FESTO MPS500 Manual Vision A004

MPS500
Manual
Vision
Order-NR.:
Type: Manual MPS500
Designation MPS500_Manual_Vision.doc
Printed: Sep-10
Autor: Schober
Graphics: Schober
Layout: Schober
Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2010
Internet: www.festo.com/didactic
e-mail: did@festo.com
This manual, all text and illustrations contained included, is protected by copyright. Any utilization
outside the limits of the copyright law and other than training purposes are not permissible without
our definite approval. This applies in particular to reproductions, operations, translations, micro
filming and the storing and processing into electronic systems. Parts of this manual may be copied by
the authorized user, exclusively for teaching purposes. Distribution of this documentation, as well as
reproduction, use and spread of its contents is prohibited, insofar not permitted explicitly. Offences
are liable to compensation. All rights reserved, especially the right to execute registrations concerning
patents, designs for use and patterns.
2 Festo Didactic GmbH & Co.KG MPS500

1. Intended use
The User Manual must be to hand at all times. Keep it close to the machine.
This installation was developed and manufactured only for use in basic and further
training in the fields of automation and communications. The training company
and/or the training staff must ensure that the trainees observe the safety
precautions described in the accompanying manuals.
Furthermore this manual describes setup and possible uses of the singular stations.
It contains all information and data required for commissioning, maintenance and
operation.
Festo Didactic accepts no liability for injury or harm to trainees, the training
company and/or any third parties occurring when the installation is used for any
purpose apart from training, except Festo Didactic has caused such injury or harm
intentionally or by grossly negligence.
The manual is divided into four parts:
Part A
In addition to technical data, Part A contains an overview of the possible uses of
the stations.
Part B
Part B contains some exercises and the solutions for this exercises (Not available
for each station).
Part C
Part C contains the pneumatic and electrical diagrams for the station and the
listing of the control programs (Not available for each station).
Part D
Part D contains data sheets and technical information about the electrical and
electronic modules used.
Festo Didactic GmbH & Co.KG MPS500 3

List of applicable standards The list below provides an overview of the most important standards and
and regulations regulations relating to mechanical, electrical and safety-engineering design and
production.
DIN EN 292 -Machine safety

DIN EN 60204 - Electrical equipment of industrial machines
DIN VDE 0113 - See DIN EN 60204
DIN 40719 - Circuit documentation
VDI 2853 - Technical safety requirements concerning the building, equipping and
operation of industrial robots
VDI 2853 - Technical safety requirements concerning automated production
systems
VDI 2411 - Terms and explanations in conveying and handling
VDI 2860 - Assembly and robotics - terms
VDI 2861 - Assembly and robotics - characteristic quantities
DIN 19245 - PROFIBUS Part 1-3
As far as possible, the System is maintenance-free. All bearings are lubricated for
life. The installation was designed in such a way as to keep the number of wearing
parts to a minimum. This does not include machines that are part of optional
expansions (such as industrial robots).
At this point we would like to point out that this manual and the concept of the
operating instructions for a Flexible Training System of this type are regularly
updated. To ensure that the instructions are ever more user-friendly, you would help
us a great deal by passing on your suggestions for improvement. Please let us know
of your suggestions, corrections or ideas, either in writing or via telephone:
+49(711-3467-0)

Contents
1. Intended use _______________________________________________________ 3
2. Introduction _______________________________________________________ 9
2.1. General _______________________________________________________ 9
2.2. Vision station _________________________________________________ 10
2.3. Didactic structure ______________________________________________ 11
2.4. Scope of tasks of the stations ____________________________________ 12
2.4.1. Mechanics ________________________________________________ 12
2.4.2. Pneumatics _______________________________________________ 12
2.4.3. Electrics __________________________________________________ 12
2.4.4. Informatics _______________________________________________ 12
2.4.5. Bus technology ____________________________________________ 12
3. General safety instructions __________________________________________ 13
3.1. Use according to regulations _____________________________________ 13
3.2. Handling the system____________________________________________ 13
3.2.1. Dangers in handling the machine _____________________________ 13
3.2.2. Safety precautions in standard operation ______________________ 13
3.2.3. Dangers due to electric current _______________________________ 14
3.2.4. Dangers due to pneumatic energy ____________________________ 14
3.2.5. Maintenance Servicing Malfunction removal _________________ 15
3.2.6. Organisational measures ____________________________________ 15
3.3. Personnel ____________________________________________________ 15

Contents
3.3.1. Notes on personnel ________________________________________ 15
3.3.2. Training operations ________________________________________ 15
3.3.3. Outside training operations _________________________________ 15
3.3.4. Safety symbols ____________________________________________ 16
4. Commissioning ____________________________________________________ 17
4.1. Transport _____________________________________________________ 17
4.2. Set up _______________________________________________________ 18
4.2.1. General information ________________________________________ 18
4.3. Commissioning ________________________________________________ 21
4.3.1. Electric commissioning _____________________________________ 21
4.3.2. Establishing communication connections ______________________ 22
4.3.3. Preparing the pallets _______________________________________ 23
4.4. Camera ______________________________________________________ 24
4.4.1. Software Checkkon ________________________________________ 25
4.4.2. Software CheckOpti ________________________________________ 39
4.4.3. EMERGENCY-STOP system __________________________________ 45
4.5. Start-up process general ________________________________________ 46
5. Operation ________________________________________________________ 47
5.1. General operation notes ________________________________________ 47
5.1.1. Behaviour rules ___________________________________________ 47
5.1.2. Operation rules ____________________________________________ 47
5.2. Process description ____________________________________________ 48

Contents
5.2.1. Vision station _____________________________________________ 48
5.3. Reset mode ___________________________________________________ 48
5.4. Automatic mode _______________________________________________ 48
5.4.1. Start automatic mode ______________________________________ 48
5.4.2. Stop automatic mode _______________________________________ 48
6. Technology _______________________________________________________ 49
6.1. drawings _____________________________________________________ 49
7. Electrical system ___________________________________________________ 51
7.1. Power supply _________________________________________________ 51
7.2. Wiring _______________________________________________________ 52
7.2.1. I/O-Components ___________________________________________ 52

Contents

2. Introduction
2.1. General This manual describes the handling of a MPS 500 system. It contains explanations
and descriptions of all the processes required for operation. Facts are partly
described with the help of graphics or images subserving an easier understanding.
The MPS 500 system is a successively expandable system consisting of individual

stations. However, the central unit is always the transport system.
Operation is not dependant on the operating position the material flow is being
started from conveyor system. Still, the sequential order of the stations requires
adherence, as it is pre-defined in the SPS-program.
The MPS 500 system is designed in such a way, that the amount and kind of
attached MPS-stations attached is not important. A complete processing cycle of the
work-piece is always warranted. Therefore, the transport system is required under
any circumstances.
In complete set-up, the work-piece is seperated from the distribution station to be

transfered to the testing station. The testing station checks the condition of the
work-pieces, ejects junk in case of occurrence and transfers the faultless pieces to
the transport system. Consequently, the product input into the system takes place
from the distribution station. In case the distribution station does not exist in the
system, the work-piece can be placed onto a work-piece carrier, anywhere in the
system. It is to be noted that no work-piece carriers should be extracted/removed
from the system.
The processing station is loaded a PIC-alfa station. The work-piece receives
processing, followed by testing. The PIC-alfa station returns the work-piece to the
transport system.
The work-piece is tested for shape tolerance in the vision station.
The robot station assembles a model cylinder from a basic body.
The AS/RS station is able to store work-pieces and, on demand, returns them to the
system.
In the sorting/commissioning station the work-pieces can be re-retrieved from the
system. The work-pieces are transported from the transport system to the sorting
station by a PIC-alfa station, where the work-pieces are arranged according to
colour, ready for product output. From the commissioning station the work-pieces
are not released by colour, but by the number of pieces. Each time 18 pieces are
commissioned. The three upper slides are on stand-by for the work-pieces, the
fourth slide is for parts storage in the adjustment process.

Introduction
2.2. Vision station The vision station is responsible for testing the work pieces!

Introduction
2.3. Didactic structure The installation is structured, to enable methodical learning, i.e. from single use of
modules to the complex and complete installation. Perhaps even in combination
with further systems.
For example, it is possible to pick out a single module to start with the first steps,
e.g. the robot.
First the mechanical assembly is considered. The robots radius of action

requires integration into the location of the robot.
The following step could be the connection of all cables required for operation
and the set-up of the robot.
Moving the robot and teaching the required positions are the first real operations
with the robot, which introduces the user how to deal with the teach-box.
The robots programming can be started, as soon as the robot can be moved by
the teach-box. Small programs, which can be created by using the
Cosimir/Cosirob software, are expandable for the complex programs.
Orders to further stations and from other controls can be installed in the
programs.
Once the learning process of this module has been concluded, these learning steps
can be transferred to the next module. As soon as all of the modules have been
processed individually, the modules can be interconnected and the programs can be
adapted. A complete production process can be simulated.
This is an ideal training area for the professional practice of mechatronis, as well as
all of the technical ranges (mechanical, electrical and pneumatic processes) are
represented in a simple and clearly way, concerning each one of the modules and
the complete system.

Introduction
2.4. Scope of tasks of the The stations are possessing a varied range of functions. A small extraction of the
stations various possibilities of the stations follows.
2.4.1. Mechanics
Obtaining basic mechanical skills about the assembly of basic modules

Obtaining complex mechanical skills about the assembly of a complete station or
complex modules
Assembly provides instructions about the technical connections between the
various components
2.4.2. Pneumatics
Understanding of a pneumatic circuit by set-up and pipe connection of the

cylinders and valves
2.4.3. Electrics
Obtaining electrical knowledge of reading a circuit diagram, concerning the

wiring of sensors and valves
Functional understanding of the individual modules e.g. in case of error
detection, by means of a circuit diagram and a measuring device
2.4.4. Informatics
Understanding of programs receiving an insight by controlling the individual

components of the programs
Changing and improving programs recognising and removing errors in a
complete program
Writing new programs new programs can be written by combination of the skills
obtained in the steps before.
2.4.5. Bus technology
Instructions in the various bus technologies avoidance to gain intimate

knowledge about the various bus technologies is made impossible by working
with the programs

3. General safety instructions
3.1. Use according to This installation has been developed and produced exclusively for training purposes
regulations in the fields of automation and communication. The training company, as well as the
instructors have to ensure, that the trainees pay strict attention to the safety
precautions, as described in the accompanying manuals.
Festo Didactic accepts no liability charges for possible damages to any trainee of the
training company and/or further third parties, which might occur during
use/operation of the installation, if it is not part of a real training situation; except
Festo Didactic caused such damages deliberately or by negligence.
Due to the product liability law and various EC-directives, the following directions
are required and are to be strictly observed by the operator.
3.2. Handling the system 3.2.1. Dangers in handling the machine
The installation has been constructed technologically up to date and in conformance

with the recognized rules of safety engineering. Nevertheless, during operation it is
possible that harm might be caused to the user or third parties or that the
installation or other property might get damaged. Therefore, the installation has to
be handled according to specified operational use in perfect technical condition
only.
Safety endangering malfunctions cannot be tolerated during training and have to be

removed immediately.
3.2.2. Safety precautions in standard operation
Put the installation into operation only, once all of the protection settings are
completely functional.
At least, before starting operation, check the installation for externally visible
damages and for the reliability of the safety devices.
Do not grip into the installation while in operation.
Before circuit construction, circuit disassembly and circuit modification: switch off
air pressure and power supply.
General safety regulations are to be observed: DIN 58126 and VDE 0100.

General safety instructions
3.2.3. Dangers due to electric current
As soon as maintenance is completed, check the function reliability of the safety

devices.
Only trained experts in electric or electronic engineering are permitted to carry out
work on the electric supply system.
The terminal boxes are to be kept closed at all times. Access must be permitted only
under supervision of a member of the training staff.
Do not activate electric limit switches manually during fault search. Tools are to be
used.
Only low voltage 24VDC is to be used.
3.2.4. Dangers due to pneumatic energy
Accidents might occur due to bouncing off tubes, caused by air pressure. Interrupt
air pressure supply immediately.
Caution! When the air pressure supply is activated, cylinders may move in or out.
Do not uncouple any tubes under air pressure supply. Exception: Fault finding. In
this case, keep on holding the end of the tube.
Do not exceed the permitted operating pressure. See data sheets.

3.2.5. Maintenance Servicing Malfunction removal
Carry out adjustments and inspections as instructed, in accordance with the

specified intervals.
Secure the compressed air and electricity supplies to prevent unintentional start-up.
During inspections, maintenance and repair work, the machine must be de-
energised, de-pressurised and secured against unexpected restart.
All screw connections released during maintenance, inspection or repair work must
be checked to ensure correct re-tightening.
3.2.6. Organisational measures
All existing safety devices must be checked at regular intervals.
3.3. Personnel 3.3.1. Notes on personnel
Basically two situations have to be considered, concerning matters on personnel.
Activities during training operations

Activities outside training operations
3.3.2. Training operations
Trainees are permitted to work with the machine only under strict supervision of an
experienced person or an instructor.
Activities of trouble-shooting and fault correction are to be checked by the

instructor. Special care should be taken regarding safety aspects.
3.3.3. Outside training operations
Activities in the areas of maintenance, service and repair are to be carried out by
only persons with appropriate technical qualifications.

3.3.4. Safety symbols
In this manual the following danger designations and signs are being used:
This symbol indicates an immediate

threat to a persons health or life.
DANGER !
Failure to pay attention to this symbol may result in serious health damage, which
may even lead to life-threatening injuries.
This symbol emphasises important

information for correct machine
handling.
IMPORTANT
Failure to pay attention to this symbol may result in damages to the machine or to
its surroundings.
This symbol indicates operational tips

and especially useful directions.
i
INFORMATION
This symbol assists you to make optimal use of all of your machines functions.

4. Commissioning
4.1. Transport Care is to be taken that the transport of the stations is to be executed only by a
suitable transport vehicle. The weight amounts up to 500 kg, depending on the
station.
The route of transport is to be cleared in advance, to be accessible to the transport

vehicle. Installation of warning signs or barriers may be required.
i The transport boxes are to be opened with care, as additional components, such as
computers may be contained in the delivery, which are to be protected from falling
out.
Once the transport box has been opened and the possibly contained additional
components removed, the station can be taken out to be transported to its
destination by means of two fork-lifts or one fork-lift truck.
Please check the stability of all of the profile connectors by means of an Allen key
size 6. The connectors may have come loose during transport, due to inevitable
vibration.
Pay special attention to all overhanging components. Sensors and similar small
parts are very easily damaged in case of improper transport.
The stations are not to be picked up by or even under the mounted feet increased
risk of becoming trapped or contused.

Commissioning
4.2. Set up 4.2.1. General information
The installation is to be set up in a frost-free room with maximum relative air

humidity of 70%.
In countries with an atmospheric humidity over 70% and temperatures above 25

degrees Celsius, the premise is to provide an air-conditioning system for constant
surrounding conditions.
To comply with the levels of the regulatory guidelines, sources of electrical

interference such as welding plants, large motors and contactors are to be checked
for electromagnetic compatibility in advance and screened where necessary.
To ensure faultless operation a load-bearing floor is required to avoid settling.
Allow sufficient distance between the installation and the wall of the room.
Any dust originating from construction work has to be kept off the installation (by
covering).

Commissioning
For a more simple room planning the complete installation design is shown in the
following. The vision station is to line up that a fault-free work piece handing over
can take place.
Set-up situation MPS 500 example

Commissioning
Dimensional drawing of set-up MPS 500 example

Commissioning
4.3. Commissioning The vision station can be built up only if the transport system stands on its final
position and the commissioning for the transport system has been carried out.
The vision station has to be mounted at the transport system, utilising the included
profiles. Afterwards, the distance of the station is fixed in such a way, that the
camera is able to focus the work piece in the operating position. At this point, screw
and lean the profiles lightly onto the basic frame of the transport system station, by
means of the angles. Align the vision station by means of a spirit-level and tighten
the connector profiles afterwards.
It is necessary to adjust the camera for the new operating position.
4.3.1. Electric commissioning
The power supply (24 VDC) of the station is provided in each case by means of a 2-
pin cable which is plugged into the conveyor system.

Commissioning
4.3.2. Establishing communication connections
The communication connections to the transports system is to be set up according

to the following example.
In order that the system knows that the station is present and processing can
occur the station, it has to be connected to the system by I/O-connectors.
For more detailed information, the connection possibilities are listed below:
Handshake transport system / operation panel station
Pos Description
1 SYS Link plug at the backside from a operation panel
2 I/O terminal at operating position from transport system
3 SYS-Link cable pluggable at both sides
Clamp at station Description Clamp at transport system
I0 Start Vision Output 0
O3 Not ok Input 3
O2 Measurement ready Input 2
O1 ok Input 1
O0 ready Input 0

Commissioning
This kind of data types are transferred over Digital I/O
Trigger
I/O for Scripts
Pass /Fail
Users (Quality evaluated)
4.3.3. Preparing the pallets

Commissioning
4.4. Camera
The camera is for the optical check of the work pieces. The colour and the
orientation of the work piece is recognized.
Description Name
Camera QBOC-Q-R1C /548317
Lens with 25mm focal distance
Checkkon Software to configuration the picture
Checkopti Software for operation and flow of measurement

Commissioning
4.4.1. Software Checkkon
Checkkon is the program to set the parameter for the picture and the communication
of the camera. After starting the software, the following picture is announced.
Connect ChekKon with

camera
Screen 1
Position
1 Choose modification (password), the standard password is mission
2 Choose via Ethernet interface to connect the camera
3 Further to next step (see screen2)
4 Exit CheckKon

Commissioning
Select camera
Screen 2
Position
1 Select camera (SBO Camera)
2 If there is no camera available, search available cameras with this button (see screen 6)
3 Further to next step (see screen 3)
4 Chancel back to main screen

Commissioning
Screen 3
Insert the password - mission
Screen 4
Confirm with OK-Button
Screen 5

Commissioning
Search camera
Screen 6
Position
The camera is announced automatically. Take care for the IP address The address
1
from the programming PC has to fit to the cameras address 192.168.10.x
2 If there is no camera available, search for a new camera (See screen 7)
3 Further to next step only possible if the camera is chosen

Commissioning
Screen 7
Position
The camera is announced automatically. Take care for the IP address The address
1 from the programming PC has to fit to the cameras address 192.168.10.x
click on the camera to chose this device (blue marked if chosen)
2 If there is no camera available, search for a new camera
3 Further to next step (see screen 2)

Commissioning
Load parameter from saved The following description is only necessary if there is a new camera installed or to
project restore the original state. Click on Open in File menu to open a saved project.
Screen 8 - Load parameter

Commissioning
Screen 9 synchronize device
Position
1 Select open system file
2 Click on next to select the respective file

Commissioning
Screen 10 open file
This example is explained with an iCIM project
Position
1 Choose project
2 Open selected project

Commissioning
Screen 11
Position
1 This option has to be selected
2 This option has to be selected
3 Click on next to continue

Commissioning
Screen 12
Position
1 The view the unsupported parameter
2 Click to finish the synchronization

Commissioning
Screen 11 program manager
Close this window without any changes.
Position
1 Actual chosen program
2 Button to import programs
3 Button to export programs to a file
4 Copy chosen program from range of programs
5 Active program in the range of programs
6 Delete chosen program on the right range of programs
7 Delete chosen program on the left range of programs
8 Close program manager

Commissioning
Adjust picture
Screen 12
With a click on the live image button, it is possible to adjust the camera with a live
image.

Commissioning
Screen 13
Position
1 Play must be active for live view
2 Adjust picture like shown
Adjust camera manually, the position, focus and the aperture can be adjusted.

Commissioning
Screen 14
Position
1 Click on this button to activate camera live image
2 Click on this button to activate pro processing picture 1 (greyscale image)
3 Click on this button to activate pro processing picture 2 (binary image)
4 Click on this button to activate pro processing picture 3 (filtered image)
5 Announcement live image
6 Announcement greyscale image
7 Announcement binary image
8 Area to adjust white balance and image section
9 Adjustment for greyscale
10 Announcement filtered image
Adjust the exposure time to the available light conditions.

Commissioning
4.4.2. Software CheckOpti
Adjust the application

Example with iCIM project
Position
1 Open a existing file hast to be active
2 Click on Next to go further
Choose the iCIM_Vision.sbp file and click on open.

Commissioning
Position
1 Click here to record a new picture
Here the camera can be chosen. Select the SBO Camera with the Ethernet-address
192.168.2.10

Commissioning
Confirm this window with ok.
Position
1 Activate this option to record a binary image
2 Activate this option to record an original colored picture.
Switch to main window of CheckOpti

Commissioning
Position
1 Click on this button to record a new picture
2 The actual picture is announced here.
Position
1 Activate centre tool
2 Move centre tool to centre of recorded object.

Commissioning
Load program to camera
Position
1 Start check program manager with this icon
Position
1 Connect camera

Commissioning
Position
1 This program has to be selected
2 Copy program from PC to camera
3 Select program on camera, has to be chosen
4 Close program manager

Commissioning
4.4.3. EMERGENCY-STOP system
See transport system manual

Commissioning
4.5. Start-up process For the MPS500-installation the first start-up has been executed at the customer
general already.
For the installation to be ready for operation execute the following directions:
1. Mains supply 230 V AC for power supply unit, connect control cabinet of
transport system and commissioning station.
2. Power supply unit 24V DC with connections +24V/0V/earth are connected
correctly to the stations and activated (except for robot: only after adjustment of
the transport system).
3. Each station is supplied with ca. 6 bar compressed air.
4. I/O-communication connectors (laboratory plugs) are connected according to
communication plan.
5. All of the PLC-programs are loaded into the respective controls. The controls are
switched to RUN and the red error indicators of the controls are not on.
6. All of the EMERGENCY-STOP signal generators (push-buttons, door contact, light
barriers, a.s.o.) are not to be switched on, i.e. activated.
7. Activate the main switch of the transport system station.
8. Acknowledge the EMERGENCY-STOP of the control cabinet of the transport
system.
9. Remove all of the work-pieces from the installation, i.e. stations:
- Remove work-pieces from the palettes on the transport system
- Clear the storage shelves of the AS/RS station (HRL20)
- Clear the slides of the sorting/commissioning station
10. The magazines of all of the stations are to be stocked up:
- Magazines (piston, spring and cover) of the robot station with assembly
- Fill magazine of the distribution station with basic bodies
11. Now adjust the stations and the transport system (see chapter Operation).

5. Operation
This chapter describes the necessary control units for starting and stopping the
system, as well as operating with the system.
5.1. General operation The stations require some rules of operation which should be observed. If they are
notes not complied, faults in the processes are possible. Dangers for the physical health
also cannot be excluded.
It is recommended to observe the following rules strictly.
5.1.1. Behaviour rules
During the operation of the stations it is forbidden to grip in by hand.

With larger audience a mechanical protection of the stations is necessary.
Removing any cable under tension is forbidden.
Water has to be kept away from the plant.
5.1.2. Operation rules
The stations only may be used by introduced persons.

The operation has to be carried out according to the operating instructions.
A pushing the different switches/push buttons of all control units uncheckedly
has to be stopped.
No work piece carriers may be taken by the system.

Operation
5.2. Process description 5.2.1. Vision station
Process description for vision station.
Transport system is starting a store process

Occupied work piece carrier is stopping in front of the vision station
The camera makes a picture from the work piece, the measure datas are given to
the transport system
Work piece carrier is released
5.3. Reset mode There is now reset mode for the vision station
5.4. Automatic mode 5.4.1. Start automatic mode
If the station is connected to the transport system and the camera is adjusted, the
station is ready for automatic mode.
5.4.2. Stop automatic mode
If the emergency stop is pressed or the automatic mode at the conveyor system ist
stopped, the automatic mode at the station is also stopped.

6. Technology
This chapter refers to the technology of the vision station.
For better construction understanding of the station, the technical drawings should
be a very helpful data.
The rooms must be checked for their technical datas before built up the
station/system. The size of the door openings and the entrance must be big enough
for the measurements of the system. Even the load-capacity of the floor must be
high enough for the system.
6.1. drawings
Technical drawing vision station

Technology
Technical datas
Pos. Designation / Criterion Measurements / Feature
1 Width: 360 mm
2 Max. width 360 mm
3 Length 830 mm
4 Max. length 830 mm
5 height 1 635 mm
6 Max. height 1 635 mm
7 Weight approx. 50 kg

7. Electrical system
To operate the station it is required to connect all of the supply cables and
communication lines included. The cables used to program the system are explained
additionally.
To give you a better survey of the being lines used in the plant, these are explained
in the following.
7.1. Power supply The devices are delivered together with the respective power supply plugs,
protectively contact covered, in case they require power supply.
The customer must ensure that the power supply is earthed correctly and is
equipped with a fault current monitor.
If it is required for several devices to be in operation at the same time, it is possible

to connect these to a switchboard containing distribution board, provided that the
permissible maximum rating is not exceeded.

Electrical system
7.2. Wiring The wiring within the station and the wiring to the other stations are explained in the
following.
7.2.1. I/O-Components
The operation panel, the modules from station are pluggable connected via
I/O-terminals to the I/O-cards from the control.
So that a perfect communication can be ensured, the I/O interface is standardised.

The I/O terminal is at all work positions at the disposal.
I/O-Terminal
Technical data
Plug type IEEE 488 24 pins
Inputs 8
Outputs 8
Current consumption Max. 1A/PIN
Power supply 24 VDC

Electrical system
Allocation I/O- Terminal
Clamp Bit Function Color Clamp Bit Function Colour
01 0 Output White 13 0 Input Grey-pink
02 1 Output Brown 14 1 Input Red-blue
03 2 Output Green 15 2 Input White-green
04 3 Output Yellow 16 3 Input Brown-green
05 4 Output Grey 17 4 Input White-yellow
06 5 Output Pink 18 5 Input Yellow-brown
07 6 Output Blue 19 6 Input White-grey
08 7 Output Red 20 7 Input Grey-brown
09 Power
24V Power supply Black 21 24V White-pink
supply
10 22
11 Power
0V Power supply Pink-brown 23 0V White-blue
supply
12 0V Power supply purple 24

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MPS500

Type: Manual MPS500

Festo Didactic GmbH & Co.KG., D-73770 Denkendorf, 2010

2 Festo Didactic GmbH & Co.KG MPS500

The manual is divided into four parts:

Festo Didactic GmbH & Co.KG MPS500 3

DIN EN 292 -Machine safety

4 Festo Didactic GmbH & Co.KG MPS500

1. Intended use _______________________________________________________ 3

2.1. General _______________________________________________________ 9

2.2. Vision station _________________________________________________ 10

2.3. Didactic structure ______________________________________________ 11

2.4. Scope of tasks of the stations ____________________________________ 12

2.4.1. Mechanics ________________________________________________ 12

2.4.2. Pneumatics _______________________________________________ 12

2.4.3. Electrics __________________________________________________ 12

2.4.4. Informatics _______________________________________________ 12

2.4.5. Bus technology ____________________________________________ 12

3. General safety instructions __________________________________________ 13

3.1. Use according to regulations _____________________________________ 13

3.2. Handling the system____________________________________________ 13

3.2.1. Dangers in handling the machine _____________________________ 13

3.2.2. Safety precautions in standard operation ______________________ 13

3.2.3. Dangers due to electric current _______________________________ 14

3.2.4. Dangers due to pneumatic energy ____________________________ 14

3.2.5. Maintenance Servicing Malfunction removal _________________ 15

3.2.6. Organisational measures ____________________________________ 15

3.3. Personnel ____________________________________________________ 15

Festo Didactic GmbH & Co.KG MPS500 5

3.3.1. Notes on personnel ________________________________________ 15

3.3.2. Training operations ________________________________________ 15

3.3.3. Outside training operations _________________________________ 15

3.3.4. Safety symbols ____________________________________________ 16

4.1. Transport _____________________________________________________ 17

4.2. Set up _______________________________________________________ 18

4.2.1. General information ________________________________________ 18

4.3. Commissioning ________________________________________________ 21

4.3.1. Electric commissioning _____________________________________ 21

4.3.2. Establishing communication connections ______________________ 22

4.3.3. Preparing the pallets _______________________________________ 23

4.4. Camera ______________________________________________________ 24

4.4.1. Software Checkkon ________________________________________ 25

4.4.2. Software CheckOpti ________________________________________ 39

4.4.3. EMERGENCY-STOP system __________________________________ 45

4.5. Start-up process general ________________________________________ 46

5.1. General operation notes ________________________________________ 47

5.1.1. Behaviour rules ___________________________________________ 47

5.1.2. Operation rules ____________________________________________ 47

5.2. Process description ____________________________________________ 48

6 Festo Didactic GmbH & Co.KG MPS500

5.2.1. Vision station _____________________________________________ 48

5.3. Reset mode ___________________________________________________ 48

5.4. Automatic mode _______________________________________________ 48

5.4.1. Start automatic mode ______________________________________ 48

5.4.2. Stop automatic mode _______________________________________ 48

6.1. drawings _____________________________________________________ 49

7. Electrical system ___________________________________________________ 51

7.1. Power supply _________________________________________________ 51

7.2. Wiring _______________________________________________________ 52

7.2.1. I/O-Components ___________________________________________ 52

Festo Didactic GmbH & Co.KG MPS500 7

8 Festo Didactic GmbH & Co.KG MPS500

The MPS 500 system is a successively expandable system consisting of individual

In complete set-up, the work-piece is seperated from the distribution station to be