Planar surface gantry EXCM-40 - Festo€¦ · – Design engineer – Machine manufacturer – Installer – Commissioner Only qualified personnel may perform mounting, installation,

Instructions

Mechanical

installation

8058760

1602

[8058762]

EXCM-40

Planar surface gantry

EXCM-40

2 Festo – EXCM-40-EN – 1602 – English

Translation of the original instructions

EXCM-40-EN

LOCTITE® is a registered trademark of its respective trademark holder in certain countries.

Identification of hazards and instructions on how to prevent them:

Danger

Immediate dangers which can lead to death or serious injuries

Warning

Hazards that can cause death or serious injuries

Caution

Hazards that can cause minor injuries

Other symbols:

Note

Material damage or loss of function

Recommendations, tips, references to other documentation

Essential or useful accessories

Information on environmentally sound usage

Text designations:

� Activities that may be carried out in any order

1. Activities that should be carried out in the order stated

– General lists

� Result of an action/References to more detailed information

EXCM-40

Festo – EXCM-40-EN – 1602 – English 3

Table of Contents – EXCM-40

1 Requirements for product use 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Target group 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Intended use 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Possible misuse 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Applicable documents 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Obligations of the machine manufacturer 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Service 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Transport and storage 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Restraints in the packaging 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Product overview 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Configuration 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Functional principle 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Permitted mounting position 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Mounting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Safety instructions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Preparation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Installation space 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Mounting surface 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.3 Mounting points 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.4 Types of mounting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.5 Mounting components 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.6 Transport restraints 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Installation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Aligning and adjusting the product 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Mounting profile covers 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 Aligning and adjusting X-axis 1 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3 Aligning and adjusting X-axis 2 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.4 Aligning X-axes parallel with each other 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.5 Checking the toothed belt pretension 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.6 Setting the toothed belt pretension 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Optional work 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Positioning mounting components 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.2 Manually moving the Y-axis (traverse) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.3 Attachments on the energy chain 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.4 Dismantling/mounting motors 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.5 Adapting cable outlets 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXCM-40


4.6 Attachment components 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Power supply line 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Accessories 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 X-axis proximity sensor 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2 Y-axis (traverse) proximity sensor 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Installation 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.2 Electrical installation 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Multi-pin plug distributor 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Drive motors of the X-axis/Y-axis 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 Electrical attachment component 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.4 Earthing 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Pneumatic installation 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Commissioning 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Maintenance 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


7.2 Cleaning 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Lubrication 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Repair 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Dismantling 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


8.2 Procedure 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Recycling 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Technical appendix 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 General features 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Evenness 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.3 Approvals 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.4 Materials 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.5 Operating and storage conditions 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 Requirements for product use



1.1 Target group

� Provide this documentation to the following persons:

– Design engineer

– Machine manufacturer

– Installer

– Commissioner

Only qualified personnel may perform mounting, installation, commissioning, maintenance and disas

sembly of the product. Qualified personnel must be familiar with:

– Mounting and operation of mechatronic systems

– Installation and operation of electrical control systems

– Installation and operation of pneumatic systems

– Regulations for accident prevention and occupational safety

– Documentation and mode of operation of the product

1.2 Intended use

This product is a handling system. The handling system executes positioning tasks within machines or

automated systems with a higher-order controller.

Only use the product as follows:

– In perfect technical condition

– In its original status, without unauthorised modifications

– Within the limits of the product defined by the technical data

– In an industrial environment

Note

In the event of damage caused by unauthorised manipulation or other than intended

use, the guarantee is invalidated and the manufacturer will not be liable for damages.

1.3 Possible misuse

Never use the product as follows:

– With unauthorised modifications or alterations to the product

– In an invalid mounting position

– With load limits exceeded

– Without a risk assessment of the complete system

– Without a safety concept for the complete system



1.4 Applicable documents

Further information can be found in the support portal (� www.festo.com/sp).

1.5 Obligations of the machine manufacturer

The product is an incomplete machine. Commissioning of the product is prohibited until it has been

established that the machinery in which the product will be installed is in compliance with the provi

sions of Machinery Directive 2006/42/EC.

Take the following into consideration for the destination:

– Regulations and standards

– Regulations of the testing organisations and insurers

– National specifications

1.6 Service

Please consult your regional Festo contact if you have any technical problems.

2 Transport and storage


2 Transport and storage

Note

Damage to the product due to incorrect transport.

� Observe the transport labelling and information on the packaging.

1. Transport the product to the installation/storage location in its packaging and set it down on a firm

and flat base.

2. When storing the product please observe the storage conditions

(� A.5 Operating and storage conditions).

Note

Damage to the product due to incorrect unpacking.

� Observe the labelling for unpacking on the packaging.

� Unpack the product with at least 2 persons present.

� Use appropriate tools.

� Parts of the packaging are large and heavy:

– Do not let any parts fall onto the product.

– Use suitable aids to raise and lower the product (e.g. crane).

3. Remove the packaging in accordance with the printed sequence.

2.1 Restraints in the packaging

Transport restraints prevent uncontrolled movement of the product in the packaging during transport

and installation.

The product is provided with the following designated transport restraints:

Transport screws Cable ties

Fig. 2.1

3 Product overview


3 Product overview

3.1 Configuration

4

5

6

7

89

2

1

aJ

aA

aB

3aCX

Y

7

6

aD

1 End cap

2 X-axis 1 (with energy chain)

3 End cap with belt tensioning device

4 X-axis 2

5 Mounting component

(adjusting kit or mounting accessories)1)

6 Drive cover (with cover)2)

7 Coupling housing and motor flange3)

8 Motor 23)

9 Energy chain of the Y-axis (traverse)

aJ Y-axis (traverse)

aA Slide of the Y-axis

(for fastening the attachment component3))

aB Motor 13)

aC Multi-pin plug distributor

aD Energy chain of the X-axis

1) Depending on the order

2) Cover only for variant EXCM-…-B-… (attachment position of motors underneath)

3) Optional

Fig. 3.1 Example illustration of EXCM-40-…-B

3 Product overview


3.2 Functional principle

Two fixed stepper motors drive a toothed belt arrayed in an H-shape.

The toothed belt moves the Y-axis (traverse) and the slide located on the Y-axis (traverse) in a 2-dimen

sional space. A controller calculates the position of the slide. The controlled interaction of the motors

results in the corresponding movement of the slide.

Motor 1

Mo

tor

2

Motor 2Motor 1

Y-axis

X-a

xis

1

2

3

1

4

Fig. 3.2 Directions of move

ment (slides of the

Y-axis)

Fig. 3.3 Functional principle

1 Guide pulleys (for toothed belt)

2 Toothed belt

3 Y-axis (traverse)

4 Slide of the Y-axis

The depicted directions of movement of the Y-axis slide (Fig. 3.2) refer to the directions of

rotation of the motor of the functional principle shown (Fig. 3.3).

3.3 Permitted mounting position

Note

The product must be mounted horizontally.

Overhead mounting or other mounting positions are not permissible.

4 Mounting


4 Mounting

4.1 Safety instructions

Warning

Unexpected movement of the product.

Risk of impact and crushing injuries.

� Before working on the product, switch off the power supply and secure it against

being switched on again.

� Before working on the product, switch off the compressed air supply, vent if neces

sary and secure it against being switched on again. Pneumatic system parts can still

contain compressed air even when they are switched off.

– Vent pneumatic system parts accordingly.

� When lifting the product, perform the following measures:

– Secure movable components with transport restraints to prevent unexpected

movement.

– Observe the product weight.

– Observe the position of the centre of gravity.

– Use suitable lifting gear.

– Use all of the transport lugs.

– Adjust the lifting speed.

� When securing the product, perform the following measures:

– Secure the product in a professional manner.

– Only use the supplied mounting components.

– Secure the screw connections.

– Make sure the mounting surface is sufficiently strong to absorb the maximum

forces.

Observe the safety data sheet for adhesives (� www.festo.com/en/msds).

4.2 Preparation

Note

For mounting, Festo recommends using adjusting kits.

� After alignment, the limit values of the axis alignment must be complied with

(� Tab. A.2, page 45).

4 Mounting


4.2.1 Installation space

The installation space required for the product depends on the following factors:

– Stroke of the X- and Y-axes (� www.festo.com/catalogue)

– Attachment position and type of motor

– Sufficient clearance for movement of the axes and the attachment component (Z-axis)

– Access to belt tensioning device (� Fig. 4.20, page 24).

4.2.2 Mounting surface

The mounting surface must exhibit the following characteristics:

– Torsionally rigid

– Free of stress

– Sufficient strength to absorb the maximum forces

– Sufficient evenness ( � Tab. A.2, page 45)

4.2.3 Mounting points

L6 L7L L

L6

1 1

B6

B7

L7

B7

B8

B8

B7

23 4

1 Mounting component

2 End cap

3 Drive cover

4 Belt tensioning device

Fig. 4.1 Illustrated: EXCM-40-… with 6 mounting components

Dimensions [mm]

Thread L1) L6 L7 B6 B7 B8

Size Depth

M 8 � 14 Stroke X-axis + 141

n – 1

37.5 +2 30.5 +2 Stroke Y-axis

+ 385.8 +0.5

78.0 ± 0.

2

13.0

1) If the stroke of the X-axis 900 mm, arrange the mounting kits in equal distances.

n = number of mounting kits per X-axis (� Tab. 4.2, page 13)

Tab. 4.1

4 Mounting


4.2.4 Types of mounting

The product can be mounted in 2 ways: Namely with mounting kits or with adjusting kits.

Mounting kit

Mounting kits are only intended for mounting the product.

Note

The mounting kits are not adjustable.

� To align the product and maintain the limit values, some actions are required.

� Reordering adjusting kits (� www.festo.com/catalogue).

1 Slot nut1)

2 Adjusting plate1)

3 Hexagon head screw1) M6x30 (2x)

4 Washer2) (2x)

5 Socket head screw2) M8x40 (2x)

1) mounted

2) supplied loose

1

2

3

4

5

Fig. 4.2

Adjusting kit

Adjusting kits are intended for mounting and adjusting the product.

The adjusting kits compensate for height differences in the mounting surface of up to

5 mm.

1 Slot nut1)

2 Adjusting plate1)

3 Hexagon head screw1) M6x30 (2x)

4 Square nut1) (2x)

5 Adjusting bolt1) (2x)

6 Washer2) (2x)

7 Socket head screw2) M8x40 (2x)

1) mounted

2) supplied loose

1

2

3

4

5

6

7

Fig. 4.3

4 Mounting


The term mounting component is subsequently used to refer to the mounting kit and

adjusting kit.

4.2.5 Mounting components

The number of mounting components pre-assembled on the product depends on the stroke of the X-ax

is.

Stroke of the X-axis Number of mounting components

Total per X-axis (number n)

900 mm 4 2

900 … 1799 mm 6 3

� 1800 mm 8 4

Tab. 4.2

4.2.6 Transport restraints

1. Remove the transport screws and retain for

future use.

4 Mounting


4.3 Installation

Note

If there are temperature differences between the product and the mounting surface:

� Adapt the temperature of the product to the temperature of the mounting surface.

Observe the permissible ambient temperatures

(� A.5 Operating and storage conditions).

1. Make sure that the product and mounting surface have the same temperature.

2. Make sure that all of the transport screws have been removed.

3. Attach appropriate lifting gear to the 4 transport lugs 2 and 6 (� Fig. 4.4).

1

2

3

4

15

6

4

5

6

2

1 End cap

2 Transport lug with support plate (2x)

3 Lifting gear1) with mounting points

4 Transport restraint (2x)

5 Drive cover (motor side)

6 Transport lug (on transport restraint) (2x)

1) not included in scope of delivery

Fig. 4.4 Depicted: EXCM-40-…-B (motor attachment position underneath).

4 Mounting


Warning

Transport lugs may break if loaded incorrectly.

Danger as a result of product falling.

� Load all of the transport lugs evenly and at an angle of 45° (� Fig. 4.5).

� Do not laterally stress the transport lugs (� Fig. 4.5).

4. Adapt the transport lugs to the direction of

force of the lifting gear:

� Loosen the nuts of the lifting eye bolts.

� Turn the lifting eye bolts in the respective

direction of load (� Fig. 4.4).

� Tighten the nuts of the lifting eye bolts

(tightening torque 24 Nm).

Fig. 4.5

Warning





movement.






5. Use the lifting gear to position the product on the mounting points of the mounting surface

(� Fig. 4.1).

If mounting kits are covered by the Y-axis (traverse), this can be moved manually. To do

this, remove the motors (� 4.5.4 Dismantling/mounting motors) or release the holding

brake.

If mounting points are covered by the energy chain, this can be detached

(� 4.5.3 Attachments on the energy chain).

6. Position the product in such a way that the elongated holes of the mounting kits are located cent

rally over the prepared mounting points. Reposition the mounting components if necessary

(� 4.5.1 Positioning mounting components).

7. Secure the X-axes with screws and washers. The X-axes must be able to be moved.

4 Mounting


8. If present:

Remove the labelled transport restraints

(cable ties) from the moving parts.

9. Remove the transport restraints and transport lugs with support plates (� Fig. 4.4, page 14).

Note

Keep reusable transport restraints and the corresponding screws for future use (main

tenance, dismantling).

10.For motor attachment underneath: Mount loose covers with the supplied shorter screws (M5 x 40)

(tightening torque 8.3 Nm).

11.Manually move the Y-axis (traverse) back and forth over the entire stroke of the X-axes

(� 4.5.2 Manually moving the Y-axis (traverse)).

12.Tighten the screws of all mounting kits with a reduced tightening torque (10 … 20 Nm).

13.Check the position of the cable outlets on the motors and adapt if necessary

(� 4.5.5Adapting cable outlets).

4 Mounting


4.4 Aligning and adjusting the product

Note

The product is not aligned and adjusted upon delivery. Operating the product without

aligning and adjusting it will result in malfunctions and increased wear.

� Alignment and adjustment of the product is always required.

The subsequent steps are based on the use of adjusting kits. When using mounting kits,

some actions are required to align the product and maintain the limit values

(� A.2 Evenness).

Required aids:

– Precision spirit level (accuracy at least 0.05 mm/m)

– Steel straightedge (straightness at least 0.05 mm/m)

– Inspection bases (2x):

– Adjusting tool (accessories) (� www.festo.com/catalogue) or

– Final dimensions (height at least 10 mm, width max. 40 mm, accuracy 0.05 mm/m)

4.4.1 Mounting profile covers

1. Unscrew the screws from the profile covers.

� If required, move the already loosened energy chain.

2. Remove profile covers.

1

23

1 Screw of the profile cover

(tightening torque 1 Nm)

2 Profile cover of the X-axis

3 Energy chain of the X-axis

Fig. 4.6

4 Mounting


4.4.2 Aligning and adjusting X-axis 1

1. Place the inspection base onto the guide rail in the area of the adjusting kit of X-axis 1 (with energy

chain).

Checking evenness

2. Make sure that the inspection base 3 lies cor

rectly on the guide rail.

3. Check the guide rail 1 in the area of the ad

justing kit 2 for evenness by using a precision

spirit level 4.

� Setpoint value: � 0.1 mm/m

(� A.2 Evenness)

3

4

1

2

Fig. 4.7

Checking sideways tilting


rectly on the guide rail.


justing kit 2 for sideways tilting by using a

precision spirit level 4.


(� A.2 Evenness)

1

23

4

Fig. 4.8

Adjustment

6. Loosen one of the screws 7 on the adjusting

kit.

7. Screw the corresponding adjusting bolt 5 in

or out (h = 6 … 11 mm).

Use a spanner with a width of . 5 mm.

Observe sufficient screw-in depth of the screw

(for steel › 8 mm).

5

7

Fig. 4.9

4 Mounting


8. Apply counter pressure to the adjusting

bolt 5 to maintain alignment.

9. Tighten the screw 7 (tightening torque

24 Nm).

10.Repeat the previous steps for all adjusting

kits. 5

7

Fig. 4.10

11.Inspect the guide rail of the X-axis 1 again for compliance with the limit values for evenness and

sideways tilting.

� The X-axis 1 is aligned and now forms the basis for further alignment of the product.

4.4.3 Aligning and adjusting X-axis 2

Checking height offset

1. Place inspection bases 3 onto the two guide rails 1 and 6 in the area of the opposing adjusting

kits 2 (� Fig. 4.11).

2. Make sure the inspection bases lie correctly on the guide rails.

3. Place the steel straightedge 5 onto the two inspection bases.

4. Use a precision spirit level 4 to check the guide rail of X-axis 2 6 in the area of the adjusting kit for

an offset in height in relation to the already aligned guide rail of X-axis 1 1.

� Setpoint value: � 0.1 mm/m (� A.2 Evenness)

1 3

4

5

6

2

3

Fig. 4.11

4 Mounting


Checking evenness


rectly on the guide rail 8 of X-axis 2.

6. Check the guide rail in the area of the adjust

ing kit 2 for evenness by using a precision

spirit level 4.


(� A.2 Evenness)

3

4

2

8

Fig. 4.12

Checking sideways tilting


rectly on the guide rail 8 of X-axis 2.


justing kit 2 for sideways tilting by using a

precision spirit level 4.


(� A.2 Evenness)2

3

4

8

Fig. 4.13

4 Mounting


Adjustment

9. Loosen one of the screws 7 on the adjusting

kit.

10.Screw the corresponding adjusting bolt 5 in

or out (h = 6 … 11 mm).

Use a spanner with a width of . 5 mm.

Observe sufficient screw-in depth of the screw

(for steel › 8 mm).

5

7

Fig. 4.14

11.Apply counter pressure to the adjusting

bolt 5 to maintain alignment.

12.Tighten the screw 7 (tightening torque

24 Nm).

5

7

Fig. 4.15

13.Repeat the previous steps for all adjusting kits.

14.Inspect the guide rail of X-axis 2 again for compliance with the limit values for height offset in rela

tion to X-axis 1, evenness and tilting.

� X-axis 2 is aligned.

4.4.4 Aligning X-axes parallel with each other

1. Loosen all of the screws of the adjusting kits one after the other on X-axis 2 by a ¼ turn. When do

ing this, apply counter pressure to the adjusting bolts to prevent them from turning.

2. Manually move the Y-axis (traverse) back and forth over the entire stroke of the X-axes to establish

the parallelism of the X-axes (� 4.5.2 Manually moving the Y-axis (traverse)).

3. Move the Y-axis (traverse) to the motor side. Tighten the screws of the adjusting kit located at this

position of X-axis 2 (tightening torque 24 Nm).

4. Move the Y-axis (traverse) to the next adjusting kit. Tighten the screws of the adjusting kit located

at this position of X-axis 2 (tightening torque 24 Nm).

5. Repeat the process for all of the other adjusting kits on X-axis 2.

6. Inspect both guide rails again for compliance with the limit values for evenness, sideways tilting and

height offset (� A.2 Evenness).

4 Mounting


Eliminating warping in the product

Note

Warping in the product can result in malfunctions and increased wear and thus a re

duced service life.

1. Loosen each of the 8 screws 4 on the side of

X-axis 2 1 by 1 turn.

2. Manually move the Y-axis (traverse) 2 back

and forth over the entire X-stroke to eliminate

warping (� 4.5.2).

3. Unscrew a screw 4, secure with Loctite 243

adhesive and screw tight immediately (tight

ening torque 5.9 Nm).

4. Repeat this process for all screws 4.

3 14 42

Fig. 4.16

4.4.5 Checking the toothed belt pretension

Note

Incorrect toothed belt pretensioning can damage the product. Possible consequences:

– Reduced service life of the toothed belt, guides and ball bearings

– Altered performance of the product

– Impaired positioning accuracy

– Position errors and risk of collision caused by skipping of the toothed belt

Remedy: Check and adjust the toothed belt pretensioning in the following cases:

– After installing the product for the first time

– After the initial commissioning phase (after approx. 30 strokes at operating temper

ature)

– After removal/installation or replacement of the toothed belt

The toothed belt pretensioning can be inspected with mounted or dismounted profile

cover of the X-axis.

Use an acoustic frequency meter to check the toothed belt pretensioning.

4 Mounting


1. During initial start-up:

Remove motors with holding brake

(� 4.5.4 Dismantling/mounting motors).

After commissioning:

Release holding brake.

2. Place the belt tension setting piece 4 on the

guide rail 2 between the drive cover (motor

side) 3 and carriage 5.

3. Slide the Y-axis (traverse) 1 with the carriage

against the belt tension setting piece.

� The distance dimension of 144.4 mm (L11)

for checking is set.

3

1

4

2

5

Fig. 4.17

4. Align the probe 8 underneath the belt ten

sion setting piece 4 in the middle of the

toothed belt 7. When doing this do not touch

the toothed belt.

4

6

7 8

Fig. 4.18

Note

The toothed belt must be able to vibrate freely and must not touch the probe of the

frequency measurement device. For evaluation of the toothed belt pretension, perform

several measurements to balance out any measurement tolerances.

5. Make the toothed belt vibrate by hitting it once with a slim, heavy object (e.g. an Allen key 6).

6. Read the self-generated frequency of the toothed belt on the frequency meter. The measured value

must be in a frequency range of 150 … 160 Hz.

� If the measured value is within this tolerance range, the toothed belt has the correct pretension.

� If the measured value is outside this tolerance range, the toothed belt pretensioning must be

adjusted.

4 Mounting


4.4.6 Setting the toothed belt pretension

Note

The toothed belt pretensioning diminishes during storage and operation. This is normal

and must not be changed by increasing the tension of the toothed belt. The reduced

pretension is not suitable for evaluating the level of wear of the toothed belt.

1. Unscrew the 2 threaded pins 1.

� The locking element of the belt tensioning

device is released.

1

Fig. 4.19

Note

Clockwise rotation of the adjusting screws will increase the tension and frequency of

oscillation of the toothed belt.

Anti-clockwise rotation of the adjusting screws will reduce the tension and frequency of

oscillation of the toothed belt.

2. Change toothed belt pretensioning by evenly

turning the 2 adjusting screws 2.

3. Move or travel the Y-axis (traverse) once over

the entire stroke of the X-axis. This causes the

toothed belt to fully settle and equalises dif

ferences in tension.

2

Fig. 4.20

4 Mounting


4. Check the toothed belt pretensioning

(� 4.4.5 Checking the toothed belt pretension).

Repeat this process until the measured value is

within the specified frequency range.

5. Secure the toothed belt pretensioning by

screwing in the 2 threaded pins 1


6. Pull out belt tension setting piece.

1

Fig. 4.21

Note

Within the framework of the initial start-up phase, check the toothed belt tension again

after 30 strokes (� 4.4.5 Checking the toothed belt pretension) and adjust if necessary

(� 4.4.6 Setting the toothed belt pretension).

7. Mount the profile covers of both X-axes (tightening torque 1 Nm) (� 4.4.1 Mounting profile covers).

8. Secure the energy chain to the retainers with the screws and nuts

(tightening torque 2.9 Nm) (� 4.5.3 Attachments on the energy chain).

Use Loctite 243 adhesive.

9. For motors with holding brake: Mount drive motors of the X-axes

(� 4.5.4 Dismantling/mounting motors)

4.5 Optional work

4.5.1 Positioning mounting components

The mounting components are supplied pre-positioned. If required, these may be moved within the

mounting tolerance.

1. Prepare threaded holes in the mounting surface

(� Fig. 4.1) and (� Tab. 4.1).

2. Loosen hexagon head screws 3 half a turn.

3. Position the mounting component 2

(� 4.2.3 Mounting points).

4. Tighten hexagon head screws 3

(tightening torque 9.9 Nm).

32

Fig. 4.22

4 Mounting


5. Place washers 6 under the socket head screws 7.

6. Secure the mounting component 2 to the mount

ing surface with socket head screws 7.

7. Tighten socket head screws 7


77

6

2

Fig. 4.23

4.5.2 Manually moving the Y-axis (traverse)

The Y-axis (traverse) can be moved manually for mounting and alignment purposes. The Y-axis (tra

verse) is secured against uncontrolled movements with transport restraints (cable ties) when delivered.

1. Remove the labelled transport restraints (cable

ties) from the moving parts.

2. For motors with holding brake: Remove motors (� 4.5.4 Dismantling/mounting motors).

3. Manually move the Y-axis (traverse) to the desired position.

4.5.3 Attachments on the energy chain

If mounting points are covered by the energy

chain 3, this can be detached while observing

the following points:

1. Remove screw 5 and nut 4.

2. If necessary, remove screws 1 and nuts 2 on

the energy chain retainer as well.

3. Remove the metal sheet 6.

3

2

1

4

5 6

Fig. 4.24

4 Mounting


4.5.4 Dismantling/mounting motors

Note

Third-party motors with a driving torque that is too high can damage the product.

� When using third-party motors observe the following:

– Maximum permissible driving torque (� www.festo.com/catalogue)

– Mounting dimensions of motor interface (� www.festo.com/catalogue)

– Suitable combination of coupling, coupling housing and motor flange

EXCM-…-B - motor underneath EXCM-…-T - motor on top

1

2

3

4

5

6

5

4

3

2

6

1 Cover

2 Drive cover1) with drive pinion

3 Coupling housing

4 Motor flange

5 Mounting screw (4x)

6 Motor

1) With motor attachment position on top: With sealing disc

Fig. 4.25

4 Mounting


Dismantling the motors

Motors with a holding brake must be removed for mounting and aligning the product, as well as for

setting the toothed belt pretensioning.

EXCM-40-… Motor EMMS-ST-57-M…

…-SB-… …-SEB-G2 with holding brake

…-ST-… …-SE-G2 without holding brake

Tab. 4.3

1. Disconnect all of the cables from the motor.

2. Unscrew and remove the fastening screws.

3. Remove the motor.

Mounting the motors

Note

� The Y-axis (traverse) and the slide of the Y-axis must have a freedom of movement of

10 cm in both directions in order to mount the motors.

1. Position the motor.

2. Tighten the mounting screws (tightening torque 3 Nm).

3. Connect the cables to the motor.

4.5.5 Adapting cable outlets

The position of the cable outlets can be adapted to the installation situation by turning the motors in

90 ° increments.

Note

� The Y-axis (traverse) and the slide of the Y-axis must have a freedom of movement of

10 cm in both directions in order to mount the motors.

1. Disconnect the cables 3 from the motor 1.

2. Unscrew the mounting screws 2.

For motor attachment underneath:

Secure motor from falling.

3. Turn motor into the desired position.

� For motors with holding brake, the traverse

and slide of the Y-axis move

4. Tighten the mounting screws (tightening

torque 3 Nm).

5. Connect the cables to the motor.

2

13

Fig. 4.26

4 Mounting


4.6 Attachment components

Note

� Observe the following when designing and mounting attachment components:

– Reduced freedom of movement through parts of the product

– Maximum screw-in depth on the slide of 10 mm

– Documentation of the attachment component

– Limits of the product (� A Technical appendix)

Attachment components 7 are attached to the slide of the Y-axis 1 by using an adapter plate 4.

Precise alignment is carried out by means of centring sleeves 6 and cylindrical dowel pins 2

(� Fig. 4.27).

1

2

3

4

5

6

7

5

3


2 Cylindrical dowel pin

3 Screws for attachment component

4 Adapter plate

5 Screws for adapter plate

6 Centring sleeves

7 Attachment component (Z-axis)

Fig. 4.27 Illustrated: EXCM-40-…-P-… (with pneumatic attachment component)

4 Mounting


4.6.1 Power supply line

Without attachment component

(EXCM-…-T0-…)

The following pneumatic and electrical interfaces

are available for products without an attachment

component:

1 Multi-pin plug distributor (� 5.2.1)

2 Bulkhead fitting (black tubing)

3 Bulkhead fitting (silver tubing)

12

3

Fig. 4.28

With electrical attachment component

(EXCM-…-E…)


are available for products with an electrical at

tachment component:



3 Bulkhead fitting (silver tubing)

3

1

2

Fig. 4.29

With pneumatic attachment component

(EXCM-…-P…)


are available for products with a pneumatic at

tachment component:



� Connect the silver tubing for controlling the

pneumatic attachment component to the com

pressed air supply at the start of the energy

chain.

1

2

4 Mounting


4.7 Accessories

Select suitable accessories from the Festo catalogue

(� www.festo.com/catalogue).

Observe the assembly instructions for the accessories.

4.7.1 X-axis proximity sensor

The proximity sensor detects the position of the

Y-axis (traverse) 2.

A sensor mount 1 is also required for mounting

the proximity sensor (not included in the scope of

delivery). The sensor mounting and the proximity

sensor can be moved on the X-axis.

12

Fig. 4.30

4.7.2 Y-axis (traverse) proximity sensor

The proximity sensor detects the position of the

slide on the Y-axis 3

The slot for mounting the proximity sensor is loc

ated in the slide of the Y-axis 3.

The 2 switch lugs 1 for actuation of the proximity

sensor are mounted under the cover of the Y-axis

(traverse) 2.

The positions of the proximity sensor and the

switch lugs cannot be changed.

1

23

Fig. 4.31

4 Mounting


Installation

4

6

5

7

8

9

aJ

1 2 3

Fig. 4.32

aCaD

aB

aE

aF aA

Fig. 4.33

4 Mounting


1. Unscrew the screws 2.

2. Remove the retaining plate 8 and the cover 3.

3. Unscrew the screw 5 and loosen the earthing cable.

4. Unscrew the screws 7 and remove the earthing component 6.

5. Unscrew the screws 9 and remove the cross plate aJ.

6. Remove all of the cable ties 4.

7. Push the guide plate 1 with the energy chain in the direction of the arrow.

� The sensor slot aB is accessible.

8. Remove the cable clamp aE.

9. Insert the proximity sensor aC into the sensor slot aB.

10.Align the proximity sensor aC flush with the outer edge of the adapter plate aD .

11.Secure the proximity sensor aC with the supplied screw (tightening torque 0.3 Nm).

12.Insert the cable of the proximity sensor into the slot aF.

13.Mount the cable clamp aE with the 2 screws (tightening torque 1.2 Nm).

� The cable is routed within the slots aB and aF.

14.Insert the plug connecter of the proximity sensor into the multi-pin plug distributor aA

(� Tab. 5.1, sensor connection 4).

15.Position the guide plate 1 with the energy chain.

16.Position the cross plate aJ.

17.Tighten the screws 9 with Loctite 243 adhesive (tightening torque 4.0 Nm).

18.Position the earthing component 6.

19.Tighten the screws 7 with Loctite 243 adhesive (tightening torque 1.2 Nm).

20.Secure the earthing cable to the earthing component 6 with screw 5 (tightening torque 1.2 Nm).

21.Secure the cables between the energy chains with cable ties 4 for strain relief.

22.Position the cover 3 and retaining plate 8.

23.Tighten the screws 2 (tightening torque 1 Nm).

5 Installation


5 Installation


Warning







contain compressed air even when they are switched off. Vent pneumatic system

parts accordingly.

5.2 Electrical installation

5.2.1 Multi-pin plug distributor

123456 7

Sensor connections 1…6 Multi-pin plug connec

tion 7

Pin Function/assignment Pin Colour2)

1…6 1 Operating voltage 5 GY

3 0 V 7 BU

1 4 Plug socket with cable for the solenoid valve1) 1 WH

2 4 Proximity sensor1) end position top 2 BN

3 4 Proximity sensor1) end position bottom 3 GN

4 4 Proximity sensor for slide of Y-axis (optional) 4 YE

5 4 free for additional sensors 6 PK

6 4 free for additional sensors 8 RD

1) For variant with pneumatic attachment component (EXCM-…-P…)

2) in accordance with IEC 757, at the loose end of the cable

Tab. 5.1

5 Installation


Note

Unsealed sensor connections influence the degree of protection

(� A Technical appendix).

� Seal any unused sensor connections with cover caps.

5.2.2 Drive motors of the X-axis/Y-axis

Note

Before installing the motor and encoder cables - especially with regard to non-Festo

products:

� Refer to the corresponding documentation for installation information.

1 Motor connection Sub-D (9-pin)

(� Tab. 5.2)

2 Encoder connection M12 (8-pin)

(� Tab. 5.3)

12

Fig. 5.1

Pin allocation for the motor cable (X-axis/Y-axis)

Motor side Controller side

Connection Pin Function Colour1) Pin Connection

Sub-D plug

(9-pin)

1 String A WH 1 Plug connector

(6-pin)

1

6

2 String A/ BN 2

3 String B GN 3

4 String B/ YE 4

5 -

6 -

7 Holding brake2) (+24 V DC) GY 5

8 Holding brake2) (GND) PK 6

9 -

Screening2) Cable lug

1) Specification of cable colour in accordance with IEC 60757:1983-01

2) Only for motors with holding brake EMMS-ST-…-SEB: Screening on the housing

Tab. 5.2

5 Installation


Pin allocation for the encoder cable (X-axis/Y-axis)


Connection Pin Function Pin Connection

Socket M12,

(8-pin)

1 Signal trace A 1 Sub-D plug

(9-pin)2 Signal trace A/ 6

3 Signal trace B 2

4 Signal trace B/ 7

5 GND encoder 4

6 Signal trace N 3

7 Signal trace N/ 8

8 VCC auxiliary supply 5 V 5

Tab. 5.3

5.2.3 Electrical attachment component

Note

Before installing the motor and encoder cables:

� Refer to the corresponding documentation for installation information.

Pin allocation for the motor cable (attachment component)


Connection Pin Function Colour1) Connection

Sub-D plug

(9-pin)

1 String A WH Cables with wire end

sleeves2 String A/ BN

3 String B GN

4 String B/ YE

5 -

6 -

7 Holding brake (+24 V DC) GY

8 Holding brake (GND) PK

9 -

1) Specification of cable colour in accordance with IEC 60757:1983-01

Tab. 5.4

5 Installation


Pin allocation for the encoder cable (attachment component)


Connection Pin Function Pin Connection

Socket M12,

(8-pin)

1 Signal trace A 1 Sub-D plug

(9-pin)2 Signal trace A/ 6

3 Signal trace B 2

4 Signal trace B/ 7

6 Signal trace N 3

7 Signal trace N 8

5 Encoder (GND) 4

8 VCC auxiliary supply 5 V 5

Tab. 5.5

5.2.4 Earthing

Earthing of the Y-axis (traverse) and the attachment component

In the energy chain, 2 earthing cables are laid for

earthing the Y-axis (traverse).

� Connect the open ends of the earthing cables

to the central earthing point (e.g. in the con

trol cabinet).

1 X-axis

2 Earthing point

3 Y-axis (traverse)


5 Earthing component

1

2

3

4

5

Fig. 5.2

The earthing point 2 on the slide of the Y-axis 4 is used, for example, to earth an addi

tional gripper on the attachment component.

5 Installation


Earthing the X-axis

Connect the earthing cable 6 (not included in the scope of delivery) to the earthing component 2 on

the underside of the X-axis 1.

1. Place the cable lug of the earthing cable between the large washer 7 and the serrated washer 5.

2. Attach small washer 4.

3. Tighten the hex nut 3 (tightening torque 4 Nm).

4. Connect the open end of the earthing cable to the central earthing point (e.g. in the control cabinet).

1 23

4

56

7

Fig. 5.3

5.3 Pneumatic installation

Description of the pneumatic interfaces: � 4.6.1 Power supply line

6 Commissioning


6 Commissioning

The commissioning process is described in separate documents (� www.festo.com/sp).

If you require additional support during the commissioning phase:

� Please contact your regional Festo contact person.

� Additional information can be found online (� www.festo.com/sp).

7 Maintenance


7 Maintenance


Warning







contain compressed air even when they are switched off.

– Vent pneumatic system parts accordingly.

7.2 Cleaning

Note

Only clean the product in exceptional circumstances by using non-abrasive cleaning

agents and a soft cloth.

Do not clean the guide elements (e.g. guide rails).

7.3 Lubrication

The product is lubricated initially upon delivery. Lubrication is required on a regular basis

to ensure trouble free operation.

Use appropriate accessories from Festo (� www.festo.com/spareparts).

Requirements

Lubricant ISOFLEX TOPAS NB52

Lubrication interval per axis [km] 2500

Amount of lubricant per lubrication nipple [g] 1

Tab. 7.1

Note

Lubrication of the attachment components in accordance with the corresponding docu

mentation.

7 Maintenance


Lubrication points

1

2

33

33

4

5

6

4


2 Lubrication nipples on guide carriage of the

Y-axis slide (2x)

3 Lubrication nipples on guide carriages of the

X-axis (at the carriages) (4x)

4 Carriage of the X-axis

5 Maintenance opening

6 Y-axis (traverse)

Fig. 7.1

7 Maintenance


Danger

Serious crushing due to axis movements of the product.

� Slowly move or travel the Y-axis (traverse) and the slide of the Y-axis.

� Make sure that no one is located in the movement area during the axis movements.

Note

For motors with holding brake, it is not possible to manually move the Y-axis (traverse)

and the slide of the Y-axis.

The product must be connected and ready for operation.

� Move the Y-axis (traverse) and slide of the Y-axis in manual override.

Observe the documentation (� Description EXCM-… “Commissioning”).

1. Lubricate each of the guide carriages of the X-axes at the 4 lubrication nipples 3 with half of the

specified amount of lubricant (� Tab. 7.1).

2. Move the Y-axis (traverse) to a suitable position for access to the maintenance opening 5

(� Fig. 7.1).

3. Move the slide of the Y-axis until the 2 lubrication nipples 2 are accessible one after the other in

the maintenance opening (� Fig. 7.1).

4. Lubricate each of the guide carriages on the Y-axis (traverse) at the lubrication nipples with half of

the specified amount of lubricant (� Tab. 7.1).

5. Move the Y-axis (traverse) and slide of the Y-axis once along the entire stroke to evenly distribute

the lubricant

6. Perform steps 1. to 5. again.

7.4 Repair

If you require support for repairs: (� www.festo.com/sp).

� Please contact your regional Festo contact person.

� Additional information can be found online (� www.festo.com/sp).

8 Dismantling


8 Dismantling


Warning







contain compressed air even when they are switched off. Vent pneumatic system

parts accordingly.



movement.






8.2 Procedure

1. Move the Y-axis (traverse) to the mechanical end position opposite the motors.

2. Disconnect all of the electric cables and pneumatic tubing from the product.

3. Mount the retaining plates with transport lugs and transport restraints (� Fig. 4.4).

4. Secure movable parts (e.g. Y-axis (traverse), attachment component, etc.) with cable ties

(� Fig. 4.4).

5. Mount transport lugs with support plate to the X-axes (� Fig. 4.4).

6. Dismantle the product.

8.3 Recycling

Incorrect disposal is harmful to the environment.

� Observe local regulations regarding disposal and the environment.

� Observe local regulations for disposal of modules.

� Use lubricants (greases, oils) in accordance with the applicable regulations for health

and safety and hazardous substances.

A Technical appendix



A.1 General features

Feature

Design Planar surface gantry

Motor type Stepper motors (for details see motor data sheet)

Guide Recirculating ball bearing guide

Mounting position Horizontal

Type of mounting – Mounting kit

– Adjusting kit

Operating medium Compressed air in accordance with

ISO8573-1:2010 [7:4:4]

Operating pressure [bar] 1 … 8

Pneumatic connection (power supply) Hose size 6

Dynamic data Observe catalogue specifications

� www.festo.com/catalogue

Tab. A.1



A.2 Evenness

1

1

2

1 Guide rails of the X-axes 2 Mounting component

Fig. A.1

Limit values of the X-axis alignment

(A) Evenness [mm/m] � 0.1

(B) Sideways tilting [mm/m] � 0.1

(C) Height offset [mm/m] � 0.1

(D) Parallelism [mm/m] � 0.1

Tab. A.2

A.3 Approvals

Feature

Declaration of incorporation (� www.festo.com/sp) in accordance with Machinery Directive

2006/42/EC

Tab. A.3



A.4 Materials

Component

Profiles of the X-axis Aluminium

Profile of the Y-axis

Cover of the X-axis and the Y-axis

Drive and end caps

Guide pulley

Slide

Coupling Aluminium with elastomer ring gear

Guide Steel

Drive pinion

Ball bearing

Toothed belt PU with steel cord

Tab. A.4

A.5 Operating and storage conditions

Feature

Storage temperature [°C] –10 … +60

Storage location dry, solid and flat base 2)

Maximum shelf life 60 months

Ambient temperature [°C] +10 … +50

Air humidity [%] 0 … 90 (non-condensing)

Degree of protection (in accordance

with EN 60529)

IP40

Noise level1) [dB(A)] 65

Duty cycle [%] 100

1) Energy-equivalent A-weighted noise level at 1 m distance determined locally over the measurement surface

2) In the original packaging

Tab. A.5

Reproduction, distribution or sale of this document or communication of its contents to others without express authorization isprohibited. Offenders will be liable for damages. All rights reserved in the event that a patent, utility model or design patent isregistered.

Copyright:Festo AG & Co. KGPostfach73726 EsslingenGermany

Phone:+49 711 347-0

Fax:+49 711 347-2144

E-mail:[email protected]

Internet:www.festo.com

Original: de

Documents

Planar surface gantry EXCM-40 - Festo€¦ · – Design engineer – Machine manufacturer – Installer – Commissioner Only qualified personnel may perform mounting, installation,