

3. The I/O module...... 3-1

3.1 Interfaces...... 3-3 3.2 ACTUATORS...... 3-5 3.3 BUFFER/FEEDER...... 3-7 3.4 DIAG...... 3-10 3.5 ENCODER...... 3-12 3.6 PLC...... 3-14 3.6.1 Start/Stop mode...... 3-17 3.6.2 Controlling the teach procedure...... 3-19 3.6.3 Selecting the parts type...... 3-19 3.6.4 Counting function...... 3-23 3.6.5 Actuators...... 3-26 3.6.6 Buffer zone sensors/small parts conveyor...... 3-27 3.6.7 Fault messages...... 3-30 3.6.8 Locking the control panel...... 3-31

4. Teaching parts...... 4-1

4.1 Preparing the Teach procedure...... 4-3 4.2 The Teach procedure...... 4-5 4.2.1 Positioning the sample parts...... 4-9 4.2.2 Observing the scatter of characteristics...... 4-10

5. Testing parts...... 5-1

5.1 The test procedure...... 5-3 5.2 Test mode...... 5-4 5.3 Influence of tolerance...... 5-7 5.4 Evaluation of the test results...... 5-9 5.4.1 Checking the features...... 5-9 5.4.2 Checking the orientation...... 5-10

6. Maintenance...... 6-1

IV Festo P.BE-CB-COMP-EN en 1102d Contents and general instructions

A. Technical appendix...... A-1

A.1 Operating malfunctions...... A-3 A.1.1 General fault finding...... A-3 A.1.2 Fault messages and warnings...... A-4 A.2 Status displays on the control panel...... A-9 A.3 Examples for calculation of the features...... A-12 A.3.1 Band width and tolerance...... A-12 A.3.2 Scatter of characteristics...... A-14 A.3.3 Inspection part deviation...... A-15 A.4 Connections...... A-17 A.5 Technical data...... A-22 A.6 Accessories...... A-25

B. Index...... B-1

Festo P.BE-CB-COMP-EN en 1102d V Contents and general instructions

Intended use

The Festo Checkbox® has been designed for use under normal operating conditions in closed rooms in industrial installations.

The Checkbox Compact described in this manual is intended exclusively for use as follows: for contactless checking of the position and quality of small parts e.g. screws, springs, bolts, which pass through on a conveyor belt.

Use the Checkbox only as follows:

– as intended in an industrial environment

– in perfect technical condition

– in original status without unauthorised alterations. Only the conversions or modifications described in the documentation supplied with the product are permitted. The guarantee will become invalid if the Checkbox is opened.

The maximum values specified for pressures, temperatures, electrical connections etc. must not be exceeded.

Please observe the standards specified in the relevant chapters and comply with the regulations of the trade associ- ation and the German Technical Control Board (TÜV), the VDE conditions as well as the relevant national regulations.

VI Festo P.BE-CB-COMP-EN en 1102d Contents and general instructions

Laser irradiation The Checkbox is a device of laser class 2 according to EN 60825-1:1994 + A1:2002 + A2:2001 (Class II according to CFR 21 §1040.10, USA), but contains a laser of class 3B. Therefore, observe the following: • Do not open the device. • Do not remove any housing parts (e.g. prism support, covers). • Operate only with intact housing. Avoid injuries to the eyes due to laser irradiation. Observe the following rules for working with lasers of class 2: • Do not bring any mirrors or reflecting items into the laser beam. • Never stare into the laser beam and never direct the bean into the eyes of other people. • If the laser beam hits the eye, consciously close your eyes and move your head out of the beam. Work with laser devices is subject to accident prevention regulations. Users must be instructed on the risks of look- ing directly into the beam.

Festo P.BE-CB-COMP-EN en 1102d VII Contents and general instructions

Operating requirements

– The features of the conveyed part which determine the orientation and quality must be recognizable and distinguishable for the Checkbox:

– ItmustbepossibletointegratetheCheckboxinthe material flow.

Target group

This manual is intended exclusively for technicians trained in control and automation technology who have experience in installing and commissioning electronic systems.

Service

Please consult your local Festo Service if you have any technical problems.

Scopeofdelivery

Checkbox Compact Module with control panel, I/O interface, laser beam and camera

Documentation Checkbox Compact manual

Accessories 24-pin cable for connecting the PLC

VIII Festo P.BE-CB-COMP-EN en 1102d Contents and general instructions

Important user instructions

Danger categories This manual contains instructions on the possible dangers which may occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc.), printed on a shaded background and marked additionally with a picto- gram. A distinction is made between the following danger warnings:

Warning This means that failure to observe this instruction may result in serious personal injury and/or damage to property.

Caution This means that failure to observe this instruction may result in personal injury and/or damage to property.

Note This means that failure to observe this instruction may result in damage to property.

The following pictograms also mark passages in the text which warn about the incorrect handling of certain components.

Electrostatically sensitive devices. Incorrect handling can result in damage to components.

Festo P.BE-CB-COMP-EN en 1102d IX Contents and general instructions

Danger of injury caused by laser irradiation Do not look into the laser beam. Incorrect handling can lead to injury to the eye and/or skin.

Identification of specific information The following pictograms designate texts that contain special information.

Pictograms

Information Marks recommendations, tips and references to other information sources.

Accessories Marks information on suitable accessories.

Environment Marks sections dealing with environmentally protective measures.

Text markings S Bullet points indicate activities that may be carried out in any order.

1. Figures denote activities which must be carried out in the numerical order specified.

– Hyphens indicate general activities.

X Festo P.BE-CB-COMP-EN en 1102d Contents and general instructions

Conventions – The names of the operating, display and connecting elements are represented in the text in upper case letters, e.g. START, TEACH.

– Menu commands of the software are framed in brackets, e.g. in the menu [Window], the command [System parameters] opens the window for creating parameters.

– For selections within tree structures, e.g. for setting the system parameters in CheckKon, the paths are marked with a square. You will therefore find e.g. in the path Z System Z Operating modes the parameter z Lock the Teach button = Off.

– 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 represented as when viewed on the device. This representation corresponds to the view of the (cable) connections which are to be wired.

Festo P.BE-CB-COMP-EN en 1102d XI Contents and general instructions

Notes on the use of this manual

This manual refers to the standard designs of the Checkbox Compact type CHB-C-X with operating system version 3.x.

When the Checkbox is switched on, the version number of the operating system will be shown briefly (see Chapter 2.5).

The options and parameters available depend on the operating system, the type of connected Checkbox and on the factory pre-settings. Customer-specific designs may differ in technical data, parameter settings and method of functioning.

The pre-setting of the Checkbox can be modified if required with the software packages CheckKon (function “Modify system”) or CheckOpti (see Chapter 1.2).

DocumentationontheCheckbox

Information on using the Checkbox can be found in the following manuals:

Documentation Contents

Manual for checkbox CHB-C-X Description of the function, – P.BE-CB-COMP-... commissioning, operation and maintenance of the Checkbox.

Manuals on the software packages – Software CheckKon P.SW-KON – Operation of the CheckKon software – Software CheckOpti P.SW-OPTI – Operation of the CheckOpti software

Tab. 0/1: Documentation on the Checkbox

XII Festo P.BE-CB-COMP-EN en 1102d Contents and general instructions

Product-specific terms and abbreviations

Term/abbreviation Significance

AUTO mode Operating mode of the Checkbox for automatic parts testing (pre-set when CHB-C-X is started).

CHB-C-X Adeviceof thetype CheckboxCompact (withouttransporting device)for identifying conveyed parts of a parts type.

C-value During the Teach procedure the C-value shows the extent of the scatter of characteristics of the sample parts. The C-value specifies the maximum value of the scatter of characteristics for the current feature which differs to the greatest extent.

Deviation The Checkbox assesses the feature of an inspection part which differs most from the Teach data. The smaller the value of the inspection part deviation, the more accurately the inspection part corresponds to the sample parts.

Feature Characteristic features are ascertained from the contour data of the sample and inspection parts. These are e.g. length, height, etc. as well as a feature for each configuration tool (CheckOpti).

Good part An inspection part on which all features lie within the tolerance.

Inspection parts All parts shown during the test procedure.

Laser class Labelling of the laser beam according to EN 60825-1:1994 + A1:2002 + A2:2001. Laser devices are classified according to increasing degree of danger into classes 1, 2, 3A, 3B and 4. Class 2 An accidental, brief exposure (up to 0.25s) will not damage the eye. With longer lasting exposure, damage to the eye is possible. Laser devices of class 2 may be used without further protective measures, providing it can be guaranteed that during operation the user is not required to look intentionally over a long period (longer than 0.25 s), or to look repeatedly into the laser beam or mirror-reflected laser beam. Class 3B Lasers of class 3B can produce serious eye damage. Longer radiation of a class 3B laser onto the skin causes erythema formation (reddened skin), pigmenting, burns or photochemical damage.

Festo P.BE-CB-COMP-EN en 1102d XIII Contents and general instructions

Term/abbreviation Significance

Orientation The parts to be tested by the Checkbox can be placed on the conveyor belt facing in different directions. During the Teach procedure you can define the orientations by showing the different directions. Orientation 1 is the preferred orientation (nominal orientation)

Parts type Conveyed part defined by the Teach data of the sample parts.

Reject part An inspection part on which at least one feature lies outside the tolerance.

Sample parts Good parts which have been selected for the Teach procedure and which possess all the features necessary for identifying the parts type.

(System) parameters Settings of the Checkbox (in some cases can only be set with configuration software)

Teach data All features ascertained during the Teach procedure, each with min./max. limits and the average value.

TEACH mode Operating mode of the Checkbox in which the Teach procedure is carried out.

Teach procedure During the Teach procedure, sample parts on the conveyor belt are shown to the Checkbox and the features are scanned. This is also referred to as “Teaching parts”.

Test data Thetestdataarethedatausedforthetest.Thesecorrespondtothe Teach data plus admitted tolerances.

Test procedure During the test procedure, inspection parts on the conveyor belt are shown to the Checkbox and graded according to their features with regard to orientation and observance of the tolerances. This is also referred to as “Testing parts”.

Tolerance Factor in per cent related to the average values and which affects the min./max. limits of all features.

Tab. 0/2: Terms and abbreviations

XIV Festo P.BE-CB-COMP-EN en 1102d Contents and general instructions

Festo P.BE-CB-COMP-EN en 1102d XV System summary

System summary Chapter 1

Festo P.BE-CB-COMP-EN en 1102d 1-1 1. System summary

Contents

1. System summary...... 1-1

1.1 The Festo Checkbox...... 1-3 1.2 Software packages for the Checkbox...... 1-4 1.3 Functional range...... 1-5 1.4 Operating principle...... 1-6 1.5 Buffer zone...... 1-9

1-2 Festo P.BE-CB-COMP-EN en 1102d 1. System summary

1.1 The Festo Checkbox

The Festo Checkbox ® enables the optical (contactless) positioning and quality inspection of conveyed parts.

Festo P.BE-CB-COMP-EN en 1102d 1-3 1. System summary

1.2 Software packages for the Checkbox

Various software packages are available for user-friendly commissioning, optimizing and monitoring. They have been specially developed for the products in the Checkbox family and can be used with all devices in the Checkbox family.

Software Functions Package

CheckKon – Display and assessment of the last Checkbox registered test part Configurator – Displaying and logging of the parts contour as well as the characteristics derived from the contour. – Displaying the light intensity recognized by the camera – Displaying and printing out of the system configuration – Displaying and modifying the system parameters – Loading a new operating system into the Checkbox

CheckOpti – Convenient teaching of the sample parts Checkbox – Monitored testing of parts, displaying the Optimizer features registered – Evaluation of the inspection of workpieces with regard to reliability (evaluation) – Graphic display of the test sequence – Optimization of the inspection of workpieces through manual adaptation of the min./max. values of the Teach data or through configuration tools – Support in project planning, management and documentation

Tab. 1/1: Software package

The CheckKon software package, operating system updates and current product information on the Checkbox Compact can be found in the Festo Internet pages under the address www.festo.com in the area “Support / Downloads”.

1-4 Festo P.BE-CB-COMP-EN en 1102d 1. System summary

1.3 Functional range

Function

Teach function 1) – Teaching new parts without programming – Saving the features of the taught parts type

Quality inspection 2) – Testing the quality, e.g. with pivoted parts and milling parts – Machine-sorting of incorrect and foreign parts

Position test (nominal orientation) – Position-controlled transfer of the good parts to the following machine – Return of incorrectly oriented good parts to the small parts conveyor A check of the position and of the buffer zone can be made at the same time.

Buffer zone check Monitoring the buffer zone with one sensor. If the buffer zone is full: return of the good parts to the small parts conveyor. If the conveyed parts form a jam on the buffer zone for a long period, the small parts conveyor will be switched off.

Buffer zone check with switching hysteresis 3) – Monitoring of the buffer zone with two sensors for delayed switching of the small parts conveyor (hysteresis).

Good part counting with preselected number of items 3) A continuously running counter ascertains the sum of all good parts – Supplying of defined amounts of components through specification of a target number for good parts.

1) Via the PLC interface: Selection of a maximum of 16 parts types if system parameter “Number of buffer zone sensors = 1”, “External signal input activated= no”. Factory setting, can be set with CheckKon 2) Extended quality inspection with CheckOpti (as from version 2.1) 3) The system parameters must be activated or set in CheckKon

Tab. 1/2: Functional range

Festo P.BE-CB-COMP-EN en 1102d 1-5 1. System summary

1.4 Operating principle

3 2 1

1 Small parts conveyor e.g. vibration feeder, centrifuge, step conveyor

2 Transporting device e.g. conveyor belt, linear axis

3 Actuators e.g. exhaust valves

4 Further transfer of good parts to a buffer zone or the next machine

5 Sorting out bad parts (faulty parts, foreign parts)

6 Return of incorrectly oriented parts to the small parts conveyor

Fig. 1/1: Integrating the Checkbox in a conveyor device Example with conveyor belt and two actuators

1-6 Festo P.BE-CB-COMP-EN en 1102d 1. System summary

The function principle of the Checkbox is based on:

– the contactless recognition of small parts

– the teaching of new parts without programming

– anintegratedqualitycheck.

Identification A small parts conveyor separates the individual parts and passes them on to the conveyor device. The conveyor device (e.g. conveyor belt, linear axis) can be fitted with a maximum of 3 actuators for returning or separating the conveyed parts.

The Checkbox registers each part in contour pictures. From the contours the system ascertains part-specific features such as length, height and surface. On the basis of the features the Checkbox recognizes:

–thepartstype

– the orientation

– the dimensional accuracy

– the quality.

Teaching The nominal contour of a conveyed part is ascertained by a simple procedure:

1. You “show” the Checkbox samples of the conveyed part type several times one after the other (= scan) in the nominal orientation.

2. You scan the sample parts in further orientations if required.

3. You save the features of the parts type as Teach data.

4. You test the Teach data in the test mode.

Festo P.BE-CB-COMP-EN en 1102d 1-7 1. System summary

Testing Each registered conveyed part is compared with the saved Teach data and then sorted into different types. The test parts are separated basically via 3 conveying paths:

– Good parts are passed on e.g. to an assembly system.

– Incorrectly oriented parts are returned to the small parts conveyor.

– Faulty or foreign parts (bad parts) are rejected.

1-8 Festo P.BE-CB-COMP-EN en 1102d 1. System summary

1.5 Buffer zone

The buffer zone serves as a parts buffer for the next machine e.g. an assembly system.

The Checkbox can monitor the highest and lowest filling states of the buffer zone and if the jam of parts is long, it can switch the small parts conveyor on or off as required. (Buffer zone check, see Fig. 1/2).

Additionally by means of a second sensor, the small parts conveyor can be switched to delay. (Buffer zone check with hysteresis, see Fig. 1/3).

Signal delay The buffer zone inputs are processed by the Checkbox with a debounce time. The sensor signal is only evaluated if it is present for at least 1 second. This delay prevents each conveyed part from triggering the signal “Buffer zone full” when it passes the sensor.

The delay time of 1 second between the registering of a conveyed part by the sensor and the interpretation of the signal by the Checkbox must be taken into account when the buffer zone sections are planned.

Planning the size of the buffer zone Thebufferzonesections(seeFig.1/2)mustbedimensioned so that uninterrupted operation of the machine is possible. Instructions on dimensioning the buffer zone can be found in the following table.

Festo P.BE-CB-COMP-EN en 1102d 1-9 1. System summary

Dimensioning the buffer zone

A Section between the transporting device and the sensor. Section A must accept all conveyed parts which lie between the Checkbox and the sensor when a conveyed part has been registered by the sensor. The length depends on: – the geometry of the conveyed parts – the maximum feeder rate of the small parts conveyor – the length of the transporting device

B Section between the sensor and the next machine When the small parts conveyor is switched on again, uninterrupted operation of the assembly system must be guaranteed until the first new conveyed parts arrive. Section B must be designed so that a sufficient number of conveyed parts can be made available. The length depends on: – the geometry of the conveyed parts – the maximum time delay between switching on the small parts conveyor again and making the new conveyed parts available – the length and speed of the transporting device – the average feed amount of good parts in the nominal orientation.

AB *) Section between sensors 1 and 2 (Fig. 1/3). Section AB determines the switching delay (hysteresis) of the small parts conveyor for regulating the supply of parts. The longer the section is, the less the switching frequency.

*) Set the “Number of buffer zone sensors = 2” with CheckKon

Tab. 1/3: Buffer zone sections

Also observe Chapter 3.3 and Chapter 3.6.6 when connecting the buffer zone sensors.

1-10 Festo P.BE-CB-COMP-EN en 1102d 1. System summary

1 Transporting device 1

2 Sensor 1

Fig. 1/2: Buffer zone check

1 Transporting device 1

2 Sensor 2

3 Sensor 1 2 3

Fig. 1/3: Buffer zone check with hysteresis

Festo P.BE-CB-COMP-EN en 1102d 1-11 1. System summary

1-12 Festo P.BE-CB-COMP-EN en 1102d Fitting and commissioning

Fitting and commissioning Chapter 2

Festo P.BE-CB-COMP-EN en 1102d 2-1 2. Fitting and commissioning

Contents

2. Fitting and commissioning...... 2-1

2-2 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

2.1 General instructions

Caution Damage to components • Before carrying out mounting, installation and/or maintenance work, always switch off the power supply.

Laser irradiation Eye and skin injury • Do not remove any housing parts (e.g. prism support, covers). • Mount the Checkbox only in its original state with closed, intact housing. • Mount or remove the Checkbox only when the power supply is switched off. • Mount the Checkbox so that it is not possible to look directly into the laser beam. • Observe the warnings on the Checkbox.

1 Warning

2 Prism support 1 3 Opening

2 3

Fig. 2/1: Laser irradiation

Festo P.BE-CB-COMP-EN en 1102d 2-3 2. Fitting and commissioning

2.2 Mounting

Transport Always transport the Checkbox in its original packing; further transport safety devices are not necessary.

Mounting location Observe especially the following conditions:

– the mounting location must be free of vibration

– there must be stable mechanical fastening

– the ambient air must be clean: free of oil, no paint spray, no grinding dust

– Screening of external light influences and extreme magnetic fields (e.g. due to induction furnaces).

In this way you will achieve optimum test results and ensure alongservicelifeofthedevice.

Conveyor device In order that the test results can be reliable and reproducible, the conveyor device used should fulfill the following requirements:

S Use a high-grade transporting system which conveys the parts at a constant speed.

S Ensure the stable position of the parts, e.g. by means of mechanical devices.

S Use also mechanical devices to secure the parts transfer from the conveyor device to the buffer zone (e.g. drop pipe, slide, waste) of the subsequent machine.

Space requirement Note the space required for mounting the Checkbox. The dimensions of the Checkbox and specifications on weight can be found in the Appendix A.5.

Fastening On the side of the Checkbox there is a mounting profile with dovetail guide.

2-4 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

A connecting kit (type HMSV-12) is available as an accessory from Festo.

1 Mounting profile of the Checkbox 1 2 Clamping 2 elements with 4M5x45socket 3 head screws 4 3 2 M5x16 socket head screws with centring sleeves

4 Adapter plate

Fig. 2/2: Fastening the Checkbox with connecting kit type HMSV-12

Fasten the Checkbox over the conveyor device so that:

– the warning sign on the device is still visible (Fig. 2/1 )

– the Checkbox and the conveyor device are fastened stably to each other (Fig. 2/3)

– the viewing range of the camera is not impeded

– the optical channel is not covered by the conveyor device.

Festo P.BE-CB-COMP-EN en 1102d 2-5 2. Fitting and commissioning

1 Mounting profile 2 2 Optical channel of the camera –Insideheight: 40 mm – Inside passage: 60 mm 3 Glass surface on the prism support (opening 321 for laser beam)

Fig. 2/3: Arranging the Checkbox over the conveyor device (example)

Note In order that a reliable test result can be achieved, the glass surfaces on the prism supports must not be scratched or dirty. • Mount the Checkbox so that passing parts do not touch the glass surfaces. • Ensure the stable position of the parts, e.g. by means of mechanical devices. • If necessary, clean the glass surfaces, as described in Chapter 6 .

2-6 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

2.3 Electrical connection

1 FE 1234567

2 ACTUATORS

3 BUFFER/FEEDER

4 DIAG

5 24 V DC

6 ENCODER

7 PLC

Fig. 2/4: Connections of the Checkbox

Function Chapter

1 – Functional earth connection 2.3

2 – Connection of a maximum of 3 actuators for sorting out the tested conveyed 3.2 parts

3 – Connection of 1 buffer zone sensor for controlling the transfer of work items to 3.3 the next machine – 24 V power outputs for controlling the supply system (small parts conveyor) and the transporting system (conveyor device)

4 – Connection of a diagnostic PC for system diagnosis, visualizing and optimizing 3.4 the test procedure with the software packages CheckKon and CheckOpti

5 – Connection of the 24 V DC power supply 2.3

6 – Connection of a rotary pulse generator for determining the speed of the conveyor 3.5 system with increased demands for length accuracy

7 – Connection of 2 buffer zone sensors for controlling the transfer of work items to 3.6 the next machine – 24 V power output for controlling the supply system (small parts conveyor) and the transporting system (conveyor device) – I/O signals for process monitoring and higher-order control or for controlling a downstream-switched machine.

Festo P.BE-CB-COMP-EN en 1102d 2-7 2. Fitting and commissioning

Caution • Check within the framework of your EMERGENCY STOP concept to ascertain the measures necessary for putting your machine/system into a safe state in the event of an EMERGENCY STOP (e.g. switching off the operating voltage, switching off pressure).

Preparing plugs and cables Use plugs and sockets from the Festo supply programme which match the outer diameter of the cables used (www.festo.com/catalogue).

Note In this way, you will avoid interference from electromagnetic influences: • Use only screened cable. • Use large-cross-section cable that is as short as possible. • Connect both the FE earth terminal and the cable screening with low impedance to the earth potential.

Cable outside diameter Plugs/sockets

4.0 ... 6.0 mm PG 7

6.0 ... 8.0 mm PG 9

10.0 ... 12.0 mm PG 13.5

Tab. 2/1: Cable outside diameter

2-8 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

Connection Plugs/sockets

Power supply socket PG 9 or PG 13.5

Sensors, actuators PG 7

Tab. 2/2: Connection

In order to guarantee observance of the IP protection class for the completely fitted Checkbox:

S tighten the union nuts of the plugs by hand

S seal unused sockets with the protective caps supplied.

Caution Long I/O signal lines reduce the resistance to interference. • Comply with the maximum permissible I/O signal line length of 30 m.

Festo P.BE-CB-COMP-EN en 1102d 2-9 2. Fitting and commissioning

2.3.1 Selection of the power supply unit

The power supply for the Checkbox must fulfill the following requirements:

– voltage range: 24 V ± 15 %

– Power rating: 18 W with load-free outputs

– no current consumption at the outputs

In order to comply with the EMC limits, the Checkbox is equipped with a filter for the operating voltage. Use a separate power unit for the Checkbox. Only in this way can the fitted filter be effective.

Warning • Use only power sources which guarantee reliable electrical isolation of the operating voltage as per IEC/EN 60204-1. Observe also the general requirements for PELV power circuits as per IEC/EN 60204-1.

2-10 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

2.3.2 Connection of the operating voltage

S Use an operating voltage cable with sufficient cross-sectional area.

S Avoid long distances between the power supply unit and the Checkbox. Long operating voltage cables reduce the voltage supplied by the power unit.

S Protect the supply cable with a 5 A cut-out fuse with medium time-lag.

Connect the Checkbox to the operating voltage as follows:

Pin 24 V DC plug

1 Do not connect

2 +24 V DC, +/- 15 % with 5 A medium time-lag fuse

3 GND

4 Do not connect

Tab. 2/3: 24 V DC connection plug

Use only a 4-pin M18 socket for the power supply and connect this only to the connection for the power supply.

1. Connect the plug to the 24 V DC connection on the Checkbox.

2. Tighten the union nuts of the plug by hand.

Festo P.BE-CB-COMP-EN en 1102d 2-11 2. Fitting and commissioning

2.3.3 Power supply for external components

If you connect the Checkbox via the connections PLC, ACTUATOR or BUFFER/FEEDER with other devices (e.g.PLC,conveyordevice),observethefollowing:

Note In order to comply with the EMC limits, the Checkbox is equipped with a filter for the operating voltage. A connection between the 24 V potential and GND at the 24 V DC plug with other plugs on the Checkbox or with other devices will in some cases bridge the installed filter. Asymmetries of the currents in the outgoing and return lines will reduce the effect of the filter.

S Use a separate power unit for the Checkbox. Provide a separate power supply for connected current-consuming devices.

S Do not connect the 24 V potential and GND at the “24 V DC” connection of the Checkbox with other plugs of the Checkbox or with other devices.

S Make sure that the currents of the inputs and outputs flow via the Checkbox and not directly to the power unit.

Consuming devices can also be supplied with voltage via the PLC plug. Observe also the information in Chapter 3.6.

2-12 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

2.4 Adapting system parameters with CheckKon

A password is required for CheckKon for setting the system parameters and transmitting the modifications to the Checkbox (Function “Modify system”). You can obtain your password via the service hotline +49 / 711 / 347-1610. The function “Observe system” can be used without a password.

1. Install CheckKon on your diagnostic PC. Notes on installation can be found in the software manual.

2. Connect the Checkbox at the DIAG connection with the diagnostic PC (see Chapter 3.4). Connect the devices only when the power supplies are switched off.

Diagnostic mode Start CheckKon when the Checkbox has been switched on. When Checkkon is started, it carries out a system test and switches the Checkbox to the diagnostic mode.

Note In diagnostic mode the Checkbox transmits additional information via the diagnostic interface. During the transmission time no parts are checked. • Do not operate the Checkbox in diagnostic mode with thefullrateofparts. In this way you can prevent parts from passing the actuator positions unchecked.

1. Adapt the Checkbox to your system requirements with the system parameters in the menu [Window] [System parameters]. Note also the instructions in the following chapters and in the software manual.

Festo P.BE-CB-COMP-EN en 1102d 2-13 2. Fitting and commissioning

CheckKon shows the most important system parameters through the menu [Window] [System parameters] symbol “Only important parameters”. Make sure that these parameters are adapted to your application.

2. Transfer the modified settings to the Checkbox (see software manual).

3. Conclude CheckKon and with it the diagnostic mode when all settings have been completed.

Note Faulty processing data can cause incorrect functioning of the Checkbox. • Carry out the complete Teach procedure again if you have modified the system parameters with CheckKon.

2-14 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

2.5 Commissioning the Checkbox

1 Illuminated push-button START/STOP

2 Illuminated push-button STATUS/TEACH

3 Display 1 23

Fig. 2/5: Display and operating elements

Function

1 – Starting and stopping the Checkbox – Display of the switching function Start (green)/Stop (red) – Acknowledging errors – Saving the Teach data

2 – Switch between AUTO and TEACH modes – Selecting the orientation in the TEACH mode – Displaying the scan procedure – Accessing system information (e.g. belt speed during operation with encoder)

3 – System information and operating displays

Festo P.BE-CB-COMP-EN en 1102d 2-15 2. Fitting and commissioning

Before the Checkbox is switched on the first time, make sure that you have completed the following steps:

1. mounting of the conveyor device

2. mounting of the Checkbox to the conveyor device

3. connection of operating voltage to the 24 V DC connection

4. connection of external components, if required Observe the instructions on connecting external components in the following chapters:

– Chapter 3.2 “Actuators”

– Chapter 3.3 “Buffer zone sensors, small parts conveyor”

– Chapter 3.5 “Encoder”

– Chapter 3.6 “Higher-order controller”

Warning Check to see which measures are necessary for putting your machine/system in a safe state when it is switched on and off. Observe that movements of the connected actuators can cause injury to people and damage to property, for example • when the conveyor device is moved to its basic position when the power supply is switched off • the conveyor device starts automatically if controlled by the Checkbox when the Checkbox starts. In order to prevent the conveyor device from starting automatically when the operating voltage is switched on: • Select in CheckKon [Window] [System parameters] Z System Z Operating modes ... Z Automatic start after power supply on = no (factory setting).

2-16 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

Switching on • Switch on the operating voltage for the Checkbox via the power unit.

• Start CheckKon in order to display and set the system parameters during the TEACH and test modes (see Chapter 2.4).

• Start the conveyor device, if necessary manually.

The illuminated buttons on the Checkbox light up briefly and signal the readiness to operate. The display shows briefly the following items of system information one after the other:

LED Explanation

CC 30 Ident. code and version status of the operating system

04 E 1) Numberofmemorylocationsandadditionallytheletter E with operating systems with encoder evaluation

2048 System setting of the camera resolution in pixels

Stop Ready to operate (AUTO mode: stop status)

1) For evaluation of the encoder signals, the operating system version ...E must be used. Consult your Festo Service if you wish to modify your operating system.

Tab. 2/4: Operating display when switched on

If “Lock” is shown in the display, the buttons START/STOP Lock and STATUS/TEACH are locked (see Chapter 3.6.8).

Festo P.BE-CB-COMP-EN en 1102d 2-17 2. Fitting and commissioning

TEACH mode Scan the sample parts in the TEACH mode in order to record the Teach data.

Note The following list provides only an overview of the most important operating steps. Note the instructions on the Teach procedure in Chapter 4, before you start the Checkbox in the TEACH mode.

Stop The Checkbox is ready to operate as soon as it is switched on (Stop status).

1. Press button STATUS/TEACH. 1o1 Scan the sample parts of parts type 1 in orientation 1. During scanning the “C” value of the characteristic C30 scatter will be shown (e.g. 30)

2. Press STATUS/TEACH button. 1o2 Scan sample parts in the next orientation (2). Repeat the procedure for further orientations.

3. Press START/STOP button. Stop TheTeachdatawillbesavedandtheTEACHmodewillbe concluded.

2-18 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

AUTO mode Evaluate the reliability of the Teach data before you begin with the automatic parts test.

Note The following list provides only an overview of the most important operating steps. • Note the instructions on the test procedure in Chapter 5, before you start the Checkbox in the AUTO mode.

Stop The Checkbox is ready to operate (Stop status).

1. Press START/STOP button. 15 Presetting: Parts type 1; tolerance 5 % (influence and setting tolerance, see Chapter 5.3) A... 2. Check the inspection part deviation “A” and the inspec- #... tion part orientation “#” (see Chapter 5.4). 3. If necessary, correct the system settings with CheckKon.

Note Faulty processing data can cause incorrect functioning of the Checkbox. • Carry out the complete Teach procedure again if you have modified the system parameters with CheckKon.

4. Conclude CheckKon when all the settings have been completed.

Switching off Switch the Checkbox to the Stop status before switching it off.

Stop 1. Press START/STOP button.

2. Switch off the operating voltage.

Festo P.BE-CB-COMP-EN en 1102d 2-19 2. Fitting and commissioning

2.6 Error diagnostics

The Checkbox indicates operating errors as follows:

– The Checkbox switches automatically to the Stop status.

– The illuminated push-buttons on the Checkbox flash.

E... – The display shows error code E... or warning code F... F...

Key Status Significance

START/ Flashes red Error message/warning STOP

STATUS/ Flashes yellow TEACH

Tab. 2/5: Error display

Code E... Type Explanation

01 ... 19 Ambient fault Fault in power supply, parts supply; dirty lens etc.

20 ... 21 Recognition Orientations or sample parts cannot fault be distinguished.

40 ... 43 Data fault Teach data, configuration data or system parameters are not compatible or do not exist

>=60 Hardware Internal fault (can only be eliminated fault by customer support)

Tab. 2/6: Types of faults (overview)

2-20 Festo P.BE-CB-COMP-EN en 1102d 2. Fitting and commissioning

The Checkbox cannot be started again until the fault has been eliminated:

1. Eliminate cause of malfunction

2. Acknowledge the fault signals: Press the START/STOP button

3. Start the Checkbox: Press the START/STOP button

Further information:

– Details on the fault codes and instructions on eliminating faults can be found in Appendix A.1.

– The CHB-C-X signals faults also at the PLC connection via O/17 (fault) and O/23 (warning) (see Chapter 3.6.7).

Festo P.BE-CB-COMP-EN en 1102d 2-21 2. Fitting and commissioning

2-22 Festo P.BE-CB-COMP-EN en 1102d The I/O module

The I/O module Chapter 3

Festo P.BE-CB-COMP-EN en 1102d 3-1 3. The I/O module

Contents

3. The I/O module...... 3-1

3-2 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

3.1 Interfaces

1 ACTUATORS 123 2 BUFFER/FEEDER

3 DIAG

4 ENCODER

5 PLC

Fig. 3/1: The I/O module of the CHB-C-X

Function

1 – Connecting a maximum of 3 actuators for sorting out the tested conveyed parts 1)

2 – Connection of 1 buffer zone sensor for controlling the transfer of work items to the next machine – 24 V power outputs for controlling the supply system (small parts conveyor) and the transporting system (conveyor device) 1)

3 – Connection of a diagnostic PC for system diagnosis, visualizing and optimizing the test procedure

1) The connection is wired internally with the PLC connection

4 – Connection of a rotary pulse generator for determining the speed of the conveyor system

5 – Connection of 2 buffer zone sensors for controlling the transfer of work items to the next machine – 24 V power output for controlling the supply system (small parts conveyor) and the transporting system (conveyor device) – I/O signals for process monitoring and higher-order control or for controlling a downstream-switched machine.

Festo P.BE-CB-COMP-EN en 1102d 3-3 3. The I/O module

Power supply Observe the instructions on supplying power to external components in Chapter 2.3.3 and Chapter 3.6.

Electrical properties of the I/O signals

Outputs – Max. current loading per channel: 700 mA – Max. sum current of all outputs: ACTUATORS 2.1 A BUFFER 1.4 A – Positive switching

Inputs – Input current: . 30 mA – Logical “1”: Von , 15 V – Logical “0”: Von . 5V

Tab. 3/1: Electrical properties of the I/O signals

3-4 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

3.2 ACTUATORS

Connection assignment

ACTUATORS connector socket

O/1 Actuator 3 3 4 O/2 Actuator 2

3 GND

O/4 Actuator 1 2 1 5 5 Do not connect

Controlling the actuators

Note If there is a failure in the power supply to the CHB-C-X or to the actuators when the transporting device is running, this can result in: • parts passing the actuator positions unchecked • the actuators being unable to sort out checked parts. Check the measures which are required on your machine/ system in order to prevent incorrectly oriented parts or bad parts from unintentionally reaching the next machine in the event of such operating faults.

Input I/19 on the PLC plug is intended for monitoring the pneumatic supply to the actuators. In the event of a fault this input will switch the Checkbox to error status E 01 by means of a pressure switch.

Festo P.BE-CB-COMP-EN en 1102d 3-5 3. The I/O module

The CHB-C-X can control up to 3 actuators for sorting out good parts, incorrectly oriented parts and bad parts. Possible actuators are e.g. shunts, reversing stations or air nozzles which sort out the parts at certain positions on the transporting device depending on the test result. The number and assignment of the actuator positions may vary depending on application. The assignment of the actuator positions can be adapted with the CheckKon software.

Example of configuration Transporting device with 2 blow- out nozzles (see Fig. 1/1) The compressed air valves of the blow-out positions must be connected directly with the outputs for actuators 1 ... 2. These outputs are set to +24 V DC if the parts test provides the following result:

– incorrectly oriented or superfluous (good) part

– bad or foreign part

If the CHB-C-X recognizes an inspection part as good, the signal actuator 3 will be set from the rest potential 0 V to +24 V DC and the good part will be output at the end of the transporting device.

Output Signal level 1) (example of configuration)

Actuator 1 There is a +24 V DC signal when the inspection part passes the actuator position for incorrectly oriented or superfluous good parts.

Actuator 2 There is a +24 V DC signal when the inspection part passes the actuator position for bad or foreign parts.

Actuator 3 There is a +24 V DC signal when the inspection part passes the actuator position for good parts (here: the end of the transporting device).

1) The duration of the signal corresponds to the time required for the part to reach the air jet nozzle.

3-6 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

3.3 BUFFER/FEEDER

Connection assignment

BUFFER/FEEDER connector socket

O/1 24 V DC/Box ready – Reference voltage for sensors (switched off in Stop status) – Ready status – Control for transporting device 3 4 O/2 Feeder Controlling the supply system (small parts conveyor) 2 1 3 GND 5 Reference voltage for sensors

I/4 Buffer Bufferzonesensor1

5 Do not connect

Direct connection can optionally be made with a Festo Duo cable (see Accessories, Appendix A.6).

Identifying the Duo cable

Signal x Bufferzonesensor1

Signal x + 1 Small parts conveyor (feeder)

Controlling the small parts conveyor (feeder) If it is possible to connect an external enable signal (24 V DC) to the small parts conveyor, connect this signal via pin O/2 on the BUFFER/FEEDER plug.

Festo P.BE-CB-COMP-EN en 1102d 3-7 3. The I/O module

Controlling the buffer zone sensor (buffer)

Note Only in this way is the Checkbox ready to operate: • Leave non-used sensor inputs open. Otherwise the display will show the operating status “Full”, although the buffer zone is free. All good parts will be returned. The small parts conveyor will be switched off after 30 s (standard setting).

Signal duration In order to avoid unnecessary switching movements, the Checkbox reacts only after a certain signal duration to the sensor signals for “Buffer zone full” and “Buffer zone empty”.

Modification of the signal duration with CheckKon in the menu [Window] [System parameters] Z System Z Transporting systems Z Continuing systems ... z Minimum sensor signal duration for status: buffer zone full: 1.0 s (0.1 s ... 180 s) buffer zone empty: 1.0 s (0.1 s ... 180 s)

Sensor type The CHB-C-X is set at the factory for use with a buffer zone sensor, the sensor output of which lies at a potential of 0V (negative switching) in the rest state.

Modification of the sensor type with CheckKon in the menu [Window] [System parameters]: Z System Z Transporting systems Z Continuing systems ... z Buffer zone sensor types = positive switching.

3-8 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

Note You can optimize the operational safety of your supply system as follows: • Use sensors which have a sensor output with a potential of 24 V DC in the rest state. • Adapt the setting of the sensor type with CheckKon. You can then prevent the system from becoming blocked e.g.intheeventofabrokencable.

Sensor type Function Buffer zone with one sensor Normally Normally open closed contact 1) contact 2)

Sensor 1 Sensor 1 The sensor does not register a LOW HIGH conveyed part. The small parts conveyor is/remains switched on.

Sensor 1 Sensor 1 Thebufferzoneisfull.Thedisplay HIGH LOW switches to “Full”. Good parts are returned. When the preset time e.g. 30 s has expired, the small parts conveyor will be switched off; the conveyor device contin- ues to run.

1) Factory presetting; negative switching (NPN), 24 V DC active high 2) To be set with CheckKon (recommendation); positive switching (PNP), 24 V DC active low

Information on dimensioning the buffer zone can be found in Chapter 1.5.

Festo P.BE-CB-COMP-EN en 1102d 3-9 3. The I/O module

3.4 DIAG

Note In the diagnostic mode the CHB-C-X transmits additional information via the diagnostic interface. During the transmission time no parts are checked. • Use the DIAG connection only for commissioning and for servicing. • Do not operate the CHB-C-X in the diagnostic mode with the full parts rate. In this way you can prevent parts from passing the actuator positions unchecked.

In order to connect a diagnostic PC use cable KDI-SB202-BU9 (see Appendix A.6 Accessories).

1. Connect the diagnostic cable to the following connections:

– the diagnostic interface DIAG on the CHB-C-X

– a serial interface (COM) of the diagnostic PC

DIAG connector socket

I/1 Received data 43 O/2 Transmitted data

3 Data GND

4 Screened 1 2

2. Start CheckKon or CheckOpti in order to display the system data and to set the system parameters in the Teach or test modes.

3. Conclude CheckKon and CheckOpti when you have undertaken the necessary settings.

3-10 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

4. Remove the diagnostic cable from the DIAG connection in continuous operation. Seal the connection with the protective cap supplied.

Further information on commissioning, optimizing and monitoring the Checkbox via the diagnostic interface can be found in the documentation for the CheckKon and CheckOpti software packages.

Festo P.BE-CB-COMP-EN en 1102d 3-11 3. The I/O module

3.5 ENCODER

If high demands are placed on the accuracy of the length of the test part, you can connect a rotary pulse generator to the ENCODER connection for determining the speed of the conveyor system (see Accessories, Appendix A.6).

Pin ENCODER connector socket

Interface for rotary pulse generator as per RS 485 specification

1 A+

2 n.c.

3 B+ 2 4 5 4 A- 1 8 3 5 B- 67 6 5 V supply 1)

7 GND

8 n.c.

1) Maximum loading 180 mA

Tab. 3/2: ENCODER connector socket

Note Observe the following when connecting a rotary pulse generator: • Do not connect the potentials of the ENCODER connection with other potentials. • Use only suitable rotary pulse generators, e.g. encoders from the Festo product range.

3-12 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

Evaluation of the encoder signals S Check the operating system version when you switch on your CHB-C-X (see Chapter 2.5, Commissioning: Switching on).

Note • Use the operating system version ...E to evaluate the encoder signals. • Consult your Festo Service if you wish to modify your operating system.

Display of the belt speed S Press the button STATUS/TEACH in AUTO mode.

The display will then show the belt speed of the conveyor unit in [mm/s].

Festo P.BE-CB-COMP-EN en 1102d 3-13 3. The I/O module

3.6 PLC

Observe the following when connecting a higher-order controller:

S Use the PLC cable with 24-pin Binder plug supplied.

S Connect the cables of the PLC according to the cable assignment in Appendix A.4.

S Make sure that the maximum sum current of 1 A at the PLC connection is not exceeded.

Reference voltage The reference voltage is available at pin 4 (GND) and pin O/7 (+24 V). Fuse: 700 mA, automatic reset.

Pin Reference voltage

4 0V e.g. as reference potential for the PLC/reference voltage for buffer zone sensors

O/7 +24 V DC e.g. as voltage supply for opto-isolated PLC I/O module, signal level after boot procedure = HIGH

Tab. 3/3: Reference voltage

Load voltage Consuming devices can be supplied with power via pin 4 (GND) and pin O/7 (+24 V) under the following conditions:

S Connect only consuming devices which return the complete current to the CHB-C-X. In this way you can prevent asymmetries of the currents in the outgoing and return lines from reducing the effect of the filter.

S Load output O/7 with maximum 700 mA.

3-14 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

I/O functions of the PLC interface Pin

Remote Start Start/stop mode I/6

Selecting the parts type External type selection: Bit 0 I/20

External type selection: Bit 1 I/5

External type selection: Bit 2 I/13

External type selection: Bit 3 I/10

Controlling the teach procedure1) Selecting the teach mode and I/15 the next orientation

Saving teach data I/6

Locking the control panel Key lock I/11

Counting function 2) Start new counting cycle I/18

Target number reached O/22

Controlling the transfer position for: – Good parts Actuator 1 O/1

– Incorrectly orientated good parts or Actuator 2 O/2 Incorrect parts type

– Bad/foreign parts Actuator 3 O/3

Controlling the parts supply Bufferzonesensor1 I/12

Controlling the small parts conveyor O/8

Readiness to operate, controlling the conveyor O/21 device

Error messages Fault status 1: Status signal “Fault” O/17

1) User-specific function. Consult your Festo Service if you have any problems. 2) Counter function and special function “External sensor” cannot be used at the same time.

Tab. 3/4: I/O functions of the PLC interface

Festo P.BE-CB-COMP-EN en 1102d 3-15 3. The I/O module

Special functions of the PLC interface 1) Pin

Error messages Fault status 0: Warning O/23

Monitoring the buffer zones and controlling the parts Buffer zone sensor 2 2) I/13 supply with switch hysteresis

Additional test of material features which are not checked External sensor 3) 4) I/10 during contour registering (e.g. by metal detector or colour sensor). Downstream-switched test function, e.g. only good parts are checked.

Externally controlled switching on/off of the picture Camera trigger I/9 registration under particularly difficult conditions.

Such as for monitoring the pneumatic supply for the External fault I/19 actuators: In the event of a fault, the CHB-C-X will be switched to fault status E 01 by means of a pressure switch.

1) Deactivated at the factory Functions can be activated and adapted with CheckKon. 2) Can be set optionally with CheckKon, set at factory “External type selection: bit 2”. 3) Counter function and special function “External sensor” cannot be used at the same time. 4) Can be set optionally with CheckKon, set at factory “External type selection: bit 3”.

Tab. 3/5: Special functions of the PLC interface

Electrical properties of the PLC interface

Inputs: 12 13 – Input current: . 30 mA – Logical “1”: Von , 15 V 4 21 – Logical “0”: V . 5V on 3 22 Outputs: – Max. current loading per channel: 1 24 700 mA – Max. sum current of all outputs: 1 A 7 17 – PNP switching 8 16

Tab. 3/6: Electrical properties of the PLC interface

3-16 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

3.6.1 Start/Stop mode

The controller of the CHB-C-X assumes that:

– the power supply for the CHB-C-X is applied

– the boot procedure has been completed (O/7 = HIGH)

– the signals for selecting the parts type are applied (see Chapter 3.6.3).

The Checkbox is started with a signal sequence (pulse) at pin I/6 LOW > HIGH > LOW and is stopped again with the signal sequence LOW > HIGH > LOW (recommended pulse duration 500 ms).

Pin Signal sequence Significance

I/6 LOW > HIGH > LOW Starts the Checkbox

LOW > HIGH > LOW Stops the Checkbox

Tab. 3/7: Signal sequence with Start/Stop mode

With varying manual operation or control via the I/O module, pressing the START/STOP button corresponds to the signal change LOW > HIGH > LOW.

The modification of the operating status with Start or Stop is sent to the controller via O/21.

Festo P.BE-CB-COMP-EN en 1102d 3-17 3. The I/O module

Pulse-time diagram Timing requirement to the higher-order controller

1 24 V Power supply 0

Pin O/7 1 PLC_Power 0

Pin I/20 20 Type 2 Type 3 Type select 1 Pin I/5 21 0 Type select Start Stop Pin I/6 Ext_Start 1 t ts 0

t rs t Pin O/8 rs Feeder 1 0 t Pin O/21 d Box_Ready 1 0

0.2 s . trs. 1s rs=remote start t ts =min0.1s ts=type select t d = duration of the switch-on delay d = delay

Tab. 3/8: Pulse-time diagram: Timing requirement to the higher-order controller

3-18 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

3.6.2 Controlling the teach procedure

Input I/15 can be used for controlling the Teach procedure. The signal sequence at input I/15 corresponds to pressing the button STATUS/TEACH.

Customer-specific function Input I/15 is assigned with this function only at the customer’s wish. Consult your Festo Service if you have any problems.

With the signal sequence LOW > HIGH > LOW at pin I/15 the CHB-C-X is switched to the TEACH mode. In order to teach the next orientation, a pulse must be given again via this input.

With the signal sequence LOW > HIGH > LOW at pin I/6 the Teach data are saved and the Checkbox is stopped.

Pin Signal sequence Significance

I/15 LOW > HIGH > LOW Switches the Checkbox to the TEACH status Pulse length: min. 200 ms (orientation 1).

LOW > HIGH > LOW Selects the next orientation. Pulse length: min. 200 ms

I/6 LOW > HIGH > LOW Stops the Checkbox. In the TEACH status the recommended pulse duration: 500 ms Teach data are saved at the same time.

Tab. 3/9: Signal sequence for controlling the teach procedure

3.6.3 Selecting the parts type

For automatic changing of the parts type via the PLC:

S Switch the CHB-C-X to the stop status.

S Set the signals at the inputs in accordance with the binary codingofthedesiredpartstype(seefollowingtables).

Festo P.BE-CB-COMP-EN en 1102d 3-19 3. The I/O module

Maximum 4 parts types can be addressed via the inputs I/20 and I/5. The signals must be applied permanently before the CHB-C-X starts again.

tool If the information “tool” is shown in the display when the parts type is selected, the memory address will be occupied with additional software tools. However, the teach procedure can still be carried out. Further information: in the CheckOpti manual.

Binary coding I/20 I/5 Parts types 1 ... 4 2 0 2 1

1 LOW LOW

2 HIGH LOW

3 LOW HIGH

4 HIGH HIGH

Tab. 3/10: Binary coding parts type 1 ... 4

Pulse-time diagram (with max. 4 parts types) Partstypechange1> 4

Type 1 Type 4

Pin I/20 1 Type select 0 0

1 Pin I/5 Type select 1 0

1 Pin I/6 Remote start 0

min 0.1 s

Tab. 3/11: Pulse-time diagram: Parts type change 1 } 4

3-20 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

The inputs I/13 and I/10 are used before leaving the factory for addressing a maximum of 16 parts types. Optionally you can use the inputs for evaluating a second buffer zone sensor (switching hysteresis) or an external sensor (e.g. for colour testing).

S Use CheckKon to modify the setting of the following parameters in the menu [Window] [System parameters] in accordance with the following table:

– Z Transporting systems Z Continuing systems z Number of buffer zone sensors

– Z System Z Operating modes Z Extended influence of the parts type assignment Z Input for external signal z External signal input activated

Optional pin assignment I/20 I/5 I/13 I/10 Setting in CheckKon

z Number of buffer zone sensors = 2 Maximum 4 parts types Buffer zone External z External signal input activated = yes sensor 2 sensor Ext. type Ext. type selection selection bit 0 bit 1

z Number of buffer zone sensors = 1 Maximum 8 parts types External z External signal input activated = yes sensor Ext. type Ext. type Ext. type selection selection selection bit 0 bit 1 bit 2

Factory setting: Maximum 16 parts types z Number of buffer zone sensors = 1 z External signal input activated = no Ext. type Ext. type Ext. type Ext. type selection selection selection selection bit 0 bit 1 bit 2 bit 3

Tab. 3/12: Maximum number of parts types

Festo P.BE-CB-COMP-EN en 1102d 3-21 3. The I/O module

Binary I/20 I/5 I/13 I/10 coding 2 0 2 1 2 2 2 3 Parts types 1…12

1 LOW LOW LOW LOW

2 HIGH LOW LOW LOW

3 LOW HIGH LOW LOW

4 HIGH HIGH LOW LOW

5 LOW LOW HIGH LOW

6 HIGH LOW HIGH LOW

7 LOW HIGH HIGH LOW

8 HIGH HIGH HIGH LOW

9 LOW LOW LOW HIGH

10 (display: “a”) HIGH LOW LOW HIGH

11 (display: “b”) LOW HIGH LOW HIGH

12 (display: “c”) HIGH HIGH LOW HIGH

13 (display: “d”) LOW LOW HIGH HIGH

14 (display: “e”) HIGH LOW HIGH HIGH

15 (display: “f”) LOW HIGH HIGH HIGH

16 (display: “g”) HIGH HIGH HIGH HIGH

Tab. 3/13: Binary coding parts type 1 ... 16

3-22 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

3.6.4 Counting function

The counter function must be activated in CheckKon in the menu [Window] [System parameters]: Z System Z Operating modes Z Counter configuration ... z Counter mode = activated. The function “External sensor” will then automatically be blocked.

Counter configuration Set the following parameters in CheckKon Z System Z Oper- ating modes Z Counter configuration according to your requirements: z Nominal value specification = 1 (1 ... 200 million) z Counting of all good parts in each orientation = on (off)

Setting the switch-off delay of the small parts conveyor when the nominal number is reached Z Transporting systems Z Supply system ... z Switch-off time when counter status is reached = 30 s (0.1 s ... 1800 s).

Counting Depending on the setting in CheckKon, only good parts in target orientation (counting of all good parts ... = off) or good parts in all taught orientations (counting of all good parts ... = on) will be counted.

If counting is interrupted, e.g. when the Start/Stop button is pressed, the current counter states will remain saved. When the device is started, counting is continued with the saved counter states.

Note When the CHB-C-X is switched off (operating voltage off), counting will be interrupted. The current counter states will be deleted. When the CHB-C-X is switched on, it starts anewcountercycle. • When the CHB-C-X is switched off, remove all good parts from the parts output. You will then avoid incorrect num- bers of items when the CHB-C-X is switched on again.

Festo P.BE-CB-COMP-EN en 1102d 3-23 3. The I/O module

If the set target number of parts types is reached, all further good parts of the parts type up to the moment when the small parts conveyor is switched off will be returned to the conveyor at the actuator position for superfluous good parts. Bad parts will be output further at the relevant position.

CFul When the last good part of a counting procedure reaches the output position for good parts, the output O/22 on the connection PLC will be set from LOW > to HIGH (“Target number reached”). The current counter status is ended. The CHB-C-X shows “cFul”.

All subsequent good parts will be returned to the small parts conveyor. When the time preset with CheckKon has expired, the small parts conveyor will be switched off.

In order to start a new counting procedure, the CHB-C-X requires the signal “Start new cycle” from the higher-order controller. In order that the counting cycle can be started, the pulse LOW > HIGH > LOW must be applied at input I/18.

During the pulse duration tsc good parts will still be returned. The new counting cycle starts with the falling edge at I/18 (see following table).

Pin Signal level Significance

I/18 LOW > HIGH > LOW Starts new counting cycle

O/22 HIGH Preselected counter status reached

LOW Preselected counter status not yet reached

Tab. 3/14: Signal sequence for controlling the counting procedure

3-24 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

Pulse-time diagram Control of counting

Pin I/18 Start Start new counting cycle 1 tsc , 15 ms 0 Pin O/22 t sc Preselected counter status 1 reached 0 10 ms t r

sc = start counting cycle r=reset

Tab. 3/15: Pulse-time diagram: Controlling the counting procedure

Festo P.BE-CB-COMP-EN en 1102d 3-25 3. The I/O module

3.6.5 Actuators

Note This chapter contains supplementary information on controlling the actuators via the PLC interface. Note also the instructions and information in Chapter 3.2.

Internal circuitry The inputs actuators 1 ... 3 at the PLC connection are connected internally with the ACTUATORS connection.

Actuators PLC Function

3 4 GND

O/4 O/1 Actuator 1

O/2 O/2 Actuator 2

O/1 O/3 Actuator 3

Tab. 3/16: Internal circuitry ACTUATORS-PLC

Monitoring Input I/19 on the PLC plug is intended for monitoring the pneumatic supply to the actuators. In the event of a fault this input will switch the CHB-C-X to fault status E 01 by means of a pressure switch.

Runtime performance Observe the following when evaluating the output signals “Actuator...” through a higher-order controller: With a high pulse rate of the test parts, parts can be returned although other parts which have already been tested are not yet delivered. This delay arises due to the (long) distance between the actuator positions.

3-26 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

3.6.6 Buffer zone sensors/small parts conveyor

Note This chapter contains supplementary information on controlling the small parts conveyor and the buffer zone sensors via the PLC interface. Note also the instructions and information in Chapter 3.3.

Internal circuitry The I/O signals for buffer zone sensors and the small parts conveyor at the PLC connection are connected internally with the BUFFER/FEEDER connection.

BUFFER Function PLC FEEDER

– 24 V reference voltage for buffer zone sensors O/1 O/21 – Ready status – Controlling the conveyor device

O/2 O/8 24 V power output for controlling a small parts conveyor (feeder)

0 V reference voltage O/3 O/4 buffer zone sensors

I/4 I/12 Bufferzonesensor1

Tab. 3/17: Internal circuitry BUFFER/FEEDER-PLC

Switch-on delay of the small parts conveyor After starting, the Checkbox triggers the actuator for sorting out the bad parts. This is to ensure that no (unchecked) parts are left on the conveyor device. This results in a delay of a few seconds between the external Start command (I/6) and the switch-on signal for the small parts conveyor (O/8). The duration of this delay depends on ambient parameters, e.g. transporting speed and geometrical variables.

Festo P.BE-CB-COMP-EN en 1102d 3-27 3. The I/O module

Pulse-time diagram Controlling the small parts conveyor

Start Stop Pin I/6 1 Ext_Start 0

Pin O/8 1 Feeder 0 t Pin O/21 d Box 1 Ready 0

t d = duration of the switch-on delay d = delay

Tab. 3/18: Pulse-time diagram: Controlling the small parts conveyor

Buffer zone sensors With CheckKon, the CHB-C-X can be configured for operation either with one buffer zone sensor or for switching delay of the small parts conveyor with two buffer zone sensors (Fig. 3/2): Menu [Window] [System parameters] Z Transporting systems Z Continuing systems z Number of buffer zone sensors = 1 (2).

The maximum number of parts types is reduced to 4 with the setting “Number of buffer zone sensors = 2” (See Chapter 3.6.3).

3-28 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

1 Buffer zone

2 Conveyor device 2 3 Sensor 2

4 Sensor 1 1 3

Fig. 3/2: Buffer zone check with switching delay

Sensor type Function Buffer zone with one or two Normally Normally sensors open closed contact 1) contact 2)

Sensor 1 Sensor 1 The sensor does not register a LOW HIGH conveyed part. The small parts conveyor is/remains switched on.

Sensor ... 3) Sensor ...3) Thebufferzoneisfull.Thedisplay HIGH LOW switches to “Full”. Good parts are returned. When the preset time has expired, the small parts conveyor will be switched off; the conveyor device still runs.

1) Factory presetting; negative switching (NPN), 24 V DC active high 2) To be set with CheckKon (recommendation); positive switching (PNP), 24 V DC active low 3) with buffer zone monitoring – with one sensor: Sensor 1 – with two sensors: Sensor 2

Tab. 3/19: Sensor function for type NPN or PNP

Festo P.BE-CB-COMP-EN en 1102d 3-29 3. The I/O module

3.6.7 Fault messages

The Checkbox signals faults at pins O/17 and O/23. The fault message is acknowledged with a pulse at pin I/6.

Pin Signal sequence Significance

I/6 LOW > HIGH > LOW Delete errors LOW > HIGH > LOW

Tab. 3/20: Signal sequence Delete errors

Evaluation of the output signals takes place e.g. with the aid of a machine light:

Light Significance O/17 O/23

Red There is a fault HIGH LOW . E60 Ambient, recognition or memory fault ≥E60 Hardware fault

Yellow A warning is present LOW HIGH

Green Faultless operation LOW LOW

Tab. 3/21: Fault display (example)

By means of factory configuration or subsequent conversion in the CheckKon menu [Window] [System parameters], fault E 05 “No supply parts” can be defined as a warning F 05: Z System Z Fault treatment z Error/Warning 5 = Warning (see following table).

3-30 Festo P.BE-CB-COMP-EN en 1102d 3. The I/O module

Malfunction Code O/17 O/23

Material blockage or small E05(fault) HIGH LOW parts conveyor is empty. F05(warning) LOW HIGH

Tab. 3/22: Fault/warning “No supply parts”

3.6.8 Locking the control panel

Via pin I/11, the buttons START/STOP and STATUS/TEACH on the CHB-C-X can be locked against unauthorized actuation. The Checkbox can then be started or stopped only via pin I/6. A change to the TEACH mode is not possible.

Pin Signal level Significance

I/11 HIGH Button lock

LOW Button release

Tab. 3/23: Signal level: Locking the control panel

Display Significance

Lock Locking the control panel – Continuous display in Stop status – Display (duration 1.5 s) when the START/STOP button is pressed.

Tab. 3/24: Display: Locking the control panel

Festo P.BE-CB-COMP-EN en 1102d 3-31 3. The I/O module

Setting the control panel lock with CheckKon The STATUS/TEACH button can also be locked via CheckKon. At I/11 only the START/STOP button can then be released.

Fix If “Fix” is in the display, the STATUS/TEACH button is locked with CheckKon (blocking the Teach button = on). Acknowledge the message with the START/STOP button.

The STATUS/TEACH button remains blocked until the function is switched off again in the menu [Window] [System parameters]: Z System Z Operating modes z Blocking the Teach button = off.

3-32 Festo P.BE-CB-COMP-EN en 1102d Teaching parts

Teaching parts Chapter 4

Festo P.BE-CB-COMP-EN en 1102d 4-1 4. Teaching parts

Contents

4. Teaching parts...... 4-1

4.1 Preparing the Teach procedure...... 4-3 4.2 The Teach procedure...... 4-5 4.2.1 Positioning the sample parts...... 4-9 4.2.2 Observing the scatter of characteristics...... 4-10

4-2 Festo P.BE-CB-COMP-EN en 1102d 4. Teaching parts

4.1 Preparing the Teach procedure

If you are using the CheckKon/CheckOpti software package: note also the instructions on preparing the Teach procedure in the software manuals.

Features and properties of the conveyed parts The Checkbox registers conveyed parts as 2-dimensional, black and white profile pictures (parts contour). Features for distinguishing various good parts are derived from the parts contour. Discolouring or surface faults do not influence the test result in this recognition procedure.

The features of the conveyed part relevant for distinguishing, as well as for determining the orientation and quality, must be recognizable for the Checkbox:

S Use the Checkbox preferably for testing rotation-symmetrical small parts. The testing of non-rotation-symmetrical parts is only possible if a pre-orientation of the conveyed parts is carried out with the small parts conveyor.

The conveyed part must be fed through in a safe manner on the conveyor device:

– The length, diameter and height of a conveyed part must be suitable for the CHB-C-X.

– The conveyed part must be supplied in a stable orientation (it must not roll away or vibrate).

Theconveyedpartmustbesortedoutreliablybythe actuators.

As standard during the Teach procedure, the parts are sorted out at the first actuator position. This is to ensure that no sample parts are transported by mistake to the next machine in the process.

Festo P.BE-CB-COMP-EN en 1102d 4-3 4. Teaching parts

Note Check in the test mode whether the actuators used (e.g. air nozzles) can reliably sort out especially large conveyed parts made of heavy materials with streamlined form. This is to ensure that no sample parts are transported by mistake to the next machine in the process.

Selecting the sample parts S Provide sample parts for each parts type as follows:

– The sample parts show all the characteristics which a part classified as “Good” should possess.

– If possible, use various sample parts with the usual scatter of characteristics (recommendation: min. 6 sample parts). With the scatter of characteristics, you determine the extent to which the test parts classified as “Good” may differ from each other.

Diagnostics mode S Start CheckKon in order to display and set the system parameters during the TEACH and test modes.

When Checkkon is started, it carries out a system test and switches the Checkbox automatically to the diagnostic mode.

Note In the diagnostic mode the Checkbox transmits additional information via the diagnostic interface. During the transmission time no parts are checked. • Do not operate the Checkbox in diagnostic mode with the full parts rate. In this way you can prevent parts from passing the actuator positions unchecked.

4-4 Festo P.BE-CB-COMP-EN en 1102d 4. Teaching parts

4.2 The Teach procedure

In the TEACH mode the Checkbox learns all the features for the parts test (Teach data) when scanning sample parts.

S Carry out the Teach procedure as realistically as possible. Use, for example, the conveyor device and feed intended for the later AUTO mode (if necessary activate with CheckKon: [Window] [System parameters] Z Transporting systems Z Supply system ... z Activate supply system in Teach mode ...).

S Start the conveyor device.

The following functions of the Teach procedure can be carried out via the PLC interface: –START/STOPmode

– selection of the parts type

– starting of the Teach mode

– selection of the (next) orientation

– saving of the Teach data

S Set the desired parts type via the PLC interface.

Further information can be found in Chapter 3.6

• Press the button START/STOP, in order to switch the Stop Checkbox into the Stop status.

S Scan sample parts of the parts type one after the other in all intended orientations (max. 8), as described below.

Festo P.BE-CB-COMP-EN en 1102d 4-5 4. Teaching parts

Scan sample parts in orientation 1 1. Press the button STATUS/TEACH, in order to switch the Checkbox to the Teach mode.

Fix If “Fix” is shown in the display and if the CHB-C-X switches to the AUTO mode again, the STATUS/TEACH button is blocked by CheckKon. Acknowledge the message with the START/STOP button. • Switch off the TEACH button blocking with CheckKon: [Window] [System parameters] Z System Z Operating modes = ... z Teach button lock = Off.

1o1 2. Scan different sample parts of parts type 1 in orientation 1 (o1 = nominal orientation). The STATUS/TEACH button lights up briefly when the sample part is registered.

• Pay attention to the positioning of the sample parts (see Chapter 4.2.1).

C ... • While scanning, observe the displayed C-value of the scatter of characteristics (see Chapter 4.2.2).

• Repeat the procedure until the C-value remains almost constant.

If a part has been incorrectly positioned (C-value changes erratically):

S Press the button START/STOP, in order to conclude the Teach procedure.

S Repeat the complete Teach procedure of the parts type.

4-6 Festo P.BE-CB-COMP-EN en 1102d 4. Teaching parts

Scan the sample parts in further orientations 3. Check whether there is at least one feature in which the various orientations differ.

4. Press the STATUS/TEACH button in order to scan the next orientation

If fault E20 is shown, the nominal orientation cannot be dis- E20 tinguished from other orientations.

Possible causes of the fault:

– The nominal orientation has been taught several times by mistake.

S Repeat the complete teach procedure. Pay attention to the positioning of the sample parts in accordance with the orientation shown.

– The nominal orientation is too similar to other orientations.

S Optimize the Teach data with CheckOpti.

With the CheckOpti software even minimum differences in the features can be recognized. Further information can be ob- tained from your technical advisor.

5. Scan the sample parts of parts type 1 in orientation 2 1o2 (o2) as described in point 2.

Festo P.BE-CB-COMP-EN en 1102d 4-7 4. Teaching parts

Save the Teach data and conclude the Teach procedure Do not save the Teach data until the sample parts of a parts type have been taught in all orientations.

Stop 6. Press the START/STOP button. TheTeachdatawillbesavedandtheTEACHmodewillbe concluded.

After saving, carry out the following steps:

S Check the Teach procedure in the test mode with regard to orientation and quality as described in Chapter 5.

S Keep a record of your work.

S Address the next parts type via the PLC inputs (Chapter 3.6.3).

S Repeat all steps as from point 1.

4-8 Festo P.BE-CB-COMP-EN en 1102d 4. Teaching parts

4.2.1 Positioning the sample parts

The sample parts should be positioned exactly like the parts to be tested later.

– Place the sample parts on the conveyor band one after the other.

– You do not need to be very careful when placing the parts on the conveyor belt.

In cases where particularly different variations of the ascertained parts contour (view) are permitted or possible in an orientation, you should show the “extreme” variations or as many different variations as possible during the teach procedure.

S Show at least 6 parts of the current parts type per orientation.

S Use different parts if possible, although if necessary the same part can be shown several times.

The parts type is not registered completely until the Checkbox has recorded all intended orientations. For reliable testing, the ascertained features of the individual orientations must be clearly distinguished.

S Make sure in particular that orientation 1 (target orientation) differs clearly in at least one feature from all the other orientations.

Festo P.BE-CB-COMP-EN en 1102d 4-9 4. Teaching parts

4.2.2 Observing the scatter of characteristics

C... Observethedisplaywhenscanningthesampleparts.It shows briefly for each part the maximum value of the scatter of characteristics for the current feature which differs to the greatest extent (C-value).

The following factors influence the scatter of characteristics:

– parts geometry

– different contours of the part, depending on the swivel angle around the longitudinal axis (e.g. with springs, screws)

– different positioning on the conveyor device.

If the displayed C-value changes erratically, you have prob- ably placed the conveyed part incorrectly on the conveyor device. If the C-value changes only minimally, a sufficient scatter of characteristics in the current orientation has prob- ably been achieved. The optimum situation is when the curve of the values changes at first considerably and then becomes increasingly more constant.

Small values indicate narrow manufacturing tolerances and a steady supply of parts. Very large values indicate that the taught sample parts differ greatly from each other with regard to their properties. If the (good) parts are allowed to differ greatly from each other, the Teach procedure can nevertheless still be continued.

C-value Significance

. 10 Sample parts are very similar in all features

, 30 Large scatter of at least one feature

An exact description of the calculation algorithm for the scatter of characteristics can be found in Appendix A.3.2.

Tab. 4/1: C-value (scatter of characteristics)

4-10 Festo P.BE-CB-COMP-EN en 1102d Testing parts

Testing parts Chapter 5

Festo P.BE-CB-COMP-EN en 1102d 5-1 5. Testing parts

Contents

5. Testing parts...... 5-1

5-2 Festo P.BE-CB-COMP-EN en 1102d 5. Testing parts

5.1 The test procedure

During the automatic inspection of workpieces, a reliable grading of the parts to be tested must be achieved with respect to orientation and quality (e.g. dimensions specified have been observed).

The following functions can only be carried out via the PLC interface: – Selection of the parts type

– Counter function or test with external sensor

– Monitoring of the buffer zone with switch delay.

Further information can be found in Chapter 3.6.

S Evaluate the reliability of the Teach data in the test mode (Chapter 5.2), before you begin with the automatic inspection of workpieces.

S Protect the Teach data against undesired modification:

– through control panel protection (see Chapter 3.6.8)

– with the CheckKon software: [Window] [System parameters] Z System Z Operating modes ... z Teach button lock = On.

Festo P.BE-CB-COMP-EN en 1102d 5-3 5. Testing parts

5.2 Test mode

Stop The Teach procedure is concluded and the Checkbox is ready to operate (Stop status)

Set the desired parts type via the PLC interface (Chapter 3.6.3)

1. Provide inspection parts for each parts type

S Use good, bad and incorrectly oriented parts from the parts assortment.

S Test a sufficient number of parts in order to obtain a reproducible result. Show, for example, 6 good parts per orientation as well as 6 bad parts.

15 2. Press the button START/STOP (AUTO mode). Test parts from the displayed parts type (e.g. 1) with the factory-set tolerance of 5%.

3. You do not need to be very careful when placing the parts on the conveyor belt. If possible, use the conveyor device intended for the inspection of workpieces. The inspection parts should be positioned (at random), as in normal operation.

E05 If the supply of parts is interrupted for a long period, the Checkbox will show fault message E 05 or warning F 05 and will stop automatically (see Chapter 2.6 and Appendix A.1.2).

4. Check the test results e.g. with regard to the following aspects: Have the orientations been recognized correctly? Is the grading of the parts recognized as good/bad correct?

5-4 Festo P.BE-CB-COMP-EN en 1102d 5. Testing parts

5. Check the correct output at the output positions for good, bad or incorrectly oriented parts with as many inspection partsaspossible.

6. On the basis of the sample parts, check the inspection parts with regard to their grading. If you have also tested faulty parts, check whether these have actually been recognized as bad.

If too many good parts have been graded and sorted out as “Bad”:

S Increasethetolerance(seeChapter5.3)

S Repeat the Teach procedure with more sample parts, using the conveyor device intended for automatic mode (see Chapter 4).

7. Note the displays on the Checkbox. When a conveyed part is registered, the status display lights up briefly.

The display shows for 1.5 seconds:

A... • The evaluation of the inspection part deviation A (Chapter 6.4.2) #... • The evaluation of the inspection part orientation # if more than one orientation has been learnt (Chapter 6.4.3).

If the quality check and position recognition for the parts assortment are not satisfactory, you can use additional operating parameters and tools with CheckOpti in order to optimize the test results. Please consult your technical advisor.

Festo P.BE-CB-COMP-EN en 1102d 5-5 5. Testing parts

Terminate the test mode when all settings have been completed and the checked parts have been graded reliably with regard to orientation and quality.

Stop 8. Press the button START/STOP, in order to switch the Checkbox into the Stop status.

9. Conclude the diagnostic mode. Close CheckKon (and CheckOpti).

10. Remove the diagnostic cable from the DIAG connection and seal the connection with the protective cap supplied.

5-6 Festo P.BE-CB-COMP-EN en 1102d 5. Testing parts

5.3 Influence of tolerance

Band width When a new parts type is taught, the features of all scanned parts are recorded. The values of the registered features differ individually from each other. For each feature, there is a value range (band width) in which test parts are graded as “Good”. You can influence this band width by means of the tolerance setting. Test parts, the features of which lie within the band width or in the subsequent tolerance range, are still accepted as good parts.

With 0 % tolerance, only those parts with features which lie exactly within the band width of the scanned sample parts will be accepted as good parts. Set therefore at least 1 % tolerance. This will ensure that good parts will be classified correctly even if their positions deviate minimally.

Set tolerance The setting is made in the Stop status.

Stop 1. Press the button START/STOP, in order to switch the Checkbox into the Stop status.

15 2. Press and hold down the START/STOP button while you increase the tolerance value by pressing the 110 TEACH/STATUS button, e.g. from 5 to 10 %:

Setting range 0 ... 20 % Standard setting 5 % Recommendation at least 1 %

Stop 3. Release the START/STOP button when the desired value has been set.

The value selected will be added automatically to the data of the parts type and saved.

Festo P.BE-CB-COMP-EN en 1102d 5-7 5. Testing parts

Optimizing Ascertain the optimum setting of the tolerance especially with critical conveyed parts in the test mode. Use one of the following methods:

S Empirical setting Vary the tolerance so that the test of a large number of parts produces correctly recognized good and bad parts.

S Setting corresponding to inspection part deviation:

S Select sample parts which are suitable as reference for good or bad parts. The recognition-specific features should lie if possible in the limit range good/bad.

S Vary the tolerance so that the following test part deviation is shown when the limit sample part is scanned: ‹ 100 limit sample part “Good” › 100 limit sample part “Bad”

5-8 Festo P.BE-CB-COMP-EN en 1102d 5. Testing parts

5.4 Evaluation of the test results

5.4.1 Checking the features

The individual features of the inspection parts differ from the average values of the sample part features. The Checkbox ascertains the feature which differs most (maximum deviation) for each test part.

A... During the test procedure the inspection part deviation will be shown for 1.5 seconds. Detailed instructions on test part deviation (arithmetical algorithm) can be found in Appendix A.3.3.

Value Evaluation Note

≤100 Good part The smaller the value, the more accurately the inspection part corresponds to the sample parts.

>100 Reject part The larger the value, the less the inspection part corresponds to the sample parts.

Indicating range: 0 to 999

Tab. 5/1: Inspection part deviation

Festo P.BE-CB-COMP-EN en 1102d 5-9 5. Testing parts

5.4.2 Checking the orientation

The Checkbox ascertains during the test procedure whether the orientation of the last scanned test part can be assigned to the orientations of the sample part.

#... The uncertainty in orientation recognition will be shown for 1.5 seconds after the display of the inspection part deviation.

Value Evaluation Significance

<100 Inspection part The smaller the value, orientation can be themorereliablythe assigned inspection part orientation will be recognized.

>100 Inspection part The larger the value, orientation cannot be the less reliably the assigned clearly inspection part orientation will be recognized.

Indicating range: 0 to 999

Tab. 5/2: Uncertainty of orientation recognition

5-10 Festo P.BE-CB-COMP-EN en 1102d Maintenance

Maintenance Chapter 6

Festo P.BE-CB-COMP-EN en 1102d 6-1 6. Maintenance

6. Maintenance...... 6-1

6-2 Festo P.BE-CB-COMP-EN en 1102d 6. Maintenance

Caution Damage to components • Before carrying out mounting, installation and/or maintenance work, always switch off the power supply.

Note Damage to the glass surfaces can result in operative malfunctions of the Checkbox. • Consult your Festo Service in case of damage.

The Checkbox has been designed for rough industrial environments and is distinguished by its high reliability, robust structure and long service life. Special maintenance work is not necessary.

Cleaning Fixed cleaning intervals are not specified. The frequency of cleaning depends on the conditions of use at your location.

Laser irradiation Eye and skin injury • Clean the Checkbox only in the switched-off state. • Observe the warnings on the Checkbox.

With plastic parts, do not use solvent-containing or abrasive cleaning agents, which can damage the surfaces. Use only mild cleaning agents free of solvents.

S Remove dirt from the housing, operating elements and conveyor belt with a soft moist cloth.

Festo P.BE-CB-COMP-EN en 1102d 6-3 6. Maintenance

Note Faultless functioning of the Checkbox optics can only be guaranteed if the glass surfaces are clean and not scratched. Make sure that the glass surfaces are not scratched; do not use any abrasive cleaning agents. Clean the glass surfaces on the prism supports if they are dirty or if there are dirt deposits on them: • with clean non-lubricated compressed air • with a soft moist cloth and non-abrasive cleaning agents. You will then avoid damage which could lead to malfunctioning of the Checkbox.

6-4 Festo P.BE-CB-COMP-EN en 1102d Technical appendix

Technical appendix Appendix A

Festo P.BE-CB-COMP-EN en 1102d A-1 A. Technical appendix

Contents

A. Technical appendix...... A-1

A-2 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

A.1 Operating malfunctions

A.1.1 General fault finding

Problem Cause Action

Device does not function, both Ambient, setting, data or 1. Identify fault coding in illuminated push-buttons are hardware fault Appendix A.1.2. flashing. 2. Eliminate fault. 3. Acknowledge with START/STOP button.

Good inspection parts are – Tolerance set too low – Increase tolerance and sorted as bad parts. repeat Teach procedure with more sample parts.

– Incorrect parts type selected – Select the (correct) parts by external type preselection type with external type at the PLC connection. preselect.

Bad inspection parts are – Tolerance is set too high. – Reduce tolerance. accepted as good parts by the –Deviationsarenot – With CheckOpti: Optimize the device. recognisable for the Teach data. Checkbox.

– Display cFul The preselected counter status – Check connection to – Good parts are blown back is reached and is not reset by controller. into the small parts conveyor the external controller. –CheckPLCprograminthe in all orientations. controller.

–Responsetime Checkbox runs in the diagnostic – With CheckKon: switch from point/duration of the mode. the diagnostic mode to the Checkbox is not correct. operating mode, or – Inspection part deviation is – Conclude shown for an unusually long CheckKon/CheckOpti. time.

Tab. A/1: Faults and remedies

Festo P.BE-CB-COMP-EN en 1102d A-3 A. Technical appendix

A.1.2 Fault messages and warnings

The Checkbox stops automatically if there is a malfunction. When the cause of the malfunction has been eliminated, error messages/warnings must be acknowledged before the Checkbox can start again.

1. Eliminate cause of malfunction

2. Acknowledge the fault signals: Press the START/STOP button

3. Start the Checkbox: Press the START/STOP button

Depending on the customer-specific design of the Checkbox or configuration with CheckKon, the following faults will not be shown:

– The error messages E 01, E 02, E 04, E 06, E 08, E 12, E 14 can be deactivated.

– Fault E 05 is redefined as warning F 05 or deactivated.

– Faults E 08 and E 14 are only shown with encoder mode.

– Fault E 06 is shown only if the CheckKon function “Forced abort of analysis” is activated.

Note If fault messages and warnings are deactivated, undefined operating states and malfunctioning can occur in the event of a fault. Before deactivating, check whether additional measures are necessary for avoiding faults.

A-4 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

Code Cause Action

The error messages marked in grey can be activated/deactivated with CheckKon.

Installation and ambient faults

E01 External fault – Check signal at PLC connection, input “External fault”: HIGH = no external fault LOW = external fault

E02 Visual fault: – Remove dirt with a soft cloth and non-abrasive cleaning – Glass surfaces on the prism agent or blow dirt off the glass surfaces with supports are dirty or unlubricated compressed air. defective – If the glass surfaces are defective: Consult your Festo – Jam of parts in front of the Service. visual channel

– Glass surface misted due to – Avoid large differences in temperature. large differences in temperature between Checkbox and the environment

– The camera registers the –WithCheckKon: lower range of the conveyor Correct the setting of the picture limits device Increase exposure time or ratio encoder frequency/ – Maximum parts length line frequency. exceeded

E04 System recognizes too many – Check the selection of the sample parts type incorrect conveyed parts: – Increase tolerance >75%ofthelast20partshave been graded as bad parts.

E05 Material jam (fault): – With manual feed: Acknowledge faults, supply further The Checkbox has not received inspection parts or stop the Checkbox. any conveyed parts for at least – With automatic supply: Fill up small parts conveyor, 30 seconds 1). check feed path for material jam, acknowledge fault 1) Duration variable, can be set with CheckKon

Festo P.BE-CB-COMP-EN en 1102d A-5 A. Technical appendix

CodeCause Action

F05 Material jam (warning) – With manual feed: Acknowledge faults, supply further Signal on plug PLC O/23 = HIGH inspection parts or stop the Checkbox. The Checkbox has not received – With automatic supply: Fill up small parts conveyor, any conveyed parts for at least check feed path for material jam, 30 seconds 1). acknowledge warning. 1) Duration variable, can be set with CheckKon

E06 Maximum permitted parts – With CheckKon: Set the parameter “Max. parts length” length exceeded correctly Fault E 06 is shown only if the – Set the conveyor device so that the parts CheckKon function “Forced follow each other at a recognizable distance. abort of analysis” is switched on.

E07 Visual fault: Clean the glass surfaces on the prism. Reduced brightness

E08 Only for operation with Checkbox has no control over the conveyor device. encoder: – Check the fitting and installation of the encoder. Conveyor device blocked or encoder does not turn.

E09 Overload of internal 1. Stop the Checkbox E10 I/O module 2. Check whether external outputs are loaded with an excessive current 3. Start the Checkbox or contact the Festo after-sales service.

E12 Overtemperature – Check ambient temperature – Prevent warmth from outside e.g. by sun shine.

E14 Only for operation with – Reduce conveyor speed encoder: –WithCheckKon:AdaptFEZ value. Conveyor speed for the set ratio encoder frequency/ line frequency of the camera (FEZ value) too high.

E19 Incorrect operating system The operating system must be appropriate for the CHB-C-X. – Install correct operating system variant.

A-6 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

CodeCause Action

Recognition fault

E20 The nominal orientation cannot – Repeat teach procedure. Pay attention to the be distinguished from other ori- positioning of the sample parts in accordance with the entations, because e.g.: orientation shown. – the parts orientations were – Optimize teach data with the CheckOpti software. swapped by mistake during the teach procedure, or – the nominal orientation is too similar to other orientations.

Data fault

E40 The teach data are not clear. – Repeat the teach procedure When the device is switched on – Check the environment for devices which do not again, the saved teach data are conform to CE requirements no longer OK. – Make sure that all electrical connections are correctly wired.

E41 The controller has lost the – With CheckKon: Load system parameters again system parameters – Contact the Festo after-sales service.

E42 The controller has lost the – With CheckKon: Load Teach data again configuration part of the teach – Contact the Festo after-sales service. data.

E43 The teach data are not – Use compatible teach data format compatible. – Repeat the teach procedure. The teach data are not organised compatibly for the Checkbox used.

Tab. A/2: Fault codes

If the hardware fault message ≥ E 60 appears, please contact the Festo after-sales service.

Festo P.BE-CB-COMP-EN en 1102d A-7 A. Technical appendix

Error status Cause Action

...Full, although the buffer zone – Control line is defective or – Make sure that circuitry is is not full. incorrect pin assignment at correct at the Good parts in all orientations the BUFFER/FEEDER BUFFER/FEEDER connection. are blown back into the small connection. –WithCheckKon:Change parts conveyor. – Incorrect sensor type is set. sensor type.

...E 02, although conveyed part – Conveyed part has a lot of With CheckKon: length is shorter than maximum holes or semi-transparent – Increase conveyor speed. length permitted. conveyed part – Increase exposure time, – Conveyor speed has been division factor changed. – Vary the grey-value threshold – Limit field of vision of camera – Activate filter function.

...E 02 appears in the morning – High fluctuations in – With CheckKon: Set the although the Checkbox temperature e.g. between picture limits. functioned faultlessly the day day and night before. – Conveyor device has been replaced.

...E 04, although only a low Moveable dirt particles on the – Clean the conveyor device number of bad parts has conveyor device. with compressed air. passed the test procedure. – Install a separator device in front of the conveyor device.

Tab. A/3: Other fault states

A-8 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

A.2 Status displays on the control panel

Push-button Status Significance

START/STOP Continuous red light Checkbox is in the –AUTOmode (Display e.g.: 1 5) or –TEACHmode (Display e.g.: = 1 o1)

Continuous green light Checkbox is ready to operate (Stop status) (display: Stop)

STATUS/TEACH Flashes yellow New part passes the camera

START/STOP Flashes red Malfunction Display fault code E... or warning F..., see Appendix A.1.2 STATUS/TEACH Flashes yellow

Tab. A/4: Illuminated push-button

Operating status displays

Tables on a grey background indicate continuous displays; the remaining displays last only a short time as a result of an event or an operating status.

Display when the device is switched on

CC30 Identification code and version status of the operating system

4..E Number of memory modules for parts types and additionally the letter E with system setting “with encoder”. Example: 4 memory modules, encoder.

2048 System setting of the camera resolution Example: 2048 pixels

Stop The Checkbox is in the Stop status

Festo P.BE-CB-COMP-EN en 1102d A-9 A. Technical appendix

Operating status displays

Display with control panel protection

Lock Display in Stop status or for 1.5 s when the START/STOP button is pressed. Lock for the START/STOP and STATUS/TEACH buttons via PLC programming. A change of operating mode is controlled exclusively by the PLC (see Chapter 4.3)

Fix Block of the STATUS/TEACH button with the CheckKon configuration software (Parameter “System/Operating modes/Block of the Teach button = ...”). The Checkbox can be started or stopped manually; a change to the Teach mode is not possible. Acknowledgment of the message with the START/STOP button.

Fault signal Details in Chapter A.1.2.

E... Fault code for system faults 01 ... 99

F... Warning 05

Display during the Teach procedure

1 o... Memory module of the parts type and 1 ... 8 number of the sample part orientation during the Teach procedure.

? ... Selecting the memory module of the parts type 1 ... 9,a,b,c,d,e,f,g

C... C-value 0 ... 999 Maximum value of the scatter of characteristics for the current feature which differs most . 10: Sample parts are very similar in all features , 30: Large scatter of at least one feature tool Memory address assigned with measuring tool or optimized Teach data (CheckOpti)

A-10 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

Operating status displays

Display during the test procedure

15 Tolerance value for the current parts type 1st number: Number of the parts type 1 ... 9,a,b,c,d,e,f,g 2nd number: Tolerance in % 0 ... 20

A... Inspection part deviation: The smaller the value, the more 0 ... 999 accurately the inspection part corresponds to the registered sample parts. ≤100: Good part >100: Reject part

#... The smaller the value, the more reliably the inspection part 0 ... 999 orientation will be recognized. <100: Inspection part orientation can be assigned >100: Inspection part orientation cannot be assigned clearly

Full Status of the buffer zone (signal from buffer zone sensor)

cFul Preselected counter setting reached

Display of the conveyor speed

The operating system version ...E is required to display the conveyor speed [mm/s]. – Press the TEACH/STATUS button while the conveyor equipment is running.

Tab. A/5: Display

Festo P.BE-CB-COMP-EN en 1102d A-11 A. Technical appendix

A.3 Examples for calculation of the features

A.3.1 Band width and tolerance

The band width B specifies how far the value of the feature may vary upwards or downwards. The tolerance T specifies the percentage increase in the band width of each feature, related to the average value of the feature.

T C = Cmax+A × max tol 100

C = C −A × T min tol min 100

B = Cmax tol−Cmin tol

2 × T × A = Cmax − C + min 100

B−(Cmax − C ) → T = min × 100 2 × A

A Average value of the feature B Band width Cmax Feature maximum Cmax tol Upper limit of the band width incl. tolerance Cmin Feature minimum Cmin tol Lower limit of the band width incl. Tolerance T Tolerance

A-12 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

Example Ascertaining the band width for the feature “Length” of a conveyed part with a set tolerance of 5 %.

Conveyed part lengths [mm] ascertained during the Teach procedurefor5sampleparts: 6060616560

This means: A = 61.2 mm Average value of the length Cmax =65mm Length, maximum Cmin =60mm Length, minimum T=5% Tolerance

2 × T × A B = Cmax − C + min 100 × × B = (65−60) + 2 5 61.2 100

B = 11, 12

Cmax tol 68.06

Cmax 65.00

12 A 61.20 Cmin 60.00

Cmin tol 56.94

1 Band width of the conveyed part length

2 Band width at 5 % tolerance

Result: All conveyed parts with a length of 57 … 68 mm are classified as good parts. The Checkbox ascertains appropriate value ranges for each feature.

Festo P.BE-CB-COMP-EN en 1102d A-13 A. Technical appendix

A.3.2 Scatter of characteristics

Cmax−C S = min × 100 % A

A Average value of the feature Cmax Feature maximum Cmin Feature minimum S Scatter of characteristics

Example Ascertaining the scatter of characteristics for the feature “Length” of a conveyed part.

The following values are taken from the example “Band width”: A = 61.2 Average value of the length Cmax =65 Length, maximum Cmin =60 Length, minimum

− S = 65 60 × 100 % 61.2 S = 8.2 %

A-14 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

A.3.3 Inspection part deviation

Calculating the deviation D for C ‹ A

C −A D = actual × 100 % Cmin tol−A

A Average value of the feature Cactual Current feature measurement Cmin tol Lower limit of the band width incl. tolerance D Feature deviation

Example Ascertaining the deviation for the current feature “Length” of a conveyed part Cactual =61(C

The following values are taken from the example “Band width”:

A = 61.2 Average value of the length Cmin tol = 56.94 Length, lower limit Cactual =61 Length, current value

− D = 61 61.2 × 100 % 56.94−61.2 D = 4.7 %

Festo P.BE-CB-COMP-EN en 1102d A-15 A. Technical appendix

Calculating the deviation D for C ‹ A

C −A D = actual × 100 % Cmax tol−A

A Average value of the feature Cactual Current feature measurement Cmax tol Upper limit of the band width incl. Tolerance D Feature deviation

Example Ascertaining the deviation for the current feature “Length” of a conveyed part Cactual =64(C>A)

The following values are taken from the example “Band width”:

A = 61.2 Average value of the length Cmax tol = 68.06 Length, upper limit Cactual =64 Length, current value

− D = 64 61.2 × 100 % 68.06−61.2 D = 40.8 %

A-16 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

A.4 Connections

Pin 24 V DC connector plug

1 Do not connect

2 +24VDC,+/-15%;protectwith 5 A medium time-lag fuse

3 GND

4 Do not connect

Tab. A/6: 24 V DC connector plug

Pin BUFFER/FEEDER connector socket

O/1 24 V DC/Box ready – Reference voltage for sensors, switched off in Stop status – Ready status – Control for transporting device 3 4

O/2 Feeder Controlling the supply system (small parts conveyor) 2 1 5 3 GND Reference voltage for sensors

I/4 Bufferzonesensor1

5 Do not connect

Tab. A/7: BUFFER/FEEDER connector socket

Direct connection can optionally be made with a Festo Duo cable (see Accessories, Appendix A.6.).

Festo P.BE-CB-COMP-EN en 1102d A-17 A. Technical appendix

Duo cable marking

Signal x Bufferzonesensor1

Signal x + 1 Small parts conveyor (feeder)

Tab. A/8: Duo cable marking

Pin ACTUATORS connector socket

O/1 Actuator 3 3 4 O/2 Actuator 2

3 GND

O/4 Actuator 1 2 1 5 5 Do not connect

Tab. A/9: ACTUATORS connector socket

Pin Connector socket DIAG 1)

I/1 Received data 43 O/2 Transmitted data

3 Data GND

4 Screened 1 2

1) Interface for diagnostics PC: Cable type KDI-SB202-BU9

Tab. A/10: DIAG connector socket

A-18 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

Pin Connector socket ENCODER 1)

1 A+

2 n.c.

3 B+ 2 4 A- 4 5

5 B- 1 8 3

6 5 V supply 2) 67

7 GND

8 n.c.

1) Interface for rotary pulse generator as per RS 485 specification 2) Maximum power rating 180 mA

Tab. A/11: ENCODER connector socket

PLC connector socket

12 13 – All outputs are limited electronically to 4 21 max. 700 mA. – Maximum permissible resultant current 1 A 3 22

1 24

7 17 8 16

Pin Cable colour Signal Function

O/1 White OUT24_Act1 Actuator 1

O/2 Brown OUT24_Act2 Actuator 2

O/3 Green OUT24_Act3 Actuator 3

4 Yellow GND_NT 0 V / reference voltage for buffer zone sensors

I/5 Grey IN24_TypeSel1 External type selection: Bit 1

I/6 Pink IN24_Ext_Start Save the Start/Stop mode and the Teach data

Festo P.BE-CB-COMP-EN en 1102d A-19 A. Technical appendix

PLC connector socket

O/7 Blue OUT24_PLC_Power Reference voltage +24 V DC (signal level after Boot procedure = HIGH)

O/8 Red OUT24_Feeder Controlling the small parts conveyor

I/9 Black IN24_Cam_Enable External camera trigger 1)

I/10 Purple IN24_Ext_Sensor External sensor 1) 2) External type selection: Bit 3

I/11 Grey/pink IN24_Key_Inhibit Button lock

I/12 Red/blue IN24_Jam1 Bufferzonesensor1

I/13 White/green IN24_Jam2 Buffer zone External type selection: Sensor 2 1) Bit 2

O/14 Brown/green OUT_PWM Do not connect

I/15 White/yellow IN24_Ext_Teach Select Teach mode / next orientation 3)

O/16 Yellow/brown OUT24_Res2 Unused

O/17 White/grey OUT24_Error Fault status 1: Status signal “Fault”

I/18 Grey/brown IN24_Counter-Rst Start new counting cycle

I/19 White/pink IN24_Ext-Fault External fault E 01 1)

I/20 Pink/brown IN24_TypeSel0 External type selection: Bit 0

O/21 White/blue OUT24_BOX_READY 24 V DC reference voltage for buffer zone sensor / Ready to operate / Control conveyor device

O/22 Brown/blue OUT24_Counter-fin Target number reached

O/23 White/red OUT24_Warning Fault status 0: Status signal “Warning” 1)

O/24 Brown/red OUT24_Res1 Unused

1) Functions with a grey background have been deactivated at the factory and can be activated and adapted with CheckKon. 2) The counting function and the special function “External sensor” cannot be used at the same time. 3) User-specific function. Consult your Festo Service if you have any problems.

Tab. A/12: PLC connector socket

A-20 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

Internal circuitry Function

ACTUATORS PLC

3 4 GND

O/4 O/1 Actuator 1

O/2 O/2 Actuator 2

O/1 O/3 Actuator 3

BUFFER/FEEDER PLC

– 24 V reference voltage for buffer zone sensors O/1 O/21 – Ready for operation – Controlling the conveyor device

O/2 O/8 24 V power output for controlling a small parts conveyor (feeder)

0 V reference voltage for 3 4 buffer zone sensors

I/4 I/12 Bufferzonesensor1

------I/13 Bufferzonesensor2

Tab. A/13: Internal circuitry of the connections

Festo P.BE-CB-COMP-EN en 1102d A-21 A. Technical appendix

A.5 Technical data

General

Temperature ranges – Ambient temperature –5 °C ... +45 °C – Storage temperature –20°C...+70°C

Ambient conditions Dry, screened from external light sources, cleanest possible ambient air

Protection against electric shock PELV (Protective Extra-Low Voltage) (Protection against direct and indirect contact)

CE marking (see declaration of conformity) According to EU EMC Directive 1)

Electromagnetic compatibility (EMC) – Emitted interference According to EN 61000-6-2 – Resistance to interference According to EN 61000-6-4 (industry)

Max. permissible I/O signal line length 30 m

Vibration and shock – Vibration resistance Severity level 2 – Shock resistance Severity level 2

Protection class (plug connector inserted or IP64 provided with protective cap)

Electrical data – Nominal operating voltage 24 V – Permissible voltage fluctuations ±15 % – Current consumption with load-free outputs 750 mA – Internal fuse protection 8Afuse

Interfaces – Connection for encoder According to RS 485 specification –Diagnosticinterface RS 232 interface (115 kBaud), socket M12x1, 4-pin

1) The device is intended for use in industrial environments. In residential areas, interference suppression measures might have to be taken.

Tab. A/14: Technical data: General

A-22 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

Dimensions

Height (without plug) 241 mm

Width 60 mm

Length 150 mm

Inside passage of the optical channel 60 mm

Inside height of the optical channel 40 mm

Tab. A/15: Technical data: Dimensions

Electrical properties of the I/O signals

Outputs – All outputs electronically limited to max. 700 mA – Max. residual current at “PLC” connection: 1 A

Tab. A/16: Technical data: Electrical properties

Camera and lighting

Camera resolution 6/100mm

Exposure time 128 ... 1024 ìs

Laser class Laser class 2 according to EN 60825-1:1994 + A1:2002 + A2:2001 (Class II according to CFR 21 §1040.10 USA). P≤1mW ë = 645 ... 665 nm

Tab. A/17: Technical data: Camera and lighting

Festo P.BE-CB-COMP-EN en 1102d A-23 A. Technical appendix

Feature of conveyed parts

Component range Rotationally symmetrical parts and pre-oriented parts of any shape

Min. part length 1mm

Max. part length Dependent on belt speed and required resolution

Part diameter 0.5 ... 25 mm

Tab. A/18: Technical data: Feature of conveyed parts

A-24 Festo P.BE-CB-COMP-EN en 1102d A. Technical appendix

A.6 Accessories

Please select the appropriate accessories from our catalogue (www.festo.com/catalogue).

Festo P.BE-CB-COMP-EN en 1102d A-25 A. Technical appendix

A-26 Festo P.BE-CB-COMP-EN en 1102d Index

Index Appendix B

Festo P.BE-CB-COMP-EN en 1102d B-1 B. Index

B. Index...... B-1

B-2 Festo P.BE-CB-COMP-EN en 1102d B. Index

Abbreviations...... XIII Accessories...... A-25 Actuators...... 3-5, 3-6, 3-26 AUTO...... XIII, 2-19

Band width...... 5-7, A-12 Belt speed...... 3-13 Buffer zone...... 1-9 Hysteresis...... 1-10 Section...... 1-10 Sensor...... 3-7, 3-27 BUFFER/FEEDER...... 3-7 Build-up area, Hysteresis...... 1-5

C-value...... XIII, 4-10, A-10 Camera...... A-23 Trigger...... 3-16 cFul...... 3-24, A-11 CHB-C-X...... XIII Checkbox...... 1-3 Checkbox Compact Control panel...... 2-15 Function...... 1-5, 1-6 CheckKon...... 1-4, 2-13, 3-23 CheckOpti...... 1-4

Festo P.BE-CB-COMP-EN en 1102d B-3 B. Index

Cleaning...... 6-3 Connection Allocation...... A-17 Electric...... 2-7 Internal circuitry...... A-21 Control...... 3-14 Control panel...... 2-15 Protection...... 3-15, 3-31, A-10 Conveyed parts...... A-24 Properties...... 4-3 Counter status check...... 3-23 Counting function...... 3-23

Deviation...... XIII DIAG...... 3-10 Diagnostic interface...... 3-10 Diagnostics mode...... 2-13 Dimensions...... A-23 Display...... 2-15 Documentation...... XII Duo cables...... A-17

EMC...... 2-10, 2-12, A-22 Encoder...... 3-12 Error...... 2-20, 3-30 Elimination...... 2-20 External...... 3-16

B-4 Festo P.BE-CB-COMP-EN en 1102d B. Index

Faults...... 3-30 Elimination...... A-4 Error messages...... A-4 Fault finding...... A-3 Feature...... XIII,4-3,5-9,A-12 Fix...... A-10 Full...... A-11

Good part...... XIII

I/O module...... 3-12, 3-14 I/O signals...... 3-4 Inspection part...... XIII Deviation...... 5-5, 5-9, A-10, A-15 Evaluate...... 5-9 Orientation...... 5-10, A-11 Intended use...... VI Interfaces...... A-17 ACTUATORS...... 3-5 BUFFER/FEEDER...... 3-7 DIAG...... 3-10 ENCODER...... 3-12 PLC...... 3-14

Laser irradiation...... X Laser class...... VII, XIII Opening...... 2-3, 6-3 Warning...... 2-3 Lock...... 3-31, A-10

Festo P.BE-CB-COMP-EN en 1102d B-5 B. Index

Maintenance...... 6-3

Operating mode AUTO...... 2-19 Change...... 4-5 TEACH...... 2-18 Operating status displays...... A-9 Operating system...... XII, 3-13 Update...... 1-4 Operating voltage...... 2-11 Orientation...... 5-5

Parts type...... XIV Operating mode...... 3-19 PLC...... 3-14, A-19 Electrical properties...... 3-16 Functions...... 3-15 Special functions...... 3-16 Symmetrical...... 3-14 Power supply...... 2-10, 2-12 Power supply unit...... 2-10 Pulse-time diagram...... 3-18 Counter status check...... 3-25 Parts type change...... 3-20 Switch-on delay of the small parts conveyor...... 3-28 Push-button START/STOP...... 2-15 STATUS/TEACH...... 2-15

Reject part...... XIV

B-6 Festo P.BE-CB-COMP-EN en 1102d B. Index

Sampleparts...... XIV,4-4,4-9,5-4 Scatter of characteristics...... 4-10 Scatter of features...... A-14 Scope of delivery...... VIII Sensor External...... 3-16 Selection...... A-25 Service...... VIII Small parts conveyor...... 3-7, 3-27 Software...... 1-4 Download...... 1-4 Start-up...... 2-17 START/STOP...... 2-15, 2-20, A-9 Start/Stop mode...... 3-17 STATUS/TEACH...... 2-15, 2-20, A-9 Switch-on delay...... 3-18, 3-27, 3-28 Switching off...... 2-19 System parameters...... 2-13

Target group...... VIII TEACH...... XIV, 2-18 Teach data...... XIV Evaluate...... 5-3 Protect...... 5-3 Teachprocedure...... XIV,1-7,4-5 Preparing...... 4-3 Test mode...... 5-4 Test procedure...... XIV, 1-8, 5-3

Festo P.BE-CB-COMP-EN en 1102d B-7 B. Index

Tolerance...... XIV,5-7,A-12 tool...... 3-20, A-10 Type of error Ambient fault...... 2-20, A-5 Data fault...... 2-20, A-7 Hardware fault...... 2-20, A-7 Recognition fault...... 2-20, A-6

Warning...... 2-20, A-4

B-8 Festo P.BE-CB-COMP-EN en 1102d