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Manual - Festo

1. 2 13 2 4 3 Controlling the small parts conveyor 2 ce eee eee ee eee 2 15 2 5 Diagnostic interface 0 eee ccc cence e 2 16 Festo P BE Checkbox EN en 0103c Ill Contents and general instructions 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 4 1 4 2 4 3 4 4 5 1 5 1 1 5 1 2 5 2 5 2 1 5 2 2 5 2 3 6 1 6 1 1 6 1 2 6 1 3 6 1 4 6 1 5 The I O module on the Checkbox eee 3 1 IO NUNES a iae si ew Da ice d 3 3 Internal power supply of the I O module ooooooooooocco oo 3 5 Connecting a higher order controller o oooooooomomo oo 3 8 Start stop mode kk cece n 3 10 Counter reading check Countbox Sortbox 0 00 cece eee 3 13 Displays at the transfer position 0 cece eee eee eee 3 14 Selecting the parts type sorting program 00 ccc eee ee eee eee 3 17 ErrOrmessSage resa cesiones hai beaks tank beet IIR daa DA hls 3 21 Commissioning soies eaea nena iaa dis eee 4 1 Control panel of the Checkbox 2 cece cee ccc ene seh 4 3 Switching on and off 0 eee eee ee ene eee eee 4 4 Operating modes of the Checkbox sce e eee eee eee eee 4 6 Error diagnosis iii cnn rm Se ee de Oe Se nd 4 7 Teaching parts with the Checkbox oooooooooomomoo o 5 1 Preparing the teach procedure 2 cee eee eee ee eee eee 5 3 Features and characteristics of the conveyed parts
2. 0 2 eee eee eee eee 6 6 Test Mode aia aes tw ke ete be eee xU 6 10 Tolerance xl eR ELE dt a he 6 6 A 16 Tolerance factor cece cee eee cece 6 14 TOOL oa A 11 X jT 2 5 2 16 M2 a b ue be og ER DEA PCR IS I SR 2 5 2 15 BL A ed de deg Ma 2 5 2 9 Xd edo tries t edes timen 2 5 2 6 2 9 3 3 Moneta hd a eee ep needles Aas 2 5 2 6 C 7 C Index C 8 Festo P BE Checkbox EN en 0103c
3. E 01 although pressure in the compressed air network is apparently constant FULL on LCD TOLERANCE although the buffer zone is not full Good parts in all orientations are blown back into the small parts conveyor E 02 although length of con veyed part is shorter than max permitted length E 02 occurs in the morning although the Checkbox worked perfectly the day before E 04 although only a small number of bad parts passes the test procedure Festo P BE Checkbox EN en 0103c Cause Brief fluctuations in pressure in the compressed air network e g by large volume consuming devices Blanking plug missing at connection Sensors Bridges missing at connec tion Controller Control cable defective or incorrect pin assignment at connection Sensors Conveyed part has lots of holes or is semi transparent Speed of conveyor belt has been modified High fluctuations in tempera ture for example between day and night Conveyor belt has been replaced Moving particles of dirt on the conveyor belt Remedy If necessary insert a pressure reservoir between the Check box and the compressed air network Operation without buffer zone sensors Insert blanking plug and check bridges Operation with buffer zone sensors Check control cable and pin assignment With CheckKon Increase belt speed Increase exposure time Vary grey value threshold Limit c
4. 5 3 Set operating mode TEACH cee eee eee eee eee nes 5 5 The teach procedure 0 cece cece teen eee 5 6 Addressing teach data is san ceio ccc cece or 5 6 Scanning sample parts 0 cee eee eee ee 5 7 Saving teach data os id ERE IR t E 5 11 Testing parts with the Checkbox eeeeeee eee 6 1 Preparing the test procedure cee eee eee eee ee een 6 3 Set operating mode SELECT 0 cece eee eee eee ee 6 3 Load the teach data 12 55 eg tee tardes tg e RAPIAT IM 6 4 Set the tolerance 22 Rete eras IRI Lae te BEd 6 6 Enable the orientations Countbox Sortbox ooooooooooooo 6 7 Set counter function Countbox Sortbox 00 c cece eee eee 6 7 Festo P BE Checkbox EN en 0103c Contents and general instructions 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 2 5 6 3 6 3 1 6 3 2 6 3 3 6 3 4 7 1 7 2 A 1 A 1 1 A 1 2 A 2 A 3 A 3 1 A 3 2 A 3 3 A 4 A 5 A 6 Test Tode erue onere esteem rod ettet ER e gre iod dee sh gee EE 6 10 Proceed as follows ccc ccc ccc cent n 6 10 Visualcheck 22e ria 12444 thee aa aA IER aes DEL bleed bee 6 12 Checking the features url ai rA PEG 6 12 Checking the orientation 0 cece ccc cee I 6 13 Influence of tolerance on the test result o ooooooooooomooo 6 14 Automatic Mode td 6 15 Set operating mode SELECT 2 cece eee eens 6 15 Manual start stop mode cece cece cent
5. Small parts conveyor on the Checkbox If an external switching contact can be connected to the small parts conveyor connect it according to the following pin as signment Connector plug Small parts conveyor on the Checkbox Normally open contact 1 Normally open contact 2 Not assigned Contact loading 48 V 100 mA On the connection Controller there is also an output 0 37 intended for controlling the small parts conveyor However this is not designed as a floating normally open contact but as a 24 V power output Festo P BE Checkbox EN en 0103c 2 15 2 Fitting and Installation 2 5 Diagnostic interface In order to connect the Checkbox to the PC use the serial diagnostic cable with 4 pin round plug connection Checkbox and 9 pin Sub D plug connection PC Diagnostic interface X1 Fig 2 6 Diagnostic connection of the controller The diagnostic cable is included in delivery with the Checkbox or with the CheckKon software If required the diagnostic cable is also available as an accessory see Appendix A 6 e Connect the diagnostic cable to the following connections the diagnostic interface X1 on the Checkbox aserial interface COM1 or COM2 of the PC e Remove the diagnostic cable as soon as you have finished working with CheckKon CheckOpti In this way you will
6. With sensors connected at the appropriate sensor inputs with unused sensor inputs connected to 24 V DC Screw the plug into the connection Controller Use the plug Sensors at the connection Sensors without the bridges fitted at the factory between the sensor inputs and 24 V DC Screw the plug into the connection Sensors B 5 B Brief instructions Teach procedure Step LCD TOL Checkbox Set operating Switch on operating mode TEACH mode TEACH with the key switch The TOLE RANCE display shows memory group 1 Addressing teach Set the desired memory group data with the keys and on the TOLERANCE display Determine the number of the parts type with one of the TYPE SELECT keys 1 6 D Scanning sample Show at least six sample parts in parts ui the current orientation 1 Scan sample parts in orienta tion 1 Observe characteristic scatter It is optimum when the value changes at first very much then remains almost constant Set the next orientation with the key TOLERANCE 4 Scan sample parts in the new orientation Saving teach data Switch to the operating mode SELECT with the key switch 1 The sorting program is defined for the Sortbox when a memory group is assigned B 6 Festo P BE Checkbox EN en 0103c B Brief instructions Test procedure Step LCD TOL Set operating mode SELECT Set the operating parameters Test mode Festo P BE Checkb
7. 1 Voy gt 15 V Logical 0 Von lt 7 V PNP switching gt Please note If you use high resistance measuring devices for measur ing the voltage at the outputs a minimum loading of 1 mA will be required In this way you can be sure that correct voltage values will be displayed 3 4 Festo P BE Checkbox EN en 0103c 3 The 1 0 module on the Checkbox 3 2 Internal power supply of the I O module The I O module of the Checkbox is connected via pin 1 15 24 V DC and pin 1 34 GND to the built in power unit or external power source Use the Sub D plug Controller pro vided for connecting the power supply gt Important note In the case of internal supply of the I O module devices connected to the Checkbox have direct electrical coupling with the power supply for the Checkbox processor The circuit type Internal supply is therefore only per mitted for connecting buffer zone sensors The circuit type External supply is stipulated for other applications Internal supply The plug Controller is wired at the factory for internal power supply for operation with buffer zone sensors The I O mod ule is operated thus via the power unit for the Checkbox Connector socket Controller on the Checkbox Internal power supply 0 16 Internal GND 0 35 Internal 24 V DC 1 15 External GND 1 34 External 4 24 V DC GND 7 2 1 e e 0 2 OOD 24 VDC oo o O 00 Festo P BE Check
8. Addressing You select a memory location for the conveyed part type Scanning You show the camera several samples of this conveyed part type in the nominal orientation one after the other If necessary you then scan the sample parts in further orientations Saving At the end of the teaching process you save the features of the parts type as the teach data under the memory address set Each conveyed part registered is compared with the saved teach data and separated according to the different types The test parts are separated basically via three paths Good parts are carried e g to an assembly plant Incorrectly orientated parts are returned to the small parts conveyor Faulty or foreign parts are rejected The conveyor unit is fitted with at least two compressed air nozzles which blow conveyed parts down from the belt at certain positions The remaining conveyed parts leave the belt at the end Festo P BE Checkbox EN en 0103c 1 System summary Standard delivery positions of the Checkbox Identbox Countbox Blow down position for incorrectly orientated parts superfluous parts or if parts are jammed Blow down position for bad parts faulty parts foreign parts Delivery position for good parts e g in the buffer zone of an assembly machine The Sortbox is fitted with 2 4 or 6 compressed air nozzles depending on type for rejecting blowing down parts Blow down position for incorrectly orientated
9. sees 1 5 1 4 Components of the Checkbox cc cece eee eect eee eens 1 6 1 5 Method of operation of the Checkbox cesses eee eee eee 1 7 1 6 B ffetZone esoo rita A 1 10 1 2 Festo P BE Checkbox EN en 0103c 1 System summary 11 The Checkbox family The devices in the Checkbox family permit the optical con tactless positioning and quality check of conveyed parts Variants of the Checkbox are available for this purpose de pending on requirements Device Manual Identbox Basic device with separate rejection of incorrectly orien tated parts and bad parts Countbox Functions as with Identbox plus Counting of good parts with preselectable nominal amount Sortbox Functions as with Countbox plus simultaneous sorting and commissioning of sev eral different conveyed parts Festo P BE Checkbox EN en 0103c 1 3 1 System summary 1 2 Software packages for the Checkbox Various software packages are available for user friendly commissioning optimizing and monitoring of the products of the Checkbox family Software package Functions Checkbox configurator CheckKon Displaying and evaluating registered test parts Display and protocoling the parts contour as well as the features derived from the contour Display of the light intensity registered by the camera Display and printout of the system configur ation Displaying and modifying the system para meters Loading a new operating system
10. 1 With the TOLERANCE button you can increase the value displayed by 1 2 With the TOLERANCE button you can reduce the value displayed by 1 3 Use one of the following methods Empirical setting Vary the tolerance so that a large number of parts are tested and corrrectly recognized as good or bad parts Setting according to test part deviation Select sample parts which are suitable as reference for good or bad parts The recogition specific features should lie where possible in the border range good bad Vary the tolerance so that the following test part deviation is shown when the borderline sample parts are scanned 100 for the borderline sample part good or 100 for the borderline sample part bad 6 14 Festo P BE Checkbox EN en 0103c 6 Testing parts with the Checkbox 6 3 Automatic mode 6 3 1 Set operating mode SELECT un Festo P BE Checkbox EN en 0103c Prepare the Checkbox as follows 1 Prepare test procedure see chapter 6 1 2 Turn key switch to AUTO 7 RM y auto 3 Ifthe STOP button is pressed down press the START button The Checkbox then triggers a blow free process This is to ensure that there are no parts on the conveyor belt The Checkbox then switches on the small parts conveyor The LCD TOLERANCE shows in faultless operation the current memory group and the tolerance setting for the current parts type in per cent The LCD COUNTER shows in faultless oper
11. Compressed air tubing with coupling plug and screw connector Hybrid connecting cable for control unit conveyor unit with two Harting connectors 5 pin connector for the conveyor unit Festo P BE Checkbox EN en 0103c Contents and general instructions Festo P BE Checkbox EN en 0103c 2configurable blanking plugs 4 pin round plug for connecting sensors Wired at the factory Operation without buffer zone sensors i e sensor inputs 1 2 wired with reference voltage 37 pin sub D plug for connecting the controller Wired at the factory Internal power supply of the I O module Operation without buffer zone sensors i e sensor inputs 3 6 wired with reference voltage Sortbox Asummary of additional accessories available can be found in chapter A 6 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 ona shaded background andmarked 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 or damage to property Caution This means that failure to observe this instruction may result in personal injury or damage to property Please note gt This means
12. V iy UN Sorting program 1 10 1 28 1 9 1 27 No preselection LOW ben iow ow om how wor ow iow bos o tow ow how ron men ow bos or wen ow how wor men um men men men Low iow ow tom wn ow mo wen ow 12 gt ben ow wen 7 tow wer wen IEEE bor cn n Festo P BE Checkbox EN en 0103c 3 19 3 The O module on the Checkbox 3 20 Identbox Countbox Pulse time diagram Parts type change 1 10 Pin 1 10 Pin1 28 Pin 1 9 Pin 1 27 Pin1 8 Pin 1 33 Remote start Sortbox Pulse time diagram Sorting program change 2 gt 1 Pin 1 10 Pin 1 28 Pin 1 9 Pin 1 27 Pin 1 33 Remote start min 1s Festo P BE Checkbox EN en 0103c 3 The 1 0 module on the Checkbox 3 8 Error message Error Festo P BE Checkbox EN en 0103c The Checkbox signals faults at the connection Controller as Warning at pin 0 22 Fault at pin 0 3 The output signals are evaluated e g with a machine light with the following displays Green faultless operation Yellow Warning Red Fault Signal level Error message 0 22 0 3 There is a fault There is a warning The classification of the warning or of the fault is made via pin 0 21 as shown in the two following tables Errors indicate a functional fault in the Checkbox The Check box stops and the operator must intervene Code E Signal level Error 0 22 0 3 0 21 Ambi
13. for contact free checking of the position and quality of the parts Use the Checkbox only as follows jnaccordance with designated use infaultless technical condition without any modifications by the user No guarantee claims can be accepted if the device is opened The specified limits for pressure temperature electrical con nections etc must be observed Please observe the standards specified in the relevant chapters and comply with technical regulations as well as with national and local regulations Operating requirements Festo P BE Checkbox EN en 0103c The features of the conveyed part which determine the orientation or quality must be recognizable and distin guishable for the Checkbox It must be possible to integrate the conveyor unit in the material flow VII Contents and general instructions Target group Service Scope of delivery Checkbox Documentation Software Accessories VIII This manual is intended exclusively for technicians trained in control and automation technology who have experience in installing and commissioning electrical systems Please consult your local Festo service centre if you have any technical problems Conveyor unit with conveyor belt or tunnel variant and inte grated line camera control unit with operating panel and 1 0 interfaces Description of the Checkbox CheckKon function observe system including diagnostic cable
14. parts superfluous parts or if parts are jammed Blow down position for different types of good parts Blow down position for bad parts faulty parts foreign parts The standard configuration set at the factory determines the positions at which the tested parts leave the conveyor belt The number and arrangement of the delivery positions can vary depending on the Checkbox version The assignment of the positions can be modified with the CheckKon software function Modify system Festo P BE Checkbox EN en 0103c 1 9 1 System summary 1 6 Buffer zone Buffer zone sensors Signal delay 1 10 The buffer zone serves as a parts buffer for the following ma chine e g assembly plant and must be of such a size as to permit operation of the machine with as litttle interruption as possible The Checkbox can monitor the status of fitted buffer zones by means of sensors and switches off the small parts conveyor e g if it is overloaded Please note When selecting the sensors make sure that the sensor output has a potential of 24 V DC normally closed func tion in the off position This ensures reliable operation of the supply system and prevents the system from becoming jammed e g in the event of a cable fracture 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 con veyed part pass
15. Display for showing and setting the test parameters Push buttons Illuminated buttons for mo nitoring and controlling the operating status STATUS yellow START green STOP red Fig 4 1 Control panel of the Checkbox Festo P BE Checkbox EN en 0103c Learning new parts Test adapt parameters Automatic mode Display of current counter status or nominal number Acceptance of the good parts OFF in nominal orientation ON in all orientations Select counter function preselect nominal number reset counter Display of configuration Error messages Test results Setting the memory group Orientation tolerance Status display error quitting Switching on Switching off 4 Commissioning 4 2 Switching on and off Before switching on the Checkbox you must carry out the following steps as described in chapters 2 and 3 1 Fitting the modules 2 Connecting the compressed air supply 3 Connecting the power supply 4 Configuration of the connectings Sensors and Con troller Insert blanking plugs or connect the control cables for buffer zone sensors Mains switch LCD TOLERANCE START button STOP button Fig 4 2 Operating panel 4 4 Festo P BE Checkbox EN en 0103c 4 Commissioning Switching on Switch on the Checkbox as follows 1 Actuate the mains switch on the connection side of the controller 2 When you have switched on all the displays and
16. Festo P BE Checkbox EN en 0103c A Technical appendix Code Cause Remedy Recognition errors The nominal orientation cannot Repeat the teach procedure Make sure that the be distinguished from other sample parts are positioned in accordance with the orientations because e g selected orientation parts orientations were Optimize the teach data with the CheckOpti software swapped during the teach process by mistake Countbox Sortbox or If it is not necessary to distinguish the nominal orienta the nominal orientation is tion too similar to other orienta 1 Turn the key switch to TEACH tions 2 Switch on the illuminated button on the LCD COUNTER 3 Repeat the teach procedure Recognition error Sortbox The taught sample part cannot Repeatthe complete teach procedure be distinguished clearly from Optimize the sorting procedure with the CheckOpti other sample parts because software e g the sample part is identical to the parts type of another TYPE SELECT memory loca tion a different orientation of the sample part has been saved on another TYPE SELECT memory location Festo P BE Checkbox EN en 0103c A 7 A Technical appendix A 8 Data error Teach data are not clear When the device is switched on again the saved teach data are no longer OK Controller has lost system parameters Controller has lost configur ation part of the teach data Teach data are not compatible Te
17. Meaning Scatter of features The value range of a feature ascertained from several parts System parameter Checkbox settings in some cases settings can only be made with configuration software Teach data All features ascertained during teaching in each case with min max limits and average value Teach procedure During the teach process sample parts on the conveyor belt are shown to the Checkbox This is also referred to as Teaching parts Test data The test data are the data used for the test These correspond to the teach data plus the specified tolerances Test parts Parts shown during the test process Test procedure During the test procedure test parts on the conveyor belt are shown to the Checkbox and classified according to their features with regard to orientation and observance of tolerances This is also referred to as Testing parts Tolerance Factor in percent related to the average values which has an effect on the min max limits of all the features Festo P BE Checkbox EN en 0103c XV Contents and general instructions XVI Festo P BE Checkbox EN en 0103c System summary Chapter 1 Festo P BE Checkbox EN en 0103c 1 1 1 System summary Contents 1 System summary 5 666 030 056k oe eo eee eee eek id 1 1 1 1 The Checkbox family 0 0 ccc cece ccc ce eee Ih 1 3 1 2 Software packages for the Checkbox cee eee eee eee eee ee 1 4 1 3 Scope of functions of the Checkbox
18. With CheckKon CheckOpti Switch from diagnostic mode to operating mode Festo P BE Checkbox EN en 0103c A Technical appendix A 1 2 Error messages Error messages are shown on the LCD TOLERANCE They must be quitted before the Checkbox can start again 1 First eliminate the cause of the fault 2 Then actuate the flashing button STATUS Code Cause Ambient error Fault in the compressed air supply No compressed air Pressure too low Fluctuations in pressure in supply network Camera fault System recognizes too many incorrect conveyed parts gt 75 of the last 20 parts were graded as bad parts Optical faults Lighting dirty or defective glass cover of camera or camera optics dirty Camera optics misted due to considerable difference in temperature of Checkbox environment Blockage in front of the optical unit Camera registers lower range of conveyor belt Max parts length exceeded Festo P BE Checkbox EN en 0103c Remedy Check compressed air supply If necessary insert a pressure reservoir between the Checkbox and the compressed air network Remove dirt with a soft cloth and non abrasive cleaning agent or blow down from the glass cover with non lubri cated compressed air Avoid large differences in temperature With CheckKon Corrrect the setting of the picture limits Increase exposure time or ratio encoder frequency line frequency Check camera connection Discon
19. avoid malfunctioning of the Checkbox If in exceptional cases the connection between the PC and the Checkbox is necessary for continuous operation e Use an electrical isolation optocoupler between the PC and the Checkbox If you have any technical problems please consult your Festo Service Further information on commissioning optimizing and moni toring the Checkbox via the PC interface can be found in the documentation for the software packages CheckOpti and CheckKon 2 16 Festo P BE Checkbox EN en 0103c The I O module on the Checkbox Chapter 3 Festo P BE Checkbox EN en 0103c 3 1 3 The O module on the Checkbox Contents 3 The I O module on the Checkbox eene 3 1 3 1 I O f licti ns 000 toa asa daa REP At a 3 3 3 2 Internal power supply of the I O module 0 0 cece eee mo 3 5 3 3 Connecting a higher order controller ooooocoocoocoocooo oo 3 8 3 4 Start stop mode c ia cin saa A es DO 3 10 3 5 Counter reading check Countbox Sortbox 0 00 cece eee eee 3 13 3 6 Displays at the transfer position 0 cece cece eee eee 3 14 3 7 Selecting the parts type sorting program 0 eee eee ee eee 3 17 3 8 Etrtrorifflessdge uec te Ren s RR ee IE ra ren m Ra RE epi 3 21 3 2 Festo P BE Checkbox EN en 0103c 3 The 1 0 module on the Checkbox 3 1 1 0 functions Controller X4 Fig 3 1 Connector socket Controller on the Checkbox The co
20. du Me PER d VIII Scope of delivery cecs ie cae ee a a EEEE E eee e ee nee ee a E VII Important user instructions 00 eee cece RR X Notes on this manual 0 cee cece ene e nent nneee XIII Documentation on the Checkbox family 00 ccc ccc cece eee teens XIV Product specific terms and abbreviations 0 cece eee eee eens XIV 1 System Summary 6 5 65 eos ces rh esr es rre vh ER bee Oe v wee 1 1 1 1 The Ghieckbox family 5 m tx XR AREE DIRECT S 1 3 1 2 Software packages for the Checkbox eee eee cece eee 1 4 1 3 Scope of functions of the Checkbox sees 1 5 1 4 Components of the Checkbox 0 cc cece eee III 1 6 1 5 Method of operation of the Checkbox cece eee eee eee eee 1 7 1 6 B ffet Zorng c ere oe halk ee EA A PA NY es 1 10 2 Fitting and Installation cece cece cence eee cece eee 2 1 2 1 Fitting the modules 0 2 cee cece ees 2 3 2 2 Power supply connections of the controller o oooooooo ooooo 2 6 2 2 1 Electrical connection 00 cece cece cee eee eens 2 6 2 2 2 Pneumatic connection 0 cece eh 2 7 2 3 Operation without buffer zone sensors eee eee eee eee eee 2 9 2 4 Operation with buffer zone sensors cece eee eee ee eee eee 2 11 2 4 1 Buffer zone sensors at the connection Sensors 00000ee 2 11 2 4 2 Buffer zone sensors at the connection Controller
21. eae ed aales bees 1 3 Weight tots seine tates rudes ub has eo aA A 25 CheckKon 2 ee bbe Sei ee IET RUE ete 1 4 CHECKOP El ci eI Ge ea IT Ar s 1 4 GheckStat a A CAS 1 4 C 3 C Index Cleaning CheckbOox xs s om Ree aee ok 7 3 Protective screens o oooooomomommomoooo 7 4 7 6 Connection Controller sersa dee sa iia such wea aa da 2 5 3 8 Conveyor unit siib aia corel eae betas 2 8 Electrical issiro arandia taa RHREEEEEISIX REA 2 6 Fitting pneumatic components 4 2 7 PC oL TS redeem red mr Ee Em deos 2 16 Small parts conveyor 0e eee 2 15 3 3 Control panel boots ias Bee GE yi 4 3 Controller 2 0 0 cc cee ees 1 6 3 3 3 8 Conveyor part Characteristics 2 0 rania cece ence eee 5 3 DIMENSIONS 2 03 0252 cansa ie cand eens A 26 Conveyor rate cece cee ee cee teen eee A 25 Conveyor unit nec ce ee eed a wees 1 6 Counter display wi stacy os ghar eed ee ee eS 6 7 Counter function 0 ccc cece eee ee 6 7 6 16 D Designated use sees VII Diagnostic interface o ooooooooooomoommo 2 16 E EMG safety mop eq Xem eed 3 6 Encoder A 10 Errore oir iaa Bete es as 3 21 4 7 5 11 Error messages ooocooooccococr teen eens A 5 Error fault Eliminating faults llle A 3 Festo P BE Checkbox EN en 0103c C Index Festo P BE Checkbox EN en 0103c F Feature deviation 0 cee eee eee eee eee A 19 FULE ii a A A Sana Go
22. mode You can set the SELECT mode in order to e save the teach data e check the test procedure e set the test parameters When you switch from TEACH mode to SELECT mode all the current teach data will be saved automatically The following parameters will be set in the SELECT mode SELECT mode Identbox CB Countbox SB Sortbox Selecting the parts type sorting program SS Optimizing the tolerance Optimizing the tolerance x xo IB CB SB Accept good part only in nominal orientation or in all orientations Selecting and setting the counter function lx x AUTO mode In the AUTO mode the test procedure runs automatically and can only be influenced manually by means of the START STOP buttons 4 6 Festo P BE Checkbox EN en 0103c 4 Commissioning 4 4 Error diagnosis A diagnostic system is incorporated in the controller of the Checkbox If an operating fault is recognized the LCD display TOLERANCE will show an error code and the illuminated but tons TYPE SELECT STATUS STOP will flash As standard all defined error messages are declared as an error in reaction to which the Checkbox stops The Checkbox can be set as the customer desires depending therefore on the design of the Checkbox or software configur ation the error E 05 can be redefined as a warning the error messages E 01 E 02 E 04 E 05 E 06 can be deactivated The following error groups are defined Code Group Explanation E0
23. simultaneously until the display is deleted min 3 s If in AUTO mode the current counter status is to be shown set the counter type Actual 6 9 6 Testing parts with the Checkbox 6 2 Test mode 6 2 1 Proceed as follows With the teach data a reliable grading must be achieved of the parts to be checked according to orientation and qualaity e g whether data of the parts have been observed There fore always evaluate the teach data in the test mode with regard to their reliability 5 Prepare the Checkbox as described in chapter 6 1 The con veyor belt runs and the LCD TOLERANCE shows the current memory group and the tolerance in per cent Test procedure Please note the following procedure 6 10 Use test parts which correspond approximately in their composition to the parts to be tested later in AUTO mode i e good bad and incorrecctly orientated parts The test parts should be by chance positioned like the parts to be checked later in AUTO mode Avoid at first particular care in placing the parts As far as is possible use the conveyor device intended for this purpose You must check a sufficient number of parts in order to obtain a reproducible result Show e g 6 parts recognized as good and 6 bad parts per orientation Press the STOP button in order to interrupt or terminate the test mode Festo P BE Checkbox EN en 0103c 6 Testing parts with the Checkbox Status display Evaluation Fe
24. slo E 2 X 5 x 612 B 65 60 007 T B 11 12 B Cra 65 00 o 61 20 in 60 00 Cmintol 56 94 ertet mme rbi M tenerent Bandwidth of conveyed part length Bandwidth with 5 tolerance Result All conveyed parts with a length of 57 68 mm are classified as good parts The Checkbox ascertains appropri ate value ranges for each feature A 17 A Technical appendix A 3 2 Scatter of characteristics Gan E m x 100 9 Average value of the feature Cmax Feature maximum Cmin Feature minimum Characteristic scatter Example Ascertaining the characteristic scatter for the feature Length of a conveyed part The following values are taken from the example Bandwidth A 61 2 Average value of the length Cmax 65 Length maximum Cmin 60 Length minimum E5 60 S eT 100 S 8 2 A 18 Festo P BE Checkbox EN en 0103c A Technical appendix A 3 3 Feature deviation Ascertaining deviation D for C lt A D Cactual TA x 100 95 rn tol A 0 Average value of the feature Cactual Current feature measurement Cmin tol Lower limit of bandwidth incl tolerance Feature deviation Example Ascertaining the deviation for the current feature Length of a conveyed part Cactual 61 C A The following values are taken from the example Bandwidth A 61 2 Average value of the length Cmintol 756 94 Length lower value Cactual 61 Length current value EZ x 100 D
25. start signal from the controller If there is a constant HIGH signal at pin 1 33 the Check box can still be switched off with the STOP button After a manual stop With a change of signal LOW gt HIGH start signal at 1 33 the Checkbox can be switched on again after a manual stop Festo P BE Checkbox EN en 0103c 3 The 1 0 module on the Checkbox The modification to the operating status with a manual start or stop is passed on to the controller via 0 14 and 0 2 The output signals differ according to operating mode and status as represented in the pulse time diagrams Operating Pulse time diagram mode Operating status after a manual stop Pin 1 33 Remote start Pin 0 14 Checkbox mode 1 Pin 0 2 Checkbox mode 0 Pin 1 33 Remote start Pin 0 14 Checkbox mode 1 Pin 0 2 Checkbox mode 0 SELECT Pin 1 33 Remote start Pin 0 14 Checkbox mode 1 Pin 0 2 Checkbox mode 0 Festo P BE Checkbox EN en 0103c 3 11 3 The O module on the Checkbox 3 12 Operating Pulse time diagram mode Operating status Switching on again after a manual stop SELECT Pin 1 33 Remote start Pin 0 14 Checkbox mode 1 Pin 0 2 Checkbox mode O Manual stop Operating Pulse time diagram mode Operating status External stop signal from the controller after a manual start SELECT Pin 1 33 Remote start Pin 0 14 Checkbox mode 1 Pin 0 2 Checkbox mode O t on min 3 s Manual sta
26. 1 12 Ambient error Fault in the compressed air sup ply the power supply the parts supply dirty lens etc E20 21 Recognition errors Orierntations or sample parts cannot be distinguished E 40 43 Loss of data Teach data configuration data or system parameters are not compa tible or do not exist gt E 60 hardware error Internal error can only be rectified by after sales service Festo P BE Checkbox EN en 0103c 4 7 4 Commissioning A detailed list of the codes and instructions on eliminating faults can be found in Appendix A 1 After eliminating faults e Quit the error message with the STATUS button e Press the STOP button then the START button Festo P BE Checkbox EN en 0103c Teaching parts with the Checkbox Chapter 5 Festo P BE Checkbox EN en 0103c 5 1 5 Teaching parts with the Checkbox Contents 5 Things learn with the Checkbox een 5 1 5 1 Preparing the teach procedure cee eee eee eee ee eee eee 5 3 5 1 1 Features and characteristics of the conveyed parts 0 5 3 5 1 2 Set operating mode TEACH eee eee cee eens 5 5 5 2 The teach procedure seseeeeeeeeeeee ee 5 6 5 2 1 Addressing teach data 20 eee eee eens 5 6 5 2 2 Scanning sample parts cece eee eee nen 5 7 5 2 3 Saving teach data 2s uiu etg Rep RA eed ede oe he d 5 11 5 2 Festo P BE Checkbox EN en 0103c 5 Teaching parts with the Checkb
27. 4 7 Festo P BE Checkbox EN en 0103c A 19 A Technical appendix Ascertaining deviation D for C A D Cactuar TA x 100 Cies tol A 9 Average value of the feature Cactual Current feature measurement Cmax tol Upper limit of bandwidth incl tolerance Feature deviation Example Ascertaining the deviation for the current feature Length of a conveyed part Cactuat 64 C lt A The following values are taken from the example Bandwidth A 61 2 Average value of the length Cmaxto 68 06 Length upper value Cactual 64 Length current value D LLL x 100 D 41 8 A 20 Festo P BE Checkbox EN en 0103c A Technical appendix A 4 Pin assignment Connector socket Controller on the Checkbox 0 12 Actuator2 o 2 Actuator2 O 2 Atuator2 000000 2 0 13 Nominal number reached Nominal numbers of all parts types reached 0 14 0 14 Identboxmode1 mode identbox mode1 Countboxmode1 mode Countboxmode1 Sortbox mode mode Sortbox mode 0 21 Error status 2 Error status 2 Error status 2 0 22 Error status O Error status O Error status O Festo P BE Checkbox EN en 0103c A 21 A Technical appendix Pin Identbox Countbox Sortbox 1 27 Ext Sorting program preselect bit 3 1 28 Ext Sorting program preselect bit 1 1 32 Start new counting cycle 0 35 Internal voltage 24 V 1 36 Ext Pressure sensor 1 19 18 2 1 O0r o e reo OQ O000r Oe C ef Oe ne O
28. CD TOLERANCE switches to FULL and flashes at 1 second intervals After a preset time e g 30 s the small parts conveyor will be switched off The conveyor belt continues to run The small parts conveyor is switched on Festo P BE Checkbox EN en 0103c Fitting and Installation Chapter 2 Festo P BE Checkbox EN en 0103c 2 1 2 Fitting and Installation Contents 2 Fitting and Installation ccc cece cece cece eee cece eee 2 1 2 1 Fitting the modules 2 2 ee rosas asa bes eae I AAA aad IE MAG 2 3 2 2 Power supply connections of the controller o ooooooooooooo 2 6 2 2 1 Electrical connection 0 2 cece cece eee eee eee 2 6 2 2 2 Pneumatic connection 0 cee cece cee eee eens 2 7 2 3 Operation without buffer zone sensors eee eee eee eee eee 2 9 2 4 Operation with buffer zone sensors esses 2 11 2 4 1 Buffer zone sensors at the connection Sensors 000e eee 2 11 2 4 2 Buffer zone sensors at the connection Controller 2 13 2 4 3 Controlling the small parts conveyor 2 0 ce eee eee eee eee 2 15 2 5 Diagnostic interface 0 eect e 2 16 2 2 Festo P BE Checkbox EN en 0103c 2 Fitting and Installation 2 1 Fitting the modules Transport Always transport the Checkbox in the original packing further transport safety measures are not required Mounting location Please note gt Handle all the modu
29. E Checkbox EN en 0103c 3 The 1 0 module on the Checkbox 3 7 Selecting the parts type sorting program Festo P BE Checkbox EN en 0103c A higher order controller can automatically change the parts type of the Identbox Countbox or the sorting program of the Sortbox Pinl 33 LOW The Checkbox switches to the stop status The signals at the inputs are then set according to the binary coding of the desired parts type or sorting pro gram see following tables The signals must be present permanently Pinl 33 HIGH The Checkbox switches to the start status The selection possibility is limited to maximum 30 parts types or 14 sorting programs The selection depends on the operating system of the Check box For this reason not all binary codings specified lead to the selection of a valid parts type sorting program 3 17 3 The O module on the Checkbox ae gt Identbox Countbox I Binary coding of the parts type uu p jit inus Parts type 1 10 1 28 1 9 1 27 1 8 No preselection LOW ben iow fiow on iow ow man tow iow o ps man or iow om how tor mon or o bos or men or om how men man uo io be an won or o how iow tow man o bos or o man o ow man on man Jos bo an cn man Jos how iow men men io bos or men man Jos No preselection 3 18 Festo P BE Checkbox EN en 0103c 3 The 1 0 module on the Checkbox LES Sortbox Binary coding of the sorting program
30. O 37 36 21 20 1 As standard the built in pressure sensor of the Checkbox is monitored If an external pressure sensor is to be connected via 1 36 the Checkbox configuration must be adapted accordingly Please consult the Festo after sales service A 22 Festo P BE Checkbox EN en 0103c A Technical appendix Connector socket Sensors on the Checkbox Oo 24V DC Reference voltage for sensors 0 Buffer zone sensor 2 1 12 13 oV Reference voltage for sensors 4 Buffer zone sensor 1 The sensor inputs are negative switching normally closed If 24 V DC is applied the small parts conveyor will be switched on As an option direct connection with a Festo DUO cable is also pos sible Cable designation signal x 1 1 signal x 1 1 2 Connector plug Small parts conveyor on the Checkbox Normally open contact 1 Normally open contact 2 Not assigned Contact loading 48 V 100 mA Festo P BE Checkbox EN en 0103c A 23 A Technical appendix A 5 Technical specifications General operating specifications Checkbox operating specifications Temperature 10 509 C for operation storage transport non condensing Electromagnetic compatibility EN 61000 2 3 EMC Protection against electric shock Protective earthing hazard Degree of protection Compressed air quality Non lubric
31. TOLERANCE and at the same time The LCD TOLERANCE shows the current memory group 2 Select the desired memory group e Increase value by 1 Press TOLERANCE briefly e Reduce value by 1 Press TOLERANCE briefly The illuminous button TYPE SELECT is switched off The con veyor belt remains at a stand SBS Sortbox E A When the memory group is selected the relevant sorting i l A program is activated Q Hm A 1 Quit the selection of the sorting program by pressing any illuminous TYPE SELECT button The conveyor belt starts again The LCD TOLERANCE shows the selected memory group and the tolerance in per cent 2 Setfurther parameters or start with the test mode chapter 6 2 6 4 Festo P BE Checkbox EN en 0103c 6 Testing parts with the Checkbox Festo P BE Checkbox EN en 0103c Identbox Countbox The current parts type selection is deleted when the memory group is changed 1 Select the new parts type with the illuminous button TYPE SELECT The conveyor belt starts again The LCD TOLERANCE shows the selected memory group and the tolerance in per cent 2 Set further parameters or start with the test mode chapter 6 2 6 5 6 Testing parts with the Checkbox 6 1 3 Set the tolerance 6 6 The tolerance increases the band width of the taught fea tures Test parts the features of which lie within the band width of the sample part or in the tolerance range bordering onto this will st
32. The Checkbox family FESTO Manual Checkbox Identbox Countbox Sortbox Manual 526 373 649 320 en 0103c Contents and general instructions AUTOR house aee ape ade a G Neumann Rasaei Editors cid ce is H J Drung M Holder Original 2mm oa oe ek German text Translation oooooo o transline Deutschland LayoUt aia Festo AG amp Co Dept KG GD Layout 000 Festo AG amp Co Dept KI DT Edition io rere bee Dep C ERAS en 0103c Titl amp 1 ce ce ee o e m ee metet MANUAL EN Designation 0 cece cece eee P BE Checkbox EN Order noz cae 526 373 Festo AG amp Co D 73726 Esslingen Federal Republic of Germany 2001 Internet http www festo com E Mail service internationalQfesto com The copying distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited Offenders will be held liable forthe payment of damages All rights reserved in par ticular the right to carry out patent utility model or orna mental design registrations Festo P BE Checkbox EN en 0103c Contents and general instructions Il Festo P BE Checkbox EN en 0103c Contents and general instructions Contents Designated USEN reali evinces a a do VII Operating requirements sssssleeeeeeee I VII Target eroup uu ve Need RE ende Rcs ene paced e Be atte Y e VIII A eetteae dae EnepAS GR Me xh qubd uM heu pied
33. UNTER As from value 9999 the 4 position LCD shows numerical values with additional decimal points multipliers The values shown must be multiplied by the power of 10 for each deci mal point Numerical value Multiplication Number 1000 x 102 100000 1000 x 103 1000000 Festo P BE Checkbox EN en 0103c A 15 A Technical appendix A 3 Calculation examples A 3 1 Bandwidth and tolerance Bandwidth B specifies the extent to which the value of the feature may vary upwards or downwards Tolerance T specifies the per cent increase in the bandwidth of each feature related to the average value of the feature C C 0 B Cmax Cmax tol Cmin Cmin tol A 16 maxtol mintol Cmax A X dis T Cu x 100 Cirsa Cria a Sen B Cs 5H Cua XA x 100 Average value of the feature Bandwidth Feature maximum Upper limit of bandwidth incl tolerance Feature minimum Lower limit of bandwidth incl tolerance Tolerance Festo P BE Checkbox EN en 0103c A Technical appendix Example Festo P BE Checkbox EN en 0103c Ascertaining the bandwidth for the feature Length of a con veyed part with a set tolerance of 5 display on the LCD TOLERANCE Conveyed part lengths mm for 5 sample parts ascertained during the teach procedure 60 60 61 65 60 Therefore A 61 2 mm Average value of the length Cmax 65 mm Length maximum Cmin 60 mm Length minimum 5 Tolerance 2xTxA B Gry A ern p
34. ach data are not compatibly organised for the Checkbox used Repeat the teach process Check environment on non CE conform devices If this occurs frequently and when other devices are connected to the Checkbox Operation with external power supply of the I O module see chapter 3 2 Load system parameters again from internal safety memory Switch off Checkbox via mains switch Press the TYPE SELECT 1 button and hold pressed down while the mains switch is switched on Release the TYPE SELECT 1 button after 2 seconds During the load procedure all the illuminous buttons light up briefly one after the other from left to right running light With CheckKon Load system parameters again Or contact the Festo after sales service Load system parameters again from internal safety memory Switch off Checkbox via mains switch Press the TYPE SELECT 1 button and hold pressed down while the mains switch is switched on Release the TYPE SELECT 1 button after 2 seconds During the load procedure all the illuminous buttons light up briefly one after the other from left to right running light With CheckKon Load the teach data again Or contact the Festo after sales service Use compatible teach data format Repeat the teach process If a hardware error message gt E 60 occurs please contact Festo after sales service Festo P BE Checkbox EN en 0103c A Technical appendix Error situation
35. al specifications 0 0 eee eect ee een eee A 24 A 6 A A SEN A 27 A 2 Festo P BE Checkbox EN en 0103c A Technical appendix A 1 Operating faults A 1 1 General cause of faults Problem Device cannot be switched on with START button START and STOP buttons light up at the same time Device does not function all illuminous buttons flash Good test parts are sorted out as bad parts Bad test parts are accepted by the device as good parts LCD COUNTER Display FULL Good parts in all orientations are blown back into the small parts conveyor In spite of light weight con veyed parts are not reliably blown down at the delivery points Festo P BE Checkbox EN en 0103c Cause No power supply of the 1 0 module Ambient setting data or hard ware error Tolerance set too low Incorrect sample part selected via TYPE SELECT Tolerance set too high Deviations not recognized by the Checkbox The preselected counter status is reached and is not reset by the external controller Blow down timing point incorrectly set Suction effect due to flow resistance of conveyed part Remedy Internal supply Insert the blanking plug preset at the factory into the connec tion Controller External supply Replace the bridges in the blanking plug by a connection to an exter nal power supply check the external power supply Compare chapter 3 2 Identify error coding in chapter A 1 2 Eliminate e
36. amera angle of vision Activate filter function With CheckKon Setting the lower picture limit Clean the conveyor belt with compressed air Install a cutting device in front of the conveyor belt A 9 A Technical appendix A 2 Status displays on the control panel Illuminous buttons Status Button Meaning Continu TYPE SELECT 1 2 3 Display of the selected ous light 4 5 or 6 memory location START Controller is switched on STOP Controller is switched off ing Test part is passed as a good part in all taught orientations Flashes STATUS New part passes the camera TYPE SELECT 1 to 6 Error message STATUS An error code also appears STOP in the LCD TOLERANCE see Appendix A 1 2 Checkbox with encoder In order to display the belt speed press the STATUS button in the select mode The LCD TOLERANCE then shows the belt speed of the conveyor unit in mm s LCD displays The grey shaded fields mark the main displays Main displays are shown continuously the remaining additional displays are only shown for a brief period due to an event or an oper ating status The counter function is not active in the operat ing mode TEACH the LCD COUNTER does not show anything A 10 Festo P BE Checkbox EN en 0103c A Technical appendix Switch on Teach mode Festo P BE Checkbox EN en 0103c Display TOLERANCE Meaning LCD 3 LJ Letter for Checkbox design I dent C ount
37. amera cover Protective screen Camera Protective screen Lighting Lighting Plugs Fig 7 1 Protective screens 7 5 7 Maintenance Cleaning the protective screen Camera 1 Loosen the locking screw next to the camera slot 2 Pull the loose protective screen by its handle carefully upwards out of the screen slot 3 Clean the glass surface as described above Refit the protective screen again after cleaning it 1 Place the protective screen by its handle carefully back into the screen slot 2 Tighten the locking screw next to the camera slot by hand Please note gt Tighten the screw only by hand You will then avoid damage to the protective screen 7 6 Festo P BE Checkbox EN en 0103c Technical appendix Appendix A Festo P BE Checkbox EN en 0103c A 1 A Technical appendix Contents A Technical appendix erret erre AC eer tada ta a A 1 A 1 Operating faults x siiis iR RR EAT A PAR REOR ER RA A 3 A 1 1 General cause of faults csse A 3 A 1 2 Errormessages ecelesie A 5 A 2 Status displays on the control panel 2 0 ee eee eee ee eee A 10 A 3 Calculation examples ccc ec cece cee eee eee A 16 A 3 1 Bandwidth and tolerance 2 0 cece eee eee ee eens A 16 A 3 2 Scatter of characteristics 2 ee ccc cee ee A 18 A 3 3 Feature deviation llle A 19 A 4 Piniassigniment ce ica Bh ad E qe OE RI ed A 21 A 5 Technic
38. ance of the relevant Check box type Identbox Countbox and Sortbox Description of the Checkbox configurator Operation of the CheckKon software package software package type P SW CB KONF Checkbox configurator Description of the Checkbox optimizer Operation of the CheckOpti software package software package type P SW CB OPTI Checkbox Optimizer Product specific terms and abbreviations Term abbreviation Meaning Bad part A test part on which at least one feature lies outside the tolerances C value The C value indicates the extent of the scatter of the features of the sample parts Checkbox Any device from the Checkbox family e g Identbox Countbox Sortbox Feature Characteristic features are ascertained from the contour data of the sample and test parts These are e g length height etc as well as a feature for each configuration tool CheckOpti Good part A test part on which all features lie within the tolerances Orientation The parts to be checked by the Checkbox may lie facing in different directions on the conveyor belt During the teach procedure you de fine the orientations by showing the part in different directions Orientation 1 is the preferred orientation nominal orientation Parts type Conveyed part defined by the teach data of the sample parts Sample parts Parts shown during the teach procedure XIV Festo P BE Checkbox EN en 0103c Contents and general instructions Term abbreviation
39. ated Dried Filtered with filter 40 pm Compressed air supply 4 6 bar overpressure Electric components Power supply self setting 85 264 V 50 60 Hz via a backup fuse of 1 A slow blowing in the mains switch Max 150 VA A 24 Festo P BE Checkbox EN en 0103c A Technical appendix Conveyor and test output Dimensions weight Festo P BE Checkbox EN en 0103c Conveyor and test output Camera resolution Resolution 2 100 mm 1 10 mm 1 10 mm Belt speed Speed 200 mm s 300 mm s 300 mm s can be set 100 300 100 400 100 400 Examples of conveyor rate Belt speed 300 mm s M3x25 screws in correct position for mounting 4 5 items s Axes Y 18x25 mm for quality check 8 items s Bolts 5x50 mm tested and in correct position 2 items s The conveyor rate depends on the size of the component the number of orientations and the belt speed Controller Dimensions and weight A 25 A Technical appendix A 26 Conveyor unit Dimensions and weight Conveyor unit with 2 blow down positions Height Width Depth Weight Height Width Depth Weight 154 142 580 Conveyor unit with 6 blow down positions Height Width Depth Weight mm 154 142 mm 880 TO ESOO Eee Conveyor unit dimensions Rotation symmetric or pre orientated parts Conveyor unit for conveyed part 7 Further lengths on request Festo P BE Checkbox EN en 0103c A Technical appendix A 6 Acce
40. ation can be recognized lt 100 Test part orientationcanbe assigned gt 100 Test part orientation can not be assigned clearly Error code for system error 01 99 Details in chapter A 1 2 A 12 Festo P BE Checkbox EN en 0103c A Technical appendix Display COUNTER Display Meaning Range Counter function without switching off Option Production counter Counter function with switching off Option Nominal value of good parts Display Meaning Range A ck Counter function with switching off Option Current counter O O Counter function with switching 0 9999 103 off Option Nominal value of good parts Teach mode Display TOLERANCE Display Meaning Range Tolerance value for the current 2nd number parts type sorting program 0 20 1st number Parts type or sorting program 2nd number Tolerance in F U L L Status of buffer zone signal from buffer zone sensor Error code for system error 01 99 Details in chapter A 1 2 Festo P BE Checkbox EN en 0103c A 13 A Technical appendix Display COUNTER Display Meaning Range Corresponding to the selected 0 9999 103 option of the counter function Without switching off Production counter With switching off Nominal value of good parts or Current counter l i F Uu LE Preselected counter reading reached A 14 Festo P BE Checkbox EN en 0103c A Technical appendix Number representation Display CO
41. ation the counter status or the nominal number Sortbox In automatic mode you can use the TYPE SELECT buttons to access the tolerance setting and the current counter status of each parts type of the current sorting program 6 15 Testing parts with the Checkbox If the parts supply is interrupted the LCD TOLERANCE will show the error message E 05 Code Explanation The Checkbox has not received a conveyed part for min 30 seconds 1 Quit the error message with the illuminous button STATUS 2 With manual supply of parts supply more parts or press the STOP button 3 With automatic supply of parts check buffer zone and material jam 6 3 2 Manual start stop mode In the operating mode AUTO manual adjustmnt is only poss ible via the illuminous button STOP Program processing is then stopped the conveyor belt switches off The current operating parameters are retained in the STOP status The automatic mode can be continued with START If alternating between manual operation and operation with a higher order controller please note the information in chapter 3 4 6 3 3 Counter function Countbox Sortbox 6 16 The display COUNTER on the Countbox Sortbox shows in faultless operation either the continuous current counter status for good parts or the nominal number of good parts With STOP the current counter states are saved With START the counting processes are continued with the saved counter states Fe
42. box EN en 0103c 3 5 3 The O module on the Checkbox External supply External supply of the I O module is stipulated to ensure EMC conformity The external supply must be electrically isolated from the internal power supply to the Checkbox The external power supply also supplies the valves at the blow down positions on the conveyor unit The power unit must therefore be designed for loading currents of 1 3 A Important note gt Connect the I O module of he Checkbox to an external power supply if you are using the Checkbox in conjunction with other devices To do this modify the factory setting of the Sub D plug Controller provided In this way you will avoid malfunctioning and damage to the device Connector socket Controller on the Checkbox External power supply 1 15 External GND 1 34 External 24 V DC 19 18 15 7 2 1 O00s Q0o 0ob 0e OD 00 0o0 rk e Q 0O0 37 36 34 26 21 20 24VDC Use the Sub D plug Controller 1 Loosen both screws and locking rings on the plug housing 2 Remove the bridge between pins 16 and 15 GND 3 Remove the bridge between pins 35 and 34 24 V DC 4 Connect pin 15 with the earth ground potential 0 V of the external power supply 3 6 Festo P BE Checkbox EN en 0103c 3 The 1 0 module on the Checkbox 5 Connect pin 34 with the 24 V potential of the external power supply 6 Place the locking rings on the screws and t
43. box Sortbox Automatic mode S Switch to the operating mode AUTO with the key switch The LCD TOLE The LCD TOLERANCE shows the current RANCE shows the memory group and the tolerance in per cent current memory The LCD COUNTER shows in faultless opera group and the tion the counter status or the nominal num tolerance in per ber cent B 8 Festo P BE Checkbox EN en 0103c Index Appendix C Festo P BE Checkbox EN en 0103c C 1 C Index Contents C Index C2 Festo P BE Checkbox EN en 0103c C Index Festo P BE Checkbox EN en 0103c A Abbreviations ooooooooooooooonomomomoooo XIV ACCESS Sir ad A 27 AUTO 240000 bad eu elias bel sd 4 3 4 6 6 15 Automatic mode ooooooooooooooonomomooo o 6 15 B Beltspeed iia a ae es A 10 A 25 Binary coding Parts type its a Bae he e re ee 3 18 Sorting program 0 eee eee eee eee 3 19 Buffer zone cata a al dara e ia e male 1 10 Section ma cti ar da ls arde ph 1 11 SENSO 24 isa a che dd atlas ss LIS echt gee DA 1 10 Buffer zone sensors 0 0 c cece eee eee 2 11 3 3 At the connection Controller 2 13 At the connection Sensors o ooooooooo o 2 11 C Camera resolution o ooooooooomomoooomo A 25 Checkbox COMPONENTS esee cr a o tt da ne RUE 1 6 COUntbOX aterrado 1 3 DIMENSIONS iia ata A 25 Identbox sti dl les 1 3 Method of operation ce eee eee coco 1 7 SOTtDOX 44d d A
44. bridges fitted at the factory between the sensor inputs and the reference voltage Connect the buffer zome sensors with the unused sensor inputs see following table Connect unused sensor inputs with the 24 V DC reference voltage HIGH Place the locking rings on the screws and tighten the plug on the plug housing Insert the plug into connection 1 Fig 2 4 2 13 2 Fitting and Installation Operation with 2 buffer zone sensors Connector socket Controller on the Sortbox 1 24 Buffer zone sensor 3 1 5 Buffer zone sensor 4 1 23 Buffer zone sensor 5 1 4 Buffer zone sensor 6 OQ e o o oo 37 36 000 nrk re o oe o 19 18 gt Please note The inputs Sensor 1 and Sensor 2 are provided both at connection Sensors as well as at connection Con troller If you are using both sensor inputs at the connection Controller Remove the bridges fitted at the factory in the plug Sensors Then screw the plug Sensors into connection Fig 2 4 Only in this way is the Checkbox ready to operate 2 14 Festo P BE Checkbox EN en 0103c 2 Fitting and Installation 2 4 3 Controlling the small parts conveyor If there is no connection on the small parts conveyor for an external switching contact you can use the power circuit module available as an accessory for controlling the small parts conveyor Conveyor unit X2 Fig 2 5 Connection
45. d on again operation of the assembly plant without interruption must be guaranteed before the first new conveyed parts arrive Section B must be de signed so that a sufficient number of conveyed parts are available The length depends on the geometry of the conveyed parts the maximum time delay beween the small parts conveyor being switched on again and the availability of the new conveyed parts the length and speed of the conveyor belt Festo P BE Checkbox EN en 0103c 1 11 1 System summary B Conveyor belt of the Checkbox Buffer zone Sensor 1 Buffer zone section A le e 9 Section B Identbox Countbox Identbox and Countbox are operated with a buffer zone The buffer zone can be monitored by one or for switching delay hysteresis of the small parts conveyor with two sensors Buffer zone with one sensor Identbox Countbox Fig 1 3 Buffer zone sections 1 sensor Signal level Meaning Result 24 V DC active low LOW Buffer zone is full LCD TOLERANCE switches to FULL at sensor 1 Good parts are blown down After a preset time e g 30 s the small parts conveyor will be switched off The conveyor belt continues to run HIGH Sensor does not The small parts conveyor is switched on at sensor 1 register any con veyed part 1 12 Festo P BE Checkbox EN en 0103c 1 System summary Buffer zone with two sensors Identbox Countbox Conveyor belt of th
46. d parts will be blown down The small parts conveyor will be switched off after 30 s stan dard setting Use the blanking plugs wired at the factory to connect the sensor inputs with the 24 V DC reference voltage The 4 pin plug Sensors for the buffer zone sensors Dini Ze The 37 pin Sub D plug Controller alternatively for the buffer zone sensors 1 2 Identbox Countbox or 1 6 Sortbox Screw the plug Sensors into connection 2 Sensor inputs 1 2 are then wired with the reference voltage e Make sure that the plug Controller is inserted at con nection 1 see 2 2 1 Supplying the I O module At the same time sensor inputs 3 6 of the Sortbox are wired with the reference voltage Festo P BE Checkbox EN en 0103c 2 9 2 Fitting and Installation 2 10 Operation without buffer zone sensors Connector socket Sensors on the Checkbox The sensor inputs are negative switching normally closed If 24 V DC is applied the small parts conveyor will be switched on The 4 pin plug Sensors wired at the factory bridges the sensor inputs 1 2 and 1 4 with 24 V DC The inputs 1 25 and 1 26 at the con nection Controller are then connected internally with the reference voltage Operation without buffer zone sensors Connector socket Controller on the Sortbox 6 e 00 krk U 7 25 24 23 26 Sortbox Buffer zone sensor 4 1 23 Sortbox Buffer zon
47. e Checkbox lt Sensor 2 H Sensor 1 Buffer zone Buffer zone section A la E e 9 Section AB Section B ES e Fig 1 4 Buffer zone sections 2 sensors Signal level Meaning Result 24 V DC active low LOW Buffer zone is full LCD TOLERANCE switches to FULL at sensor 2 Good parts are blown down After a preset time e g 30 s the small parts conveyor will be switched off The conveyor belt continues to run HIGH Sensor does not The small parts conveyor is switched on at sensor 1 register any con veyed part Festo P BE Checkbox EN en 0103c 1 13 1 System summary NAMES Y A x H Sensor 1 Buffer zone le e 9 Buffer zone section A Section B Fig 1 5 Signal level 24 V DC active low LOW at individual sensor outputs LOW at all sensor outputs HIGH onatleast one sensor output 1 14 Sortbox The Sortbox is operated with max 6 buffer zones Each buffer zone can be monitored by a sensor Buffer zones each with one sensor Sortbox Conveyor belt of the Checkbox Meaning Individual buffer zones are full All buffer zones are full At least one sensor does not register any con veyed part Buffer zone sections 1 sensor per buffer zone Result LCD TOLERANCE shows FULL for the relevant parts type Following good parts of the parts type are blown down Bad or foreign parts are transported to the delivery position L
48. e eae ag 4 3 4 6 6 3 SEMV CO 42 ota ade ee e peta i Bee eee VIII Small parts conveyor ooooocccooooccoooocooomo 1 7 Control do nio veh la TEES IAS 2 15 Switching delay 0 cece cece cece eens 1 11 Sorting program Number or cra baie det weed ta Malate 5 6 Standard delivery positions 0005 1 9 Standard transfer positions o ooooooooooo 3 14 START stato resi ases IS MEA a asad oad 4 3 4 4 Start stop mode ssssssssss eee 3 10 STATUS e ie korea ed 4 3 4 7 STOP eod eS Eee adu 4 3 4 4 Festo P BE Checkbox EN en 0103c C Index Festo P BE Checkbox EN en 0103c T Target Soup ita ad ai VIII XII TEACH ci oto 6 e c qu Mele aes 4 3 4 6 Teach data Addressing aevi iuis eek eae al eel 5 6 Ror To oar ada aa lb dd bx a 6 4 Save geet Mia ua Xv ee ud HEP REED 5 11 Teach procedure cee cece eee eee 1 8 Addressing teach data oooooooomocmommoo 5 6 Preparation 2 0 eee eee eee ee eee 5 3 Saving teach data oooooooocoocoomomo 5 11 Scanning sample parts 0 0 eee ee 5 7 Testmode i uhecik Re REI Ra eS ES 6 10 Test part deviation llle 6 12 Test procedure 2 eee eee eee eee eens 1 8 Enable the orientations 00 000 6 7 Load the teach data 0 2 00 ee eee 6 4 Preparation so baii cia Eu edness eek 6 3 Set counter function 0 0 e eee eee ee eee 6 7 Set the tolerance
49. e note With plastic parts do not use any solvent or abrasive cleaning agent which might damage the surface Use only non abrasive solvent free cleaning agents Fixed cleaning intervals are not stipulated The frequency of cleaning depends on the conditions of use at the site Faultless functioning of the Checkbox optics can only be guar anteed if the glass surfaces are clean and not scratched Festo P BE Checkbox EN en 0103c 7 3 7 Maintenance Clean the following if it they is are dirty the protective screen Camera between the camera and the conveyor unit the protective screen Lighting between the lighting and the conveyor unit Please note gt Make sure that the glass surfaces are not scratched do not use abrasive cleaning agents You will then avoid dam age which could lead to malfunctioning of the Checkbox First remove the camera cover 1 Switch off the compressed air and the power supplies 2 Loosen the four fastening screws on the bottom of the camera cover 3 Lift up the camera cover Cleaning the protective screen Lighting It is not necessary to dismantle the protective screen Lighting in order to clean it Clean the glass surface above the conveyor belt with clean non lubricated compressed air with a soft moist cloth and a non abrasive cleaning agent 7 4 Festo P BE Checkbox EN en 0103c 7 Maintenance Festo P BE Checkbox EN en 0103c C
50. e sensor 5 Sortbox Buffer zone sensor 6 Sensor inputs 1 25 and 1 26 are already connected internally to 24 V DC via the plug Sensors The plug Controller wired at the factory bridges the connections Buffer zone sensors 3 6 19 18 OO0O7xreee eee amp o 37 36 Festo P BE Checkbox EN en 0103c 2 Fitting and Installation 2 4 Operation with buffer zone sensors Use the plugs provided for connecting buffer zone sensors to the Checkbox the 4 pin plug Sensors with 1 2 sensors chapter 2 4 1 the 37 pin Sub D plug Controller with more than two sensors Sortbox chapter 2 4 2 The plug Controller is wired at the factory for internal power supply of the I O module This configuration is only permitted for operation with buffer zone sensors If you connect the Checkbox to other devices e g a PLC via the connection Controller you must connect the I O module to an external power supply 2 4 1 Buffer zone sensors at the connection Sensors Use the 4 pin plug Sensors provided 1 Loosen the knurled nut of the plug from the plug housing 2 Loosen the screw terminals on the plug and remove the bridges fitted at the factory between the sensor inputs and the reference voltage 3 Connect the buffer zone sensors to the non assigned sensor inputs 4 Screw the plug into the plug housing Festo P BE Checkbox EN en 0103c 2 11 2 Fitting and Installation Operat
51. ectors are specified with the pin number as follows Inputpin1 1 1 Output pin2 0 2 Plug connectors are shown viewed towards the device This representation corresponds to the view from the cable side of the connections to be wired Festo P BE Checkbox EN en 0103c Contents and general instructions Notes on this manual Festo P BE Checkbox EN en 0103c This manual refers to the standard design of Identbox Count box or Sortbox with operating system version 3 x When the Checkbox is switched on the version number of the operating system will be shown briefly on the TOLERANCE display The options and parameters available depend on the operat ing system the type of Checkbox connected and the pre set tings made at the factory Special customer specific designs may differ in technical data parameter settings and function ality The pre setting of the Checkbox can be modified if required with the software packages CheckKon function Modify sys tem or CheckOpti available as options Further information on the software packages can be found in the manuals listed under Documentation on the Checkbox family XIII Contents and general instructions Documentation on the Checkbox family Further information on using the Checkbox can be found in the following manuals Manual Contents User manual on the Checkbox family Description of the functioning commissioning type P BE Checkbox operation and mainten
52. eee 6 16 Counter function Countbox Sortbox sees 6 16 Modifying operating parameters 0 cece cece eee eese 6 18 Maintenance voii yews bie eet ds bees TUE eV Res 7 1 General a a e o dd dis a 7 3 A E See A A eee oe oe 7 3 Technical appendix 0 ve mE Ere tva eras Eres A 1 Operating faults cu tid ote CR RR REESE ORE EE TCR ek a A 3 General cause of faults 2 0 0 cece nent eens A 3 Error MESSAGES ii a adits TE A 5 Status displays on the control panel eese eee eee A 10 Calculation examples 0 cece cece eee A 16 Bandwidth and tolerance 0 cece cece een A 16 Scatter of characteristics 0 ec nananana nunnana A 18 Feature deviation 0 ccc ccc eee ehh hn A 19 Pin assignimient a2 eis aid da wees A 21 Technical specifications cee eee eect eens A 24 ACCesSOT GS Lm EU le eh A oh OSE ea ME S einer A 27 Brief instructions oooooocrcoooocrrorccnrronccnacnccaconoc s B 1 ORAR OO RENTA C 1 Festo P BE Checkbox EN en 0103c V Contents and general instructions VI Festo P BE Checkbox EN en 0103c Contents and general instructions Designated use The Checkbox has been designed for use in manual and in dustrial applications in enclosed work rooms under normal operating conditions The Checkbox described in this manual is intended exclus ively for use as follows for sorting and rejecting small conveyed parts such as e g screws springs bolts
53. en it is in faultless condition Use only the original connecting cable Controller X4 1 Conveyor unit with camera X5 Mains cable Fig 2 2 Electrical connections of the controller 2 6 Festo P BE Checkbox EN en 0103c 2 Fitting and Installation Connect the Checkbox modules to the power supply as fol lows e To provide the power supply for the I O module insert the plug Controller into connection 1 on the connec tion side of the controller The plug is set at the factory to Internal power supply Please refer here to the informa tion in chapter 3 2 e Connect the hybrid cable on the connection side of the controller to connection on the bottom of the con veyor unit Please note gt Insert the hybrid cable very carefully Make sure that the plug is fully inserted before you close the locking lever This will prevent the contacts from bending Plugin the mains cable for the power supply to the Check box 2 2 2 Pneumatic connection gt Please note Connect the Checkbox only to filtered non lubricated and dried compressed air In this way you will avoid damage to the devices as a result of contaminated compressed air The compressed air supply for the rejecct valves must fulfil the following requirements supply 4 6 bar overpressure non lubricated dried and filtered with filter 40 uim Festo P BE Checkbox EN en 0103c 2 7 2 Fitting and Installation g
54. ent error HIGH Recognition error or memory error As standard all error messages which stop the Checkbox are defined as errors 3 21 3 The O module on the Checkbox Warnings 3 22 By means of a factory configuration or subsequent conver sion with the aid of the CheckKon configurator software error E 05 can be redefined as a warning Warnings indicate a status of the Checkbox which requires the intervention of the operator Signal level Warning 0 22 0 3 0 21 Material jam or small parts conveyor is HIGH empty E 05 Festo P BE Checkbox EN en 0103c Commissioning Chapter 4 Festo P BE Checkbox EN en 0103c 4 1 4 Commissioning Contents 4 Commissioning emer eere lia epee E E E 4 1 4 1 Control panel of the Checkbox 0 2 cece eee eee eee eee nee 4 3 4 2 Switching ori ad Off osc ac cece tne alee a alec a ene 4 4 4 3 Operating modes of the Checkbox cscs eee ee eee 4 6 4 4 Error diagnosis viii lc De eee A 4 eee Kee PA Be 4 7 4 2 Festo P BE Checkbox EN en 0103c 4 Commissioning 4 1 Control panel of the Checkbox Functions Illuminated buttons for selecting displaying the parts type TYPE SELECT 1 6 TEACH SELECT AUTO Keyswitch for selecting the operating modes Countbox Sortbox LCD COUNTER Display for selecting the counter type and for setting the counter Illuminated buttons Push buttons LCD TOLERANCE
55. eyor belt runs The START button is lit continuously Use the key switch to start the relevant operating mode of the Checkbox TEACH for carrying out the teach procedure SELECT for saving the teach data setting the operating parameters and for checking the conveyed parts in test mode AUTO for checking the conveyed parts in automatic mode B 3 B Brief instructions Switching off Switch off the Checkbox as follows 1 Press the STOP button The STOP button is lit continu ously The conveyor belt remains at a stand 2 Switch off the mains switch on the connection side of the controller ES ES 2977 mm f Identbox Countbox Operating requirements eei ge Screw the plug Sensors wired at the factory into the connection Sensors Also insert the plug Controller for the power supply to the I O modules into the connection Controller Operation with 1 buffer zone sensor at the connection Sensors Use the plug Sensors without the bridge fitted at the factory with the sensor connected at sensor input 1 with unused input 2 bridged with input 1 Screw the plug into the connection Sensors Also insert the plug Controller wired at the factory into the connection Controller Operation with two buffer zone sensors at the sensors connection Use the plug Sensors without the bridge fitted at the factory with sensors connected at both sensor in
56. f the belt the number of reject positions Further information on the various designs of conveyor unit can be found in the chapter A 5 Technical specifications 1 6 Festo P BE Checkbox EN en 0103c 1 System summary 1 5 Method of operation of the Checkbox The rejection of incorrectly orien tated parts Rejection of faulty or foreign parts Output of good parts via a buffer zone Conveyor belt of the Chekbox Small parts conveyor The method of operation of the Checkbox is based on the contactless recognition of small parts the teaching of new parts without programming anintegrated quality check o JN e e Fig 1 2 Conveyor path example Recognizing Festo P BE Checkbox EN en 0103c A small parts conveyor e g vibrator conveyor centrifugal machine stage conveyor sorts out the conveyed parts and passes them on to the conveyor belt of the conveyor unit The conveyor belt passes the parts between the line camera and the LED lighting The camera registers each conveyed part in contour images From the contours the system ascertains part specific features such as the length breadth and sur face 1 7 1 System summary Learning Checking On the basis of the features the Checkbox recognizes the parts type the orientation the observance of dimensions the quality The nominal contour of a conveyed part type is ascertained by a simple procedure 1
57. gh at a high rate some parts may be blown back although previously tested parts have not yet been blown down This delay arises due to the long distance between the return valve and the reject valve Standard transfer positions of the Identbox Countbox on a conveyor unit with 6 reject positions The compressed air valves of the reject positions are con nected directly to the outputs actuators 1 6 These outputs are set at 24 V DC if the parts test delivers the following result incorrectly orientated or superfluous good part good part of a certain parts type If the Checkbox recognizes a test part as a bad or foreign part pin O 1 actuator 7 will be set from rest potential O V to 24 V DC 3 15 3 The O module on the Checkbox Signal level Actuators 1 7 Pin Connection Controller of the Sortbox Actuator 1 The 24 V DC signal is present when the test part passes the reject nozzle for in correctly orientated or superfluous good parts The duration of the signal corre sponds to the time the part requires to pass the nozzle Actuators 2 6 The 24 V DC signals are present when test parts pass the reject nozzle for good parts of a certain parts type The dur ation of the signal corresponds to the time the part requires to pass the nozzle Actuator 7 The 24 V DC signal is present when the bad or foreign part passes the end of the system edge guide rail of the conveyor unit 3 16 Festo P B
58. ighten the plug on the plug housing 7 Insert the configured plug into the connection Controller Reference voltages The voltage applied to pins 1 15 and 1 34 is available as refer ence voltage at pins 0 7 and 0 26 In the stop status this reference voltage is switched off Pin Title Function Reference voltage e g as reference potential for PLC GND Reference voltage e g as power supply for buffer zone 24V DC sensors Fuses 300 mA self resetting Festo P BE Checkbox EN en 0103c 3 7 3 The O module on the Checkbox 3 3 Connecting a higher order controller Important note gt If you connect the Checkbox to other devices e g a PLC via the connection Controller you must connect the 1 0 module to an external power supply see chapter 3 2 You can then guarantee faultless operation and prevent serious damage to the Checkbox electronics For remote control of the Checkbox connect the following control and signal lines of the I O module Pin Title Function Remote start Start stop mode remote Operating mode 0 Operating mode 1 Actuator 1 Displays at the transfer Actuator 2 position Actuator 3 Good parts Actuator 4 Incorrectly orientated Actuator 5 parts incorrect parts Actuator 6 type Actuator 7 Bad foreign parts Fault status 0 Warning Error messages Fault status 1 Error Fault status 2 Classification 3 8 Festo P BE Checkbox EN en 0103c 3 The 1 0 module on
59. ill be accepted as good parts The setting range of the tolerance lies between O and 20 If the tolerance 0 only those parts the features of which lie within the band width of the sample parts scanned during the teach procedure will be accepted as good parts The toler ance is preset at the factory with 5 standard setting Set at least 1 tolerance You can then be sure that good parts are correctly classified despite minimum position deviations The LCD TOLERANCE shows the current memory group and the tolerance in per cent Set the tolerance as follows 1 With the TOLERANCE button you can increase the value displayed by 1 2 With the TOLERANCE button you can reduce the value displayed by 1 The value selected will automatically be added to the data of the parts type and saved With critical conveyed parts you must ascertain the optimum setting of the tolerance in test mode see chapter 6 2 Festo P BE Checkbox EN en 0103c 6 Testing parts with the Checkbox 6 1 4 Enable the orientations Countbox Sortbox im EXI With the illuminous button LCD COUNTER you can set the test mode so that test parts are accepted as good parts either in all taught orientations or only in the nominal orientation Orientation 1 Illuminous Effect buttons Good parts are accepted in all taught orien ON tations Good parts are accepted only in one orien tation nominal orientation Good parts which a
60. illumi nated buttons of the Checkbox will light up briefly and indicate readiness to operate The LCD TOLERANCE will then show the following system information one item after the other LCD Meaning Letter for Checkbox design I dent C ount or S ort and version status of the operating system Example Identbox version 3 0 Number of memory groups or sorting programs Sortbox and also letter E with system setting with encoder Example 6 memory locations encoder Q e 4 System setting of the camera resolution Example 1024 pixels 3 Start the Checkbox with the green illuminated button START The conveyor belt runs The START button is lit continuously Switching off Switch off the Checkbox as follows 1 Press the STOP button The STOP button is lit continu ously The conveyor belt remains at a stand 2 Switch off the mains switch on the connection side of the controller Festo P BE Checkbox EN en 0103c 4 5 4 Commissioning 4 3 Operating modes of the Checkbox For teaching and checking the conveyed parts you can select one of three operating modes in the Checkbox TEACH SELECT and AUTO You can switch the operating mode with the key switch on the control panel Fig 4 1 TEACH mode In the TEACH mode the Checkbox learns all features for the parts check with the aid of sample parts The following steps are required here 1 Addressing teach data 2 Scanning sample parts 3 Saving teach data SELECT
61. ing from triggering the signal Buffer zone full at the sensor The delay time of 1 second between the registering of a con veyed part by the sensor and the interpretation of the signal by the Checkbox must be taken into account whene the buffer zone sections are planned CheckKon With the CheckKon software you can modify the following settings of the buffer zones Switching logic buffer zone sensor type normally open closed Signal delay minimum sensor signal duration for status Buffer zone empty or Buffer zone full Festo P BE Checkbox EN en 0103c 1 System summary Dimensioning Buffer zone sections IB CB SB IB Identbox CB Countbox SB Sortbox Buffer zone section A Section between conveyor belt and sensor Section A must accept all conveyed parts which lie between the camera and the sensor when a con veyed part has been registered by the sensor The length depends on the geometry of the conveyed parts the maximum transport rate of the small parts conveyor the length of the conveyor belt Buffer zone section AB Section between sensors 1 and 2 only buffer zones with 2 sensors Section AB determines the switching delay hys teresis of the small parts conveyor for regulating the supply of parts The longer the section is the less is the switching frequency Buffer zone section B Section between sensor and following machine When the small parts conveyor is switche
62. into the Checkbox Checkbox optimizer CheckOpti Modifying the teach data independently of the Checkbox offline Monitored checking of parts display of the registered features Evaluation of the parts check with regard to reliability evaluation Graphic representation of test run deviation from test part or position Optimizing the parts check by manual adap tion of the min max values of the teach data or by configuration tools Support in project planning administration and documentation Checkbox statistics CheckStat Display evaluation and printout of statistical data of the tested parts The software packages have been developed specially for the Checkbox family products and can be used with all the de vices in the Checkbox family 1 4 Festo P BE Checkbox EN en 0103c 1 System summary 1 3 Scope of functions of the Checkbox Functions of the Checkbox IB Identbox CB Countbox SB Sortbox IB CB SB Quality check Checking the quality e g for shavings or burrs in the case of swivel and milling parts Machine sorting of faulty and foreign parts Position check nominal orientation Position orientated supply of good parts to the following machine Return of incorrectly orientated good parts to the small parts conveyor Check of buffer zone Return of good parts when buffer zone is full If supplied parts block all buffer zones for a long period the small
63. ion with 2 buffer zone sensors Connector socket Sensors on the Checkbox 0 24V DC Reference voltage 0 1 Buffer zone sensor 2 13 4 oV a Reference voltage for sensors Buffer zone sensor 1 The sensor inputs are negative switching normally closed If 24 V DC is applied the small parts conveyor will be switched on As an option direct connection with a Festo DUO cable is also pos sible Cable designation signal x 1 1 signal x 1 1 2 Et If only one buffer zone sensor is required bridge the unused A sensor input according to your Checkbox type Operation with 1 buffer zone sensor Connector socket Sensors on the Checkbox Identbox Countbox Connect both sensor inputs 1 4 and 1 2 with each other Sortbox Connect the unused sensor input e g 1 2 with the 24 V DC reference voltage HIGH 2 12 Festo P BE Checkbox EN en 0103c 2 Fitting and Installation Please note Screw the ready to use plug Sensors into connection Fig 2 4 Insert the plug Controller wired at the factory into connection 1 Only in this way is the Checkbox ready to operate 2 4 2 Buffer zone sensors at the connection Controller Use the Sub D plug Controller provided if you wish to con nect more than two buffer zone sensors to the Sortbox 1 2 Festo P BE Checkbox EN en 0103c Loosen both screws and locking rings on the Sub D plug Remove the
64. isplay on the LCD COUNTER switches to Good parts counting with preselected number of items The nominal number of good parts is set separately for each parts type and saved automatically with the data of the parts type Select first the parts type and the counter func tion Preselect 1 Select the parts type with one of the illuminous buttons TYPE SELECT 1 6 2 Press the buttons COUNTER and at the same time until PrE is displayed 3 After 1 5 s the LCD COUNTER changes to represent the nominal number presetting 9 9 9 9 9999 10 Numerical values from 1 to 9999 are shown uncoded in the LCD Larger numerical values are shown with addittional mul tipliers points see chapter A2 section Representation of numbers Festo P BE Checkbox EN en 0103c 6 Testing parts with the Checkbox ay N Festo P BE Checkbox EN en 0103c Set the nominal value as follows e Increase value by 1 Press COUNTER briefly faster Hold COUNTER pressed down e Reduce value by 1 Press COUNTER briefly faster Hold COUNTER pressed down Countbox e Set nominal value to 1 Hold COUNTER and pressed down simultaneously until the display is deleted min 3 s Sortbox If with the Sortbox the nominal number of a parts type is set to O the parts arriving of this type will not be counted but blown down e Set nominal value to 0 Hold COUNTER and pressed down
65. larly suit able Non rotationally symmetric parts can however also be checked if a pre orientation of the conveyed parts is made with the small parts conveyor The conveyed part must be supplied correctly on the con veyor belt The length diameter and height of a conveyed part must be suited to the conveyor unit type see chapter 1 4 The conveyed part must be supplied in a stable orientation it must not roll away or vibrate The conveyed part must be blown down reliably by the reject nozzles Exceptionally large conveyed parts made of heavy ma terial e g steel with streamlined shape may under cer tain circumstances not be blown down Carry out a test to make sure that the conveyed parts are blown down Festo P BE Checkbox EN en 0103c 5 Teaching parts with the Checkbox 5 1 2 Set operating mode TEACH Festo P BE Checkbox EN en 0103c Prepare the Checkbox as follows 1 Mount the Checkbox ready for operation 2 Switch the Checkbox on mains switch on the rear of the controller 3 Set operating mode TEACH with the key switch 4 Press the green START button The LCD TOLERANCE shows the current setting of the memory group The START button lights up the coveyor belt remains at a stand 5 5 5 Teaching parts with the Checkbox 5 2 The teach procedure Carry out the teach procedure as follows 1 Addressing teach data 2 Scanning sample parts 3 Saving teach data A description of
66. les on the Checkbox with care Please note especially the following ambient conditions The checkbox must be placed in a location free of vibration The ambient air must be clean free of oil no varnish spray no grinding dust Screening from external light and extreme magnetic fields e g by induction furnaces In this way you will achieve optimum test results and guar antee a long service life of the devices Space required Please observe the space required for mounting the Check box The dimensions of the Checkbox and weight specifica tions can be found in chapter A5 Festo P BE Checkbox EN en 0103c 2 3 2 Fitting and Installation Fastening the There are threaded holes on the bottom of the conveyor unit conveyor unit for fastening it with standard profile sections e g ITEM HERON ROBOTUNITS ITEM profile section HERON profile section 80 x 80 mm 50x50mm Item profile section Heron profile section 80 x 80 mm 50 x 50 mm Item automatic Heron connector HV 50 connector as connector 4 x slotted head screw 2 x slotted head screw M6x40 DIN 912 M8 Fastening the controller Fasten the controller with 4 M8 screws on the rear of the con troller housing 2 4 Festo P BE Checkbox EN en 0103c 2 Fitting and Installation Fitting guides Integrate the conveyor unit in the material flo
67. lue shown changes considerably this indicates that the conveyed part has been positioned incorrectly 1 Press the STOP button to interrupt the teach procedure 2 Repeat the complete teach procedure for the parts type 5 9 5 Teaching parts with the Checkbox 5 10 Scanning further orientations A parts type is not registered completely until the camera has recorded all the intended orientations 1 Set the next orientation with the butttons TOLERANCE and 2 Scanning the sample parts in the new orientation In order to do this repeat the steps described in section 5 2 2 For the test to be reliable the features ascertained from the individual orientations must be clearly distinguishable from each other e Check whether there is at least one feature in which the various orientations differ e Make sure in particular that orientation 1 nominal orientation differs clearly in at least one feature from all the other orientations Festo P BE Checkbox EN en 0103c 5 Teaching parts with the Checkbox 5 2 3 Saving teach data Save the teach data when the sample parts of a parts type have been learnt in all intended orientations Use the key switch to switch to the operating mode SELECT The teach data will then be saved automatically 5 The LCD TOLERANCE then shows in faultless operation the current memory group and the tolerance in per cent e g memory group 1 tolerance 5 The current parts type re mai
68. nect from the mains supply before loosening the camera connection Replace the camera cable Check the selection of the sample part type Increase tolerance A 5 A Technical appendix Code Cause Material blockage No conveyed part for at least 30 seconds time varies depending on Checkbox configuration Maximum permitted parts length exceeded Optical faults Reduced brightness Conveyor belt blocked or encoder does not turn No power supply on I O module Belt speed for the set ratio encoder frequency line frequency of the camera Fgz value too high A 6 Remedy Fill up small parts conveyor With CheckKon Set parameter Max parts length correctly Set the device so that the parts follow along at a recognizable distance Clean the glass covers of the lighting and of the camera 1 Press the STOP button 2 Remove test parts which have become trapped Check units added to the conveyor unit remove obstructions on the conveyor belt Check that the encoder functions correctly Press the START butto Press the STOP button Check whether external outputs are loaded with a current too high 3 Press the START button Or contact the Festo after sales service Check the blanking plug on the connection for the higher order controller Operation with electrical isolation Checking the exter nal supply voltage Reduce belt speed With CheckKon Adapt Fgz value
69. nnection Controller contains the I O module of the Checkbox with the following switching and connecting possi bilities Connector socket Controller Pie connection o 1 4 1 6 Buffer zone Depending on Checkbox design 2 to 6 sensor in 1 23 1 25 sensors puts The configuration of these inputs is described in chapters 2 3 Operation without buffer zone sen sors and 2 4 Operation with buffer zone sensors 0 37 Conveyor unit A 24 V power output is provided at pin 37 for con trolling the small parts conveyor see also chapter 2 4 2 Controlling the small parts conveyor 21 20 009 oeb r o oo e OO 0 1 0 3 Controller For communication of the Checkbox e g with a 0 9 0 12 programamble logic controller or a subsequent 0 15 0 20 machine See further information in chapter 3 3 0 28 0 31 Connecting a higher order controller 0 21 0 22 1 32 1 33 Reference voltage GND 24 V DC 15 16 Power supply Internal or external power supply for the I O mod 34 35 ule is described in section 3 2 Power supply for the I O module Festo P BE Checkbox EN en 0103c 3 3 7 36 QQse s cer enel 19 18 3 The O module on the Checkbox Electrical characteristics Electrical characteristics of the 1 O signals Outputs Max current loading per channel 250 mA Max sum current of all outputs 1 5 A PNP switching Input current 5 mA constant Logical
70. ns selected The conveyor belt continues to run Note the following error displays on the LCD TOLERANCE Code Explanation The nominal orientation cannot be distinguished from other orientations Possible causes The nominal orientation was taught several times by mistake Repeat the teach procedure Make sure that the sample parts are positioned in accordance with the orientation shown The nominal orientation is too similar to other orienta tions Optimize the teach data with the CheckOpti soft ware With CheckOpti even minimum differences can be recognized Please consult your technical advisor in this respect Countbox Sortbox If itis not necessary to distinguish the nominal orien tation 1 Turn the key switch to TEACH 2 Switch on the illuminated button on the LCD COUNTER 3 Repeat the teach procedure Festo P BE Checkbox EN en 0103c 5 11 5 Teaching parts with the Checkbox fa gt Sortbox He Code Explanation NP The taught sample part cannot be distinguished clearly from other sample parts because e g the sample part is identical to the parts type of another TYPE SELECT memory location a different orientation of the sample part has been saved on another TYPE SELECT memory location e Repeat the complete teach procedure Optimize the sorting procedure with the CheckOpti software Please consult your technical advisor in this respect After saving you can carry out one of
71. number of different variations as possible during the teach procedure Observing the scatter of characteristics The following factors influence the scatter of characteristics Parts geometry Different contours of the part depending on the angle of rotation around the longitudinal axis e g with springs screws Different positioning on the belt A detailed description of the computational algorithm of the scatter of characteristics can be found in Appendix A 3 2 Festo P BE Checkbox EN en 0103c 5 Teaching parts with the Checkbox Festo P BE Checkbox EN en 0103c Please observe the TOLERANCE display when scanning the sample parts This display shows briefly for each part the maximum value of the scatter of chateristics for the feature which curently deviates the most C value C value Meaning Sample parts are very similar in all features Large scatter of at least one feature Low values indicate narrrow manufacturing tolerances and a uniform supply of parts Very high values indicate that the taught sample parts differ greatly in their characteristics from each other If the good parts are allowed to differ greatly from each other the teach procedure can be continued It is optimum if the curve of the values changes greatly at first and then remains increasingly constant If the value only changes slightly a sufficient scattter is then usually achieved in the current orientation If the C va
72. ode eee eee cece e eee 6 16 6 3 3 Counter function Countbox Sortbox 0 ccc cece eee eee 6 16 6 3 4 Modifying operating parameters 0 cece eee ee eens 6 18 6 2 Festo P BE Checkbox EN en 0103c 6 Testing parts with the Checkbox 6 1 Preparing the test procedure In order to prepare the test procedure switch the Checkbox to the SELECT mode and set the operating parameters for the test mode or automatic mode Operating parameters for the test procedure IB CB SB dentbox CB Countbox SB Sortbox Load the teach data Ix x x Set the tolerance ESESESR Enable the orientations the orientations Enable the orientations x x Select and set the counting function for automatic mode 6 1 1 Set operating mode SELECT All settings in the SELECT operating mode are made while the conveyor belt is running Prepare the Checkbox as follows 1 Carry out teach procedure see chapter 5 2 Set key switch to SELECT r ola v SELECT 3 Ifthe STOP button is pressed down press the START button Festo P BE Checkbox EN en 0103c 6 3 6 Testing parts with the Checkbox 5 The LCD TOLERANCE then shows the current memory group and the tolerance in per cent e g memory group 1 tolerance 5 The current parts type remains selected 6 1 2 Load the teach data L Select the memory group of the saved teach data as refe rence for the test procedure 1 Press the buttons
73. or S ort and version status of the operating system Example Identbox version 3 0 E Number of memory groups or sorting programs Sortbox and also letter E with system setting with encoder Example 6 memory locations encoder Q e 4 System setting of the camera resolution Example 1024 pixels Display TOLERANCE Display Meaning Values Selection of the memory group of Corresponding the parts type sorting program to the Check box configur Ex le Memo 1 ample Memory group PHA Characteristic scatter 10 Sample parts are very similar in all features gt 30 Large scatter of at least one feature Orientation of the sample parts 1 8 during the teach procedure Error code for system error 01 99 Details in chapter A 1 2 Memory address occupied with measuring tool or with optimized teach data CheckOpti A 11 A Technical appendix Select mode Display TOLERANCE Display Meaning Values uU Selection of the memory group of the parts type sorting program Tolerance value for the current 1st number parts type corresponding 1st number Parts type or sorting to the Check program box configura 2nd number Tolerance in tion 2nd number 0 20 Test part deviation The smaller the value the more exact the test part corresponds to saved sample parts lt 100 Good part gt 100 Bad part The smaller the value the more reliably the test part orient
74. ox 5 1 Preparing the teach procedure If you are using the CheckKon CheckOpti software packages please note the instructions in the software manuals on how to prepare the teach procedure As standard during the teach procedure the parts are blown down from the belt at the first blow down position This is to ensure that no sample parts are unintentionaly transported further to the next machine 5 1 1 Features and characteristics of the conveyed parts Festo P BE Checkbox EN en 0103c The Checkbox registers conveyed parts as two dimensional black white profile pictures parts contour Features for dis tinguishing different good parts are derived from the parts contour Discolouring and surface faults do not influence the test result during this recognition process The features of the conveyed part which determine orienta tion and quality and which are important for the distinguish ing process must be recognizable to the Checkbox Provide suitable sample parts for every parts type in accord ance with the following specifications The sample parts show all the characteristics which a part classified as good should possess Use different sample parts with a usual scatter of fea tures With the scatter of features you can determine the extent to which test parts later classified as good may deviate from each other 5 3 5 Teaching parts with the Checkbox Small rotationally symmetric parts are particu
75. ox EN en 0103c Identbox Countbox Sortbox Switch on operating mode SELECT with the key switch The LCD TOLERANCE shows the current memory group and the tolerance in per cent Load the teach data parts type Load teach data Press the keys TOLERANCE and sorting program at the same time 1 Press the keys TOL Select the memory group with ERANCE and at TOLERANCE or the same time Select the parts type with TYPE 2 Select the memory SELECT group with TOLER ANCE or Set the Set the tolerance with TOLERANCE or tolerance with standard setting 5 min 1 TOLERANCE Enable the orientations all orientations or standard or block only the nominal orientation setting 5 96 with the illluminous button on the LCD min 1 96 COUNTER Set the counter function or display Press COUNTER and at the same time Set the nominal number COUNTER 4 or Supply several test parts of the current parts type good bad incorrectly orientated LCD TOLERANCE shows briefly one after the other the test part deviation the position deviation Evaluation 1 Visual check check of the blow down positions and the blow down procedure 2 Max feature deviation of the test part test part deviation 100 Check of orientation position deviation 100 Check influence of the tolerance B Brief instructions Step LCD TOL Identbox Count
76. parts conveyor will switch off Checks of the position and of the buffer zone can be made at the same time Production count A continuous counter ascertains the sum of all the good parts Transport of defined amounts of components 1 10 million by specifying a nominal number of good parts Nominal number freely selectable for each parts type Sorting Simultaneous transport of different parts types from a small parts amount Sorting into different buffer zones Commissioning Putting together a parts assortment Transport of defined amounts of components 1 10 million by specifying a nominal number of good parts Nominal number freely selectable for each parts type Festo P BE Checkbox EN en 0103c 1 5 1 System summary 1 4 Components of the Checkbox Controller ls El Conveyor unit Conveyor belt Stop edge Conveyor unit camera housing e e Fig 1 1 Components of the Checkbox The Checkbox consists of two compact modules The controller with control panel 1 0 interfaces configurable test functions Conveyor unit with high quality line camera LED light strip and conveyor belt suitable for industrial use An encoder can be fitted onto the conveyor unit The variants of the conveyor unit are dis tinguished by the following the maximum size of the conveyed part the camera resolution the belt speed the direction of movement o
77. pter A 3 3 6 2 4 Checking the orientation During the test procedure the Checkbox ascertains whether the orientation of the test part just scanned can be assigned to the orientations of the sample part ee The LCD TOLERANCE shows the result after the display of the test part deviation for 1 5 seconds Display Evaluation Meaning Test part orientation The smaller the value can be assigned the more reliably the test part orientation can be recognized Test part orientation The greater the value cannot be assigned the less reliably the clearly test part orientation can be recognized Display range 0 to 999 Festo P BE Checkbox EN en 0103c 6 13 6 Testing parts with the Checkbox 6 2 5 Influence of tolerance on the test result When a new parts type is taught the features of all scanned parts are recorded The values of the registered features usually differ from each other For each feature there is then a value range bandwidth in which test parts are graded as good By means of the tolerance setting you can extend this bandwidth Especially with critical conveyed parts you should ascertain the optimum setting of the tolerance before switching to the AUTO mode Further information on the toler ance computational algorithm can be found in chapter A 3 1 5 Make sure that the LCD TOLERANCE shows the current mem ory group e g 1 and the current tolerance e g 5 Set the tolerance as follows
78. puts Screw the plug into the connection Sensors Also insert the plug Controller wired at the factory into the connection Controller B 4 Festo P BE Checkbox EN en 0103c B Brief instructions Festo P BE Checkbox EN en 0103c Sortbox Operating requirements Without buffer zone sensors Screw the plug Sensors wired at the factory into the connection Sensors Also insert the plug Controller wired at the factory into the connection Controller With 1 buffer zone sensor at the connection Sensors e Use the plug Sensors without the bridge fitted at the factory with the sensor connected at sensor input 1 with unused input 2 connected to 24 V DC Screw the plug into the connection Sensors Also insert the plug Controller wired at the factory into the connection Controller With two buffer zone sensors at the connection Sensors e Use the plug Sensors Without the bridge fitted at the factory With sensors connected at both sensor inputs Screw the plug into the connection Sensors Also insert the plug Controller wired at the factory into the connection Controller With more than two buffer zone sensors at the connection Sensors Use the plug Controller if you wish to connect more than two buffer zone sensors Without the bridges fitted at the factory between the sensor inputs and 24 V DC
79. re con nected directly to the outputs actuators 1 2 These outputs are set at 24 V DC if the parts test delivers the following result incorrectly orientated or superfluous good part bad or foreign part If the Checkbox recognizes a test part as a good part pin 0 30 actuator 3 will be set from rest potential O V to 24 V DC Signal level Actuators 1 3 Pin Connection Controller of the Identbox Countbox Actuator 1 The 24 V DC signal is present when the test part passes the reject nozzle for incor rectly orientated or superfluous good parts The duration of the signal corre sponds to the time the part requires to pass the nozzle Actuator 2 The 24 V DC signal is present when the test part passes the reject nozzle for bad or foreign parts The duration of the signal corresponds to the time the part requires to pass the nozzle Actuator 3 The 24 V DC signal is present when the good part passes the end of the system edge guide rail of the conveyor unit 3 14 Festo P BE Checkbox EN en 0103c 3 The 1 0 module on the Checkbox Festo P BE Checkbox EN en 0103c The outputs 0 1 0 11 0 20 0 29 are intended as an option for further actuators If the appropriate periphery is present four further reject positions can be installed via these out puts Note the following when evaluating the output sugnals Actuators by means of a higher order controller If the test parts are passed throu
80. re otherwise orientated are blown down 6 1 5 Set counter function Countbox Sortbox Festo P BE Checkbox EN en 0103c In order to select the counter function the counter display and the counter setting use the buttons COUNTER and 4 Setting Display 1 Current counter status Production Pcod Preselected nominal number Preselect P E Current Actual counter status HcE Counter function Good parts counting All good parts are counted continuously Good parts counting with preselected number of items All good parts are counted until the nominal number is reached The set nominal number or the current counter status as desired is then shown on the LCD COUNTER 1 Display only in AUTO mode The counter function is not activated in the operating modes TEACH and SELECT 6 Testing parts with the Checkbox Select counter function Reset counter Setting the nominal number 6 8 Press briefly the buttons COUNTER and simultaneously With each further pressing of the buttons you change to the next counter function The current setting is shown on the LCD COUNTER The current counter status is usually reset by a signal from the higher order controller see chapter 3 4 In order to set the counter status manually to O 1 Select the setting Actual Act or Production Prod 2 Hold the buttons COUNTER and pressed down at the same time for at least 3 s until the d
81. rror Quit with STATUS button Increase tolerance Repeat teach procedure with more sample parts Select correct sample part with TYPE SELECT buttons Reduce tolerance With CheckOpti Optimize the teach data Check connection to controller With CheckKon Modify blow down timing point Modify nozzle geometry A 3 A Technical appendix Problem Conveyed parts facing wrong way at end of conveyor belt When a new sample part has been learnt good test parts are sorted out as bad parts Blow down timing point duration of the Checkbox is not correct Test part deviation is shown unusually long on LCD TOLERANCE A 4 Cause Conveyed parts are turned the wrong way due to un evenness of the system edge or Conveyed parts are turned the wrong way when previ ous following parts are blown down Teach procedure interrupted with STOP button Checkbox runs in diagnostic mode setting via CheckKon or CheckOpti Remedy Close the compressed air restrictor Observe the conveyed parts at the end of the conveyor belt Turned Replace system edge open compressed air restrictor Not turned Open com pressed air restrictor reduce the blow down duration with CheckKon or increase the dis tance between conveyed parts Repeat teach procedure for new sample part Conclude teach process Do not press the STOP button but use the key switch to switch to operating mode SELECT
82. rt Festo P BE Checkbox EN en 0103c 3 The 1 0 module on the Checkbox 3 5 Counter reading check Countbox Sortbox Good parts counting with preselected number of items When the last good part of a counting process reaches the reject position for bad or foreign parts output 0 13 will be switched from LOW gt HIGH nominal number reached via the connection Controller In order to start the counting cycle again you must switch output 1 32 from LOW gt HIGH The Checkbox then resets out put 0 13 from HIGH gt LOW and begins the new counting cycle Pin Signal level Meaning 1 32 HIGH Starts the new counting cycle 0 13 HIGH Preselected counter reading of all parts types reached 0 13 LOW Preselected counter status not yet reached Pulse time diagram Counter reading check Pin 1 32 Start new counting cycle 100 ms lt ts lt 500 ms Pin 0 13 Preselected counter reading reached tpc Max 600 ms sc start counting cycle pc preselected counter status Festo P BE Checkbox EN en 0103c 3 13 3 The O module on the Checkbox 3 6 Displays at the transfer position The number and arrangement of the delivery positions can vary depending on the Checkbox version The following dia gram refers to the standard configuration set at the factory pud Standard transfer positions of the Identbox Countbox on a d S conveyor unit with 2 reject positions The compressed air valves of the reject positions a
83. ssories Accessories Cable for buffer zone sensors Adapter cable Duo cable order no 18 685 Extension cable 2 5 m order no 18 684 Extension cable 5 m order no 18 686 in various lengths Mounting plate supply Mounting plate exit Festo P BE Checkbox EN en 0103c A 27 A Technical appendix A 28 Festo P BE Checkbox EN en 0103c Brief instructions Appendix B Festo P BE Checkbox EN en 0103c B 1 B Brief instructions Contents B Brief instructions B 2 Festo P BE Checkbox EN en 0103c B Brief instructions Commissioning Switching on Operating modes Festo P BE Checkbox EN en 0103c Procedure Before switching the Checkbox on you must carry out the following steps 1 2 Fit the modules Connect the compressed air supply Connect the power supply Connect the plugs provided see table Operating requirements The 4 pin plug Sensors for connecting the buffer zone sensors 1 2 or for wiring unused sensor inputs with the reference voltage The 37 pin Sub D plug Controller for connecting the power supply for the I O modules and for connecting buffer zone sensors or for wiring unused sensor in puts with the reference voltage Switch on the Checkbox as follows 1 Actuate the mains switch on the connection side of the controller Start the Checkbox by pressing the green illuminated START button on the control panel of the controller The conv
84. sto P BE Checkbox EN en 0103c 6 Testing parts with the Checkbox e Festo P BE Checkbox EN en 0103c The switch position of the illuminous button on the LCD COUNTER influences the counter function Depending on the switch position only good parts in the nominal orientation or good parts in all learnt orientations will be counted Button Influence on counter function All good parts in learnt orientations will be counted OFF Only good parts in nominal orientation will be counted Good parts counting with preselected number of items The following applies to the standard design of Checkbox If the preset nominal number of a parts type is reached all further good parts of that parts type will be blown down at the delivery position for superfluous good parts until the small parts conveyor is switched off Foreign or bad parts will be further rejected at the appropriate delivery position Countbox As soon as the nominal number is reached the LCD COUNTER will show the information FULL After the preset time e g 30 s the small parts conveyor will be switched off Sortbox As soon as the nominal number is reached the LCD COUNTER for the relevant parts type will show the information FULL As soon as the preset nominal numbers of all parts types are reached the LCD shows COUNTER FULL and flashes at 1 sec ond intervals After the preset time the small parts conveyor will be switched off 6 17 6 Testing parts with
85. sto P BE Checkbox EN en 0103c Observe the Checkbox displays during the test procedure When a conveyed part is registered the status display will light up briefly The display TOLERANCE will light up for 1 5 seconds Status displays during the test procedure Evaluating the test part deviation Evaluating the test part orientation if more than one orientation has been learnt The following methods or criteria will assist you in evaluating the teach data and the test results Visual check chapter 6 2 2 Checking the features chapter 6 2 3 Checking the orientation chapter 6 2 4 Influence of the tolerance chapter 6 2 5 If too many good parts are rejected as bad parts e Increase the tolerance Please refer here to the informa tion in chapter 6 2 5 e Repeat the teach procedure with more sample parts using the conveyor device intended for use in automatic mode If the checked parts are graded reliably according to orienta tion and quality e Press the STOP button e Switch to the AUTO operating mode in order to start the automatic test chapter 6 3 6 11 6 Testing parts with the Checkbox 6 2 2 Visual check If the quality check and the position recognition for the parts assortment is not sastisfactory you can use aditional operat ing parameters and tools with CheckOpti in order to optimize the test results Please consult your technical advisor in this respect Check the tes
86. t Please note There must be an overpressure of 4 6 bar in the operating modes SELECT and AUTO Only in this way can you be sure that bad or incorrect parts are blown down and are not deposited in the following machine Compressed air connection Connecting the controller Fig 2 3 Connections of the conveyor unit gt Please note Use the Checkbox only with the compressed air tubing from Festo included in delivery part no 152 587 8 mm 3 m long quick coupling plug Connect the Checkbox conveyor unit to the compressed air supply as follows Insert the end of the compressed air tubing intended for the screw connector into the Quickstar plug connector on the conveyor unit e Provide the connection to the compressed air supply via the quick coupling plug on the compressed air tubing e Use a screwdriver to set the blow down pressure on the restrictors of the reject valves so that the conveyed parts can be reliably blown down 2 8 Festo P BE Checkbox EN en 0103c 2 Fitting and Installation 2 3 Operation without buffer zone sensors Controller X4 Sensors X3 Fig 2 4 Connecting the plugs Controller and Sensors For operation without buffer zone sensors all sensor inputs of the connections Controller and Sensors must be set to HIGH Only in this way is the Checkbox ready to operate Otherwise the LCD TOLERANCE will show the status FULL in the operating mode AUTO All goo
87. t results e g according to the following points of view Have the orientations been recognized correctly Is the grading of the parts recognized as good bad correct Use the sample parts to check the test parts with regard to their grading If you have also checked faulty parts check whether these have actually been recognized as bad Use as many test parts as possible to make sure that they are correctly output at the delivery positions for good bad or incorrectly orientated parts Note the explanations on the test procedure in the following chapter sections 6 2 3 and 6 2 4 If necessary optimize the test result via the influence of the tolerance chapter 6 2 5 6 2 3 Checking the features 6 12 The individual features of the test parts differ from the aver age values of the sample part features The Checkbox ascer tains for each test part the feature which deviates the most maximum deviation During the test procedure you can see this test part deviation for 1 5 seconds in the TOLERANCE display Festo P BE Checkbox EN en 0103c 6 Testing parts with the Checkbox Display Evaluation Remark Good part The smaller the value the more exact the test part corresponds to saved sample parts Bad part The greater the value the less the test part corres ponds to saved sample parts Display range 0 to 999 Detailed instructions on the test part deviation computa tional algorithm can be found in cha
88. that failure to observe this instruction may result in damage to property The following pictogram marks passages in the text which describe activities with electrostatically sensitive compo nents Electrostatically sensitive components may be damaged if they are not handled correctly X Festo P BE Checkbox EN en 0103c Contents and general instructions Festo P BE Checkbox EN en 0103c Marking special information The following pictograms mark passages in the text contain ing special information Pictograms Information Recommendations tips and references to other sources of information Accessories Information about suitable accessories Environment Sections dealing with environmetal aspects Identbox Countbox Sortbox Information which only applies to a certain design of Check box Identbox Countbox or Sortbox Text markings e The bullet indicates activities which may be carried out in any order 1 Figures indicate activities which must be carried out in the sequence shown from top to bottom Hyphens indicate general activities Xl Contents and general instructions XII Conventions Operating and display components of the controller are represented in the text in upper case letters e g TYPE SELECT TOLERANCE Supplementary details are shown in square brackets Example TYPE SELECT 1 indicates the luminous button 1 of the button group TYPE SELECT Inputs and outputs of the plug conn
89. the Checkbox The following functions are type specific A Pin Title Function Identbox Parts type bit O External type selection Parts type bit 1 Parts type bit 2 Parts type bit 3 Parts type bit 4 Countbox Start new counting cycle Counter reading check Preselected counter read ing reached Parts type bit O External type selection Parts type bit 1 Parts type bit 2 Parts type bit 3 Parts type bit 4 Start new counting cycle Counter reading check Preselected counter read ing of all parts types reached Sorting program bit O External sorting program Sorting program bit 1 selection Sorting program bit 2 Sorting program bit 3 Festo P BE Checkbox EN en 0103c 3 9 3 The O module on the Checkbox 3 4 3 10 Start stop mode Remote controlled starting presupposes that the Checkbox has been switched on with the mains switch The Checkbox is started with a change of signal at pin 1 33 LOW gt HIGH and stopped again by a change of signal HIGH gt LOW Pin Signal level Meaning 1 33 LOW gt HIGH Starts the Checkbox HIGH gt LOW Stops the Checkbox 1 Apply LOW for Ya second Deleting the error 2 Apply HIGH permanently The following applies with alternating control either by man ual operation or via the I O module After a manual start If the Checkbox is switched on with the START button it can still be switched off with the change of signal HIGH gt LOW stop signal at pin 1 33 After a
90. the Checkbox As soon as the last good part reaches the deliveryy position for foreign bad parts the counting process is finished In order to start a new counting process the Checkbox requires the signal Start new counting cycle from the higher order controller Information on the I O dialogue can be found in chapter 3 5 Manual resetting of the counter status is only possible in the operating mode SELECT see chapter 6 1 5 6 3 4 Modifying operating parameters All settings of the Checkbox are to be made in the operating mode SELECT Please refer here to the explanations in chapter 6 1 1 6 2 5 6 18 Festo P BE Checkbox EN en 0103c Maintenance Chapter 7 Festo P BE Checkbox EN en 0103c 7 Maintenance Contents 7 Maintenance vw siii iio e tree leo eer n an een n ra 7 1 7 1 General sac ened Yl be SH ea te AAA rael a 7 3 7 2 Cleaning ui a ee sce a A st 7 3 7 2 Festo P BE Checkbox EN en 0103c 7 Maintenance 7 1 General The Checkbox has been designed for rough industrial envi ronments and is distinguished by high reliability robust structure and long service life Special maintenance is not required A Warning Before undertaking cleaning or maintenance work switch off the following sources of energy the compressed air supply the power supplies 7 2 Cleaning Cleaning the Checkbox Remove dirt on the housing operating elements and con veyor belt with a soft moist cloth gt Pleas
91. the following steps e Keep a record of your work Register the next parts type in a further teach procedure In order to do this repeat all the steps as from section 5 4 e Check the completed teach procedure in test mode and pay attention to orientation and quality as described in chapter 6 5 12 Festo P BE Checkbox EN en 0103c Testing parts with the Checkbox Chapter 6 Festo P BE Checkbox EN en 0103c 6 1 6 Testing parts with the Checkbox Contents 6 Testing parts with the Checkbox cece cece cece cece ence 6 1 6 1 Preparing the test procedure cee eee eee eee ee eee eee 6 3 6 1 1 Set operating mode SELECT 0 eee eee eh 6 3 6 1 2 Load the teach data eee cc cence een n 6 4 6 1 3 Setithe tol rande 12s lel a aid 6 6 6 1 4 Enable the orientations Countbox Sortbox o o ooooooooooo 6 7 6 1 5 Set counter function Countbox Sortbox ooooooooronoooo o 6 7 6 2 Testmode 22 era uua ne dada RA sce EE edt oa ted 6 10 6 231 Proceed as follo WS esans ea aia bei 6 10 6 232 Visualeheck s ois a eke aad ls nd ed 6 12 6 2 3 Checking the features 0 eee cece ee 6 12 6 2 4 Checking the orientation 2 0 cece eee eee nee 6 13 6 2 5 Influence of tolerance on the test result o ooooooooooommo 6 14 6 3 Automaticimode 2006 ene ec A ee be VT 6 15 6 3 1 Setoperating mode SELECT cece eee eee 6 15 6 3 2 Manualstart stop m
92. the individual steps can be found in the fol lowing sections 5 2 1 Addressing teach data KY YV M A During the teach procedure the data of each parts type are saved in memory groups by means of memory addresses Maximum 6 different parts types can be addressed in a mem ory group Maximum 8 orientations can be assigned to each parts type A total of 48 parts types can be addressed depending on the number and assignment of the memory groups The number of memory groups and the number of orientations per parts type is configured at the factory number of memory groups x number of parts types x number of orientationss per parts type maximum 96 Sortbox With the Sortbox the sorting program is specified by the as signment of a memory group The number of sorting pro grams corresponds therefore to the number of memory groups of the Checkbox Festo P BE Checkbox EN en 0103c 5 Teaching parts with the Checkbox L The display TOLERANCE shows memory group 1 when the TEACH mode is switched on Address the teach data as fol lows 1 Set the memory group Set the desired memory group with the keys and on the TOLERANCE display 2 Determine the parts type Select with one of the TYPE SELECT keys 1 6 the number which is to be assigned to the parts type When the parts type has been addressed the Checkbox starts the conveyor belt automatically and you can start scan ning the sample parts tool If when
93. the parts type is selected in the LCD TOLERANCE the information tool is shown the memory address is assigned with additional software tools The teach procedure can nevertheless be carried out Further information can be found in the CheckOpti manual 5 2 2 Scanning sample parts The conveyor belt runs during the complete scanning pro cedure If you press the STOP button the teach procedure will be discontinued The currently registered data will be ignored and the complete teach procedure must be repeated Festo P BE Checkbox EN en 0103c 5 7 5 Teaching parts with the Checkbox Positioning sample parts The TOLERANCE display shows orientation 1 nominal orienta tion Make sure that the sample parts are positioned in ac cordance with the orientation shown Show at least six parts of the current type per orientation If possible use different parts but if necessary the same part can be shown several times Carry out the teach procedure as realistically as possible Use e g the conveyor unit and supply device intended for this purpose Place the sample parts on the conveyor belt one after the other They should be positioned exactly like the parts to be tested later Avoid particular care at first in placing the parts In cases where particularly different variations of the as certained parts contour view are permitted or are pos sible in an orientation you should show the extreme variations or as large a
94. ts A 13 G Good parts counting 3 13 6 7 6 17 Setting the nominal number o o o ooooo o 6 8 l 1 O module Functions 212 4 ditat el uber oe o ee th 3 3 Power supply 02 eee eee eee eee 2 11 3 5 Reference voltage 0 eee cece een nes 3 7 L LCD COUNTER x22 Re ERR RSEN 4 3 A 10 TOLERANCE cs as ER 4 3 A 10 N Nominal number cee eee eee 6 17 Nominal orientation ooooooo o o 5 8 6 7 Numerical representation 0000 A 15 O Operating modes 0 2 eee eee eee 4 3 4 6 Operating parameters oococcocccooccocc ee 6 18 Operating system 0 eee eee eee eee XIII C C 6 Index Orientation CHECKING scm RETE ERE Exe 6 13 Enabled cet C A 6 7 Number cbe eau SERE TQUE PR 5 6 TEACH iaa dee tee oo e de be e 5 8 5 10 P Parts type N thber 5 tadas trt e Ree ana 5 6 Pin assignment 0 ccc cece eee eee nee eee ene A 21 Power supply for the I O module External side ta iat Vedi RIEN 3 6 Intertial osx ns eet Galaga otis Rud AREE 3 5 Pulse time diagram Changing the parts type lisse esses 3 20 Changing the sorting program 3 20 Counter reading check oooooooomoomooo 3 13 Start stop mode 0 cece eee eee 3 11 5 Sample parts 0 cee eee eee eese 5 3 5 7 Scatter of characteristics o oooooo o 5 8 A 18 SELECT 55 aa Were tina ER C
95. w in order to ensure a reliable supply of parts from the small parts con veyor onto the conveyor belt Ensure also the transfer of parts from the conveyor belt to the buffer zone e g drop pipe slide shaker of the next machine by mechanical devies You can obtain mounting plates as accessories for fastening mechanical supply or delivery guides to the conveyor unit Connecting the controller There are plug connectors on the side of the controller for periphery devices control and signal connections Further information on the individual connections can be found in the chapters which follow Controller X4 Conveyor unit with camera hybrid cable X5 Mains cable Diagnostic interface X1 Small parts conveyor X2 Buffer zone sensors X3 la e le e e El Fig 2 1 Connections and interfaces of the controller Festo P BE Checkbox EN en 0103c 2 5 2 Fitting and Installation 2 2 Power supply connections of the controller 2 2 1 Electrical connection Warning A Before carrying out installation and maintenance work always switch off the power supply Connect the devices only when they are switched off The power supply for the Checkbox must comply with the following requirements Voltage range 85 V to 264 V Frequency 50 Hz 60 Hz The power unit of the Checkbox automatically recognizes the voltage applied Adjustment by hand is not necessary Warning Connect the Checkbox only wh

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