Festo EXCH-40-...-AS2, EXCH-40-...-AB1, EXCH-60-...-AB2, EXCH-60-...-W, EXCH-40-...-AS1 Mechanical Installation

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Planar surface gantry

EXCH

Description

Mechanical installation

8046388

1506a

[8046382]

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EXCH

Translation of the original instructions GDCP-EXCH-KM-KOMP-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 or serious material damage.

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. è Result of an activity / reference to further information.

2 Festo – GDCP-EXCH-KM-KOMP-EN – 1506a – English

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EXCH

Table of Contents – EXCH

1 Safety and requirements for product use 7......................................

1.1 Safety 7..................................................................

1.1.1 General safety information 7..........................................

1.1.2 Intended use 7.....................................................

1.2 Requirements for product use 8...............................................

1.2.1 Obligations of the operating company 8.................................

1.2.2 Qualification of specialized personnel 8.................................

1.2.3 Range of applications and certifications 8...............................

2 Transport and storage 9.....................................................

2.1 Transport 9................................................................

2.2 Storage conditions 9........................................................

2.3 Unpacking 10...............................................................

2.4 Check the scope of delivery 11.................................................

3 Overview 12................................................................

3.1 Function and application 12....................................................

3.2 Operational principle 12......................................................

3.3 Design 13..................................................................

4 Preparations for mounting 14..................................................

4.1 Dimensions 14..............................................................

4.1.1 Dimensions EXCH-40-…-W-… (without motor) 15...........................

4.1.2 Dimensions EXCH-60-…-W-… (without motor) 16...........................

4.1.3 Dimensions of motors EXCH-40 17......................................

4.1.4 Dimensions of motors EXCH-60 18......................................

4.2 Mounting requirements 19....................................................

4.3 Mounting position 20.........................................................

4.3.1 Horizontal mounting position 20........................................

4.3.2 Vertical mounting position 20..........................................

4.4 Types of mounting 21.........................................................

4.4.1 Adjusting kits 21....................................................

4.4.2 Mounting plates 23..................................................

4.5 Mounting 23................................................................

4.5.1 Number of mounting accessories 23....................................

4.5.2 Mounting holes 24...................................................

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EXCH

4.6 Motors 25..................................................................

4.6.1 Variants 25.........................................................

4.6.2 Attachment positions 25..............................................

4.6.3 Mounting 26.......................................................

4.6.4 Dismounting/mounting motors 27......................................

4.6.5 Adapting the position of the motor cable outlets 29........................

4.6.6 Third-party motors 31................................................

4.7 Attachment components 32...................................................

4.7.1 Fastening principle 32................................................

4.7.2 Mounting of attachment components 32.................................

4.7.3 Drill holes on the slide unit EXCH-40 33..................................

4.7.4 Drill holes on the slide unit EXCH-60 34..................................

4.7.5 Power supply line 35.................................................

4.8 Accessories for position sensing 39.............................................

4.8.1 Proximity sensors at X-axis 39.........................................

4.8.2 Proximity sensor at Y-axis 40..........................................

5 Mounting (horizontal mounting position) 44......................................

5.1 Mounting 44................................................................

5.1.1 Safety instructions 44................................................

5.1.2 Requirements 45....................................................

5.1.3 Procedure 45.......................................................

5.2 Align 51...................................................................

5.2.1 Notes 51..........................................................

5.2.2 Limit values of the X-axis alignment 52...................................

5.2.3 Requirements 52....................................................

5.2.4 Preparation 53......................................................

5.2.5 X-axis 1: Align evenness and tilting 54...................................

5.2.6 X-axis 2: Align height offset, evenness and tilting 55........................

5.2.7 Align X-axes parallel 56...............................................

5.2.8 Eliminate warping in the planar surface gantry 57..........................

5.3 Toothed belt pretensioning 58..................................................

5.3.1 Notes 58..........................................................

5.3.2 Checking the toothed belt pretension 59.................................

5.3.3 Setting toothed belt pretensioning 61...................................

5.4 Assembly 64................................................................

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EXCH

6 Mounting (vertical mounting position) 65........................................

6.1 Mounting 65................................................................

6.1.1 Safety instructions 65................................................

6.1.2 Requirements 66....................................................

6.1.3 Procedure 67.......................................................

6.2 Align 73...................................................................

6.2.1 Notes 73..........................................................

6.2.2 Limit values of the X-axis alignment 74...................................

6.2.3 Requirements 75....................................................

6.2.4 Preparation 75......................................................

6.2.5 Align X-axes 76.....................................................

6.2.6 Eliminate warping in the planar surface gantry 77..........................

6.3 Toothed belt pretensioning 78..................................................

6.3.1 Notes 78..........................................................

6.3.2 Checking the toothed belt pretension 79.................................

6.3.3 Setting of toothed belt pretensioning 82.................................

6.4 Assembly 85................................................................

7 Installation 86..............................................................

7.1 Safety instructions 86........................................................

7.2 Drive motors of the X-axis/Y-axis 87.............................................

7.3 Electrical attachment component 89.............................................

7.4 Earthing 90.................................................................

8 Commissioning 92...........................................................

9 Maintenance and care 93.....................................................

9.1 Feed constant 94............................................................

9.2 Cleaning 94.................................................................

9.3 Lubrication 94..............................................................

9.3.1 Lubrication points 95.................................................

9.3.2 Procedure 96.......................................................

9.3.3 Accessories 97.....................................................

10 Dismounting and repair 98....................................................

10.1 Dismounting 98.............................................................

10.2 Repair 99..................................................................

10.3 Disposal 99................................................................

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EXCH

A Technical appendix 100........................................................

A.1 Technical data 100............................................................

A.1.1 General 100.........................................................

A.1.2 Approvals 100.......................................................

A.1.3 Materials 100........................................................

A.1.4 Product weight 101...................................................

A.1.5 Dynamic data 102....................................................

A.1.6 Operating and environmental conditions 103...............................

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1 Safety and requirements for product use

1.1 Safety

1.1.1 General safety information

 Observe the safety instructions in the corresponding chapters.

Special safety regulations are immediately before the task instruction.

1.1.2 Intended use

The planar surface gantry EXCH-40/-60 (product) is designed for executing positioning tasks within machines or automated systems with a higher-order controller.  Use the planar surface gantry only as follows:

– in perfect technical condition – in original condition, without unauthorised modifications – within the limits of the product defined in the technical data (è A Technical appendix)

Note

In the event of damage caused by unauthorised manipulation or other than intended use, the guarantee is invalidated and the manufacturer is not liable for damages.

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1 Safety and requirements for product use

1.2 Requirements for product use

 Provide this documentation to the following persons:

– design engineer – installer – commissioner of the machine or system

 Comply with the specifications of the documentation.

Follow all accompanying documentation and the documentation of any associated accessories.

 Take the following into consideration for the destination:

– applicable legal regulations – regulations and standards – regulations of the testing organisations and insurers

– national specifications For correct and safe use:  Observe all warnings and notes.  Comply with all load limits of the product and the connected components

(è Technical data of the corresponding documentation).

1.2.1 Obligations of the operating company

The product is an incomplete machine. Commissioning is prohibited until it has been established that the machinery in which it will be installed is in compliance with the provisions of the Machinery Directive 2006/42/EC.

1.2.2 Qualification of specialized personnel

 The product should only be installed by specialized personnel with corresponding qualifications. The following knowledge is required: – applicable regulations for accident prevention and operational reliability – documentation and mode of operation of the product

1.2.3 Range of applications and certifications

Standards and test values that the product complies with and fulfills (è A.1 Technical data).

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2 Transport and storage

2.1 Transport

Note

 Observe the markings on the transport crate during transport.

1. Transport the planar surface gantry to the mounting/storage location.

2. Set the transport crate down on a fixed and flat base.

2.2 Storage conditions

For safe use, comply with the following storage conditions.

Storage conditions

Storage temperature [°C] –10 … +60 Air humidity [%] 0 … 90 (non-condensing) Maximum storage period 60 months Requirements of storage location

Tab. 2.1

Dry, solid and flat base, in original packaging

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2 Transport and storage

2.3 Unpacking

Note

Damage to the product from incorrect removal of the transport crate. At least 2 people are required for opening the transport crate.  Observe notes on the transport crate for dismounting.  Due to the weight of the cover: Use suitable aids to raise and lower it (e.g. crane).  Make sure that no packaging parts can fall onto the product.

Open transport crate

1. Dismount cover and side parts in the sequence specified on the crate.

Remove transport mounting

The product is fastened with transport screws in the transport crate. Movable parts of the planar surface gantry are fixed with cable ties. These transport fasteners are each marked with a label (è Fig. 2.1).

Warning

Movable parts of the planar surface gantry can move uncontrollably during handling and mounting. Danger of crushing and material damage.  Remove cable ties that fix movable parts and the transport protection aids on the

X-axes only after mounting the product to the mounting surface.

2. For mounting, remove only the labelled transport screws with which the planar surface gantry is

fastened to the transport crate.

Transport fastener label Transport screws Cable ties

Fig. 2.1 Labelling of the transport fasteners

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2 Transport and storage

2.4 Check the scope of delivery

The scope of delivery of the product depends on the order.

1. Check whether the product corresponds to the version you ordered.

Accessory boxes are in the transport crate.

2. Check delivery for completeness.

Designation

Planar surface gantry EXCH Adjusting kits2) or mounting plates

with screws and discs Adjusting tools

Belt tension setting piece 1

Zero point setting piece 2 Description of mechanical installation 1 USB memory card 1 Motor cable with mounting instructions Encoder cable with mounting instructions Attachment component

1) Basic filling of the energy chains: compressed air tubing PUN-6 (2x), plug socket with cable SIM-M12-8GD-PU (1x)

2) Optional

3) If no adjusting kits have been ordered

4) Already mounted

2)4)

Tab. 2.2

Number

1 Dependent on the stroke of the X-axis (è 4.4)

2 2 1

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3 Overview

3.1 Function and application

Two fixed servo motors drive a toothed belt arrayed in an H-shape. The rotating toothed belt moves the traverse (Y-axis) and the slide unit on the Y-axis in the 2-dimen sional space. The position of the slide is calculated by a controller. The slide movement in the direction of an axis is reached through the controlled interplay of the two motors (è 3.2 Operational principle). Additional tasks can be taken over through attachment components (Z-axes).

3.2 Operational principle

Motor 1

Motor 2

Fig. 3.1 Directions of

movement (slide units of the Y-axis)

The depicted directions of movement of the Y-axis slide unit (Fig. 3.1) refer to the direc tions of rotation of the motor of the functional principle shown (Fig. 3.2).

X-axis

Y-axis

Motor 1

Fig. 3.2 Operational principle

1 Guide pulleys (for toothed belt) 2 Toothed belt (rotating) 3 Traverse (Y-axis) 4 Slide units of the Y-axis

Motor 2

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3 Overview

3.3 Design

1 End cap 2 X-axis 1 (with energy chain) 3 End cap with belt tensioning device 4 X-axis 2 5 Mounting accessories (adjusting kit or

mounting plate)

6 Drive cover (with cover)

7 Coupling housing and motor flange

(è 4.6 Motors)

8 Motor 23) (è 4.6 Motors) 9 Energy chain of the Y-axis aJ Traverse (Y-axis) aA Slide unit of the Y-axis

(for fastening the attachment component3))

aB Motor 13) (è 4.6 Motors) aC Multi-pin plug distributor aD Energy chain of the X-axis

1) Depending on the order

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

3) Optional

Fig. 3.3 Depicted as an example EXCH-40-…-B with motors (attachment position underneath) and

with adjusting kits.

3aC

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4 Preparations for mounting

Warning

Unexpected movement of components. Risk of injury due to electric shock, impact, crushing.  Before performing mounting work, switch off the power supply and secure it against

being switched on again.

4.1 Dimensions

The dimensions of the planar surface gantry are dependent on: – stroke of the X- and Y-axes – attachment position and type of the motor – type of attachment element

Dimensions of the planar surface gantry without motors

è 4.1.1 Dimensions EXCH-40-…-W-… (without motor) è 4.1.2 Dimensions EXCH-60-…-W-… (without motor)

Dimensions of the motors and axial kits

è 4.1.3 Dimensions of motors EXCH-40 è 4.1.4 Dimensions of motors EXCH-60

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4 Preparations for mounting

4.1.1 Dimensions EXCH-40-…-W-… (without motor)

B11

L10

Dimensions without motors [mm]

Stroke of the X-axis +

382.0

L3 L4 L10 B1 B3 B4 B5 B11 H1 H2 H8

101.0 70.0 Stroke of the Y-axis +

360.0

65.0 69.0 Stroke of the Y-axis +

458.0

2932)100.8 E1: 243

E2: 343 P1: 208 P2: 287

34.8 …

39.8

P3: 337

1) Depending on the motor version, L1 increases by the dimensions L8 und L9 (è 4.1.3 Dimensions of motors EXCH-40 ).

2) Approximate dimension for the height of the energy chain.

3) Height with attachment component version. Type designation (è www.festo.com/catalogue).

4) Adjustable with adjusting kits.

Tab. 4.1 Depicted EXCH-40-…-P…(with pneumatic attachment component).

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4 Preparations for mounting

4.1.2 Dimensions EXCH-60-…-W-… (without motor)

B11

L10

Dimensions without motors [mm]

Stroke of the X-axis +

643.0

L3 L4 L10 B1 B3 B4 B5 B11 H1 H2 H8

131.2 100.0 Stroke of the Y-axis +

507.0

96.6 91.0 83.5 Stroke of the Y-axis +

619.0

3102)120.1 E1: 272

E2: 372 P1: 216 P2: 303

34.8 …

39.8

P3: 366 P4: 416

1) Depending on the motor version, L1 increases by the dimensions L8 und L9 (è 4.1.4 Dimensions of motors E XCH-60).

2) Approximate dimension for the height of the energy chain.

3) Height with attachment component version. Type designation (è www.festo.com/catalogue).

4) Adjustable with adjusting kits.

Tab. 4.2 Depicted EXCH-60-…-P…(with pneumatic attachment component).

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4 Preparations for mounting

4.1.3 Dimensions of motors EXCH-40

Type designation of the motors (è 4.6 Motors).

EXCH-40-…-AB1-… / EXCH-40-…-AS1-… EXCH-40-…-AB2-… / EXCH-40-…-AS2-…

H4.1

B10

1 Cover 2 Drive cover 3 Coupling housing (axial kit)

1) Not applicable if motor attachment position on top.

4 Motor flange (axial kit) 5 Motor 6 Motor cable outlet

Fig. 4.1 Depicted: motor attachment position underneath.

Size Dimensions [mm]

H3 H4 H4.1 H5 H6 B4 B9 B10 L8 L9

EXCH-40-…-AB1/AS1-… 187.3 65.0 35.3 44.9 13.8 65.0 70.0 – 39.7 – EXCH-40-…-AB2/AS2-… 192.3 57.0 20.1 100.5 15.3 15.3

Tab. 4.3

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4 Preparations for mounting

4.1.4 Dimensions of motors EXCH-60

Type designation of the motors (è 4.6 Motors).

EXCH-60-…-AB2-… / EXCH-60-…-AS2-… EXCH-60-…-AB3-… / EXCH-60-…-AS3-…

H4.1

H4.1H4

B10

1 Cover 2 Drive cover 3 Coupling housing (axial kit)

1) Not applicable if motor attachment position on top.

4 Motor flange (axial kit) 5 Motor 6 Motor cable outlet

Fig. 4.2 Depicted: motor attachment position underneath.

Size Dimensions [mm]

H3 H4 H4.1 H5 H6 B4 B9 B10 L8 L9

EXCH-60-…-AB2/AS2-… 243.3 80.6 39.0 48.0 14.5 90.5 100.5 – 39.7 – EXCH-60-…-AB3/AS3-… 209.0 24.5 140.5 19.0 20.0

Tab. 4.4

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4 Preparations for mounting

4.2 Mounting requirements

Mounting requirements for the complete function range of the planar surface gantry: – sufficient space for movement of the axes and the attachment component (Z-axis) – torsionally rigid mounting surface – tension-free and sufficient attachment to absorb the maximum forces – corresponding flatness of the mounting surface for correctly aligned axes

(è 5.2.2 Limit values of the X-axis alignment)

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4 Preparations for mounting

4.3 Mounting position

The planar surface gantry can be mounted horizontally or, if certain requirements are met, vertically.

4.3.1 Horizontal mounting position

Mounting specifications The energy chains must be located above the X-axis.

Note

The reversed mounting position with the energy chains hanging downward is not per missible.

4.3.2 Vertical mounting position

Requirements

The following components must be ordered and mounted: – drive with the higher-performance motors with brake:

EXCH-40-…-AB2-… : Motors EMMS-…-100-S-…-RMB EXCH-60-…-AB3-… : Motors EMMS-…-140-S-…-RMB

– Control system with integrated safety switching device and power failure detection

(order characteristic: EXCH-…-AB…-C…-S2-…) – Motor controller CMMP-AS-C5-11A-P3-M0 (order characteristic: B6, B7 or B8) – Additional braking resistors CACR-KL2-40-W2000 (part no. 2882343).

Accessories (è www.festo.com/catalogue)

Warning

If the above-mentioned requirements are not met: Mortal danger and material damage due to falling traverse (Y-axis). If the power supply is interrupted (e.g. power failure) during operation, the traverse can fall down without control. The motor brakes are only designed as holding brakes and cannot stop a moving tra verse.  To avoid dropping:

Make sure that the requirements for a vertical mounting position are met: All com ponents must be ordered and mounted.

Mounting specifications

– X-axes arrayed vertically. – Arc of the energy chain of the X-axis is oriented downward.

That means: The motors must be located at the upper end of the X-axis.

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4 Preparations for mounting

4.4 Types of mounting

There are two types of mounting accessories for mounting the planar surface gantry: – adjusting kits (è 4.4.1 Adjusting kits) or – mounting plates (è 4.4.2 Mounting plates). The ordered mounting accessories are pre-assembled to the planar surface gantry.

4.4.1 Adjusting kits

The adjusting kits EADC-E12-… serve to attach and align the planar surface gantry.

The adjusting kits compensate for height differences in the mounting surface of up to 5 mm. Reordering adjusting kits (è www.festo.com/catalogue).

Overview

1 Slot nut 2 Adjusting plate 3 Hexagon head screw1) M6x30 (2x)

5 Adjusting bolt1) (2x) 6 Washer2) (2x) 7 Socket head screw2) M8x40 (2x)

4 Square nut1) (2x)

1) Mounted to the profiles of the axes, if ordered. 2) Enclosed separately, if ordered.

Fig. 4.3

Note

Incorrect mounting can cause malfunction and material damage. In the following, only the basic positioning, mounting and aligning with adjusting kits is explained.  For mounting the planar surface gantry, also observe:

è 5 Mounting (horizontal mounting position) or è 6 Mounting (vertical mounting position)

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4 Preparations for mounting

Positioning adjusting kits

1. Loosen hexagon head screws 3 approximately

½ turn.

2. Position adjusting plate 2

(è 4.5.2 Mounting holes).

3. Tighten hexagon head screws 3

(tightening torque 9.9 Nm).

Mounting on mounting surface

Observe detailed descriptions for mounting (è 5.1 or è 6.1).

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

2. Attach adjusting plate 2 with socket head

screws 7 onto the mounting surface.

3. Tighten socket head screws 7

(tightening torque 24 Nm).

Aligning and adjusting profiles

Observe detailed descriptions for aligning (è 5.2 or è 6.2).

1. On the adjusting kit to be set: Loosen only the

socket head screw 7 that will currently be set.

Do not loosen both screws of the adjusting kit sim

ultaneously.

2. Screw adjusting bolts 5 in or out (h = 6 … 11 mm).

Use spanner with width . 5 mm.

Observe sufficient screw-in depth of the socket

head screw (for steel  8 mm).

Fig. 4.4

Fig. 4.5

Fig. 4.6

3. Tighten socket head screw 7

(tightening torque 24 Nm).

Hold adjusting bolt 5 to maintain alignment.

Fig. 4.7

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4 Preparations for mounting

4.4.2 Mounting plates

The mounting plates are an alternative to the adjusting kits and are used to attach the planar surface gantry.

Note

The mounting plates are not adjustable.  To align the planar surface gantry and maintain the limit values, some actions are

required.

The distance dimension for the mounting screws is identical to that of the adjusting kits. Reorder mounting plates (è www.festo.com/catalogue).

4.5 Mounting

4.5.1 Number of mounting accessories

The required and pre-mounted number of mounting accessories depends on the stroke of the X-axis.

Stroke of the X-axis Number of mounting accessories

Total per X-axis (number n)

 899 mm 4 2 900 … 1799 mm 6 3  1800 mm 8 4

Tab. 4.5

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4 Preparations for mounting

4.5.2 Mounting holes

Note

 Observe the following:

– mounting position of the planar surface gantry (è 4.3 Mounting position) – number of mounting accessories (è Tab. 4.5) – Behind the end cap of the toothed belt tensioning device: keep a distance of at

least 5 cm in the extension of the X-axis free for mounting access.

 Prepare threaded holes in the mounting surface (è Fig. 4.8) and (è Tab. 4.6).

Hole pattern

1 Mounting accessories (adjusting kit or mounting plate) 2 End cap 3 Drive cover

Fig. 4.8 Depicted EXCH-40-… with 6 mounting accessories.

Size Dimensions [mm]

Thread L

L6 L7 B6 B7 B8

Size Depth

EXCH-40 M8  14

Stroke X-axis + 141

n – 1

EXCH-60 Stroke X-axis + 328

n – 1

1) For stroke of the X-axis  900 mm, arrange the mounting accessories in equal distances.

n = number of mounting accessories per X-axis (è 4.5.1 Number of mounting accessories)

2) Measured from the end cap 2 and drive cap 3 (not from the projecting profile).

37.5 +2 30.5 +2 Stroke Y-axis + 385.8 +0.5

42.5 +2 30.5 +2 Stroke Y-axis + 531.6 +0.5

Tab. 4.6 Mounting holes: distance dimensions and equations for calculation

78.0 ±0.2 13.0

98.0 ±0.2 13.0

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4 Preparations for mounting

4.6 Motors

4.6.1 Variants

The motors differ in the flange sizes 70, 100 and 140 as well as in the version with brake (…-RMB) or without brake (…-RM).

EXCH-40 EXCH-60 EXCH-40-… Motor EMMS-… EXCH-60-… Motor EMMS-…

…-AB1-… …-70-M-…-RMB …-AB2-… …-100-M-…-RMB …-AS1-… …-70-M-…-RM …-AS2-… …-100-M-…-RM …-AB2-… …-100-S-…-RMB …-AB3-… …-140-S-…-RMB …-AS2-… …-100-S-…-RM …-AS3-… …-140-S-…-RM

Tab. 4.7

4.6.2 Attachment positions

The motors can be ordered with the attachment position underneath (EXCH-…-B) or attachment posi tion on top (EXCH-…-T). The line outlets are premounted (è Fig. 4.9). The position of the line outlet can be changed (è 4.6.5 Adapting the position of the motor cable outlets).

Motor attachment position underneath (EXCH-…-B)

Motor attachment position on top (EXCH-…-T)

Fig. 4.9 Presented EXCH-40-…-AS1-… or EXCH-40-…-AB1-…

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4 Preparations for mounting

4.6.3 Mounting

The motors can be mounted in both attachment positions.

Motor underneath Motor on top

1 Cover 2 Drive cover1) with drive pinion 3 Coupling housing

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

4 Motor flange 5 Mounting screws 6 Motor

Fig. 4.10 Presented EXCH-40-…-AS1-… or EXCH-40-…-AB1-…

If the planar surface gantry was ordered without motor: The drive cover is mounted corresponding to the ordered attachment position.

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4 Preparations for mounting

4.6.4 Dismounting/mounting motors

Motors with brakes must be dismounted for mounting, alignment and for setting the toothed belt pre tensioning of the planar surface gantry.

Danger

With mounted planar surface gantry, severe injuries due to motor falling from a high position.  On a transport pallet: Dismount motors with brakes before mounting the planar

surface gantry.

 Before loosening the motor attachment screws: secure motor from falling down.

Warning

Electric shock.  Make sure that the motors are not connected to the power supply.

Motor attachment position underneath Motor attachment position on top

1 Motor flange

3 Motor

2 Mounting screw (4x)

Fig. 4.11 Presented EXCH-40-…-AS1-… or EXCH-40-…-AB1-…

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4 Preparations for mounting

Dismounting

1. Separate connections of the motor and encoder lines to the motors.

2. Dismount the 2 motors at each of the 4 mounting screws.

3. Remove motors. Only for EXCH-40-…-AB1/AS1 (with motor EMMS-…-70-…): Also remove the motor flanges. For the other variants: motor flanges are fastened separately, no dismounting.

Mounting

1. For motors with brake: Set or hold traverse and slide unit of the Y-axis at a distance of at least 10 cm:

– between traverse and drive or end cap – between slide units of the Y-axis and X-axis For the subsequent installation of the motors, the traverse and slide unit of the Y-axis must be movable in both directions.

Danger

Severe injuries due to motors falling down during mounting.  Secure motors against falling down.

2. Mount the 2 motors with the motor flanges (for EXCH-40-…-AB1/AS1 with motor EMMS-…-70-…) in reverse sequence of dismounting (è Fig. 4.11). Tightening torque (è Tab. 4.8). For the other variants: motor flanges are fastened separately.

3. Connect motor and encoder cables to the motors.

Characteristic EXCH-40-… EXCH-60-…

Tightening torque

…-AB1-… …-AS1-…

[Nm] 8.3 18 18 30

…-AB2-… …-AS2-…

…-AB3-… …-AS3-…

motor attachment screws

Tab. 4.8

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4 Preparations for mounting

4.6.5 Adapting the position of the motor cable outlets

The position of the motor cable outlets is set at the factory outside on the planar surface gantry in the extension of the X-axis (è Fig. 4.12). If necessary, the position can be adapted to the installation situ ation by turning the motor in 90°-steps.

Danger

If the planar surface gantry is mounted vertically and the motor is mounted underneath, severe injuries due to the motor falling down.  Before loosening the motor attachment screws: secure motor from falling down.

Danger

If the planar surface gantry is mounted vertically severe crushing from the traverse falling down (Y-axis). The traverse is held with the active braking of the motors. If the mounting screws on both motors are loosened: The traverse is no longer held in place and so falls down.  At the same time, unscrew the mounting screws on only one motor.

Warning

Electric shock.  Switch power off to motor controller (if already connected). Dangerous residual voltage even after the power supply is switched off.  Wait at least one minute after the power supply is switched off. Start work only when

the residual voltage has fallen below 60 V.

1 Motor 2 Motor attachment screw (4x)

3 Motor cable outlets

(for motor and encoder cable)

Fig. 4.12 Depicted: EXCH-40-…-AB1-… (motor attachment position on top).

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4 Preparations for mounting

Procedure

1. For motors with brake: In the subsequent turning of the motor, the traverse and slide unit of the Y-axis move. To enable this movement, set a distance of at least 10 cm each: – between traverse (Y-axis) and drive or end cap – between slide units of the Y-axis and X-axis

2. Disconnect connected motor and encoder cables from the motor.

Warning

Severe injuries due to motors falling down.  Secure motors against falling down.

3. Unscrew the 4 motor attachment screws.

4. Turn motor into the desired position. For motors with brake, the traverse and slide unit of the axis move.

5. Screw in motor attachment screws. Observe the tightening torque (è 4.6.4 Dismounting/mounting motors).

6. Connect motor cable and encoder cable to the motor.

If necessary, repeat the procedure for the other motor.

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4 Preparations for mounting

4.6.6 Third-party motors

Note

Third-party motors with driving torque that is too high can damage the planar surface gantry.  Observe in the motor selection (è www.festo.com/catalogue).

Note

 To connect third-party motors, use the axial kit that fits as well as the corresponding

coupling to connect the shaft of the drive pinion.

 Observe dimensions of the drive cover (è Tab. 4.9).

Drive cover EXCH-40 Drive cover EXCH-60

Fig. 4.13

Size Dimensions [mm]

B10 B11 B12 B13 D1

D3 D4

EXCH-40 41.0 35.0 30.0 27 _0.05 38 H7 12 h6 M5 4 H7 EXCH-60 54 _0.1 51.0 39.5 27 _0.05 62 H7 23 H7 M6 –

H4 H7 L10 L11 L12 T1 T2 T3 T6

EXCH-40 65.0 20.0 70.0 46 _0.3 41.0 12.0 6.0 1.9 – EXCH-60 80.6 – 100.0 – 64 _0.1 14.0 – 3.1 6.85

Tab. 4.9

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4 Preparations for mounting

4.7 Attachment components

4.7.1 Fastening principle

1 Slide units of the Y-axis 2 Cylindrical dowel pins 3 Mounting screws for attachment component 4 Adapter plate

Fig. 4.14 Depicted EXCH-40-…-P-…(with pneumatic attachment component).

4.7.2 Mounting of attachment components

For mounting of attachment components (Z-axes), threads and centring holes are prepared on the slide unit of the Y-axis 1: EXCH-40 (è 4.7.3), EXCH-60 (è 4.7.4).

Note

 Observe the following when designing and mounting attachment components:

– reduced freedom of movement through parts of the planar surface gantry

(e.g. for motors with attachment position on top) – defined limit values (è A.1 Technical data) – maximum screw-in depth at the slide unit of 10 mm – documentation of the attachment component

 During mounting and connection of the attachment component:

Switch off power to the system and secure it from being restarted accidentally.

5 Mounting screws for adapter plate 6 Centring sleeves 7 Attachment component

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4 Preparations for mounting

4.7.3 Drill holes on the slide unit EXCH-40

L14

L13L15

L16

B15

B14

1 Centring hole Ø 6 H7, depth 7 mm (2x) 2 Thread M8 (8x) Fig. 4.15

Dimensions [mm] B14 B15 L13 L14 L15 L16

106 _0.1 85 _0.03 44 _0.1 32 _0.1 18.5 12 _0.1

Tab. 4.10

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4 Preparations for mounting

4.7.4 Drill holes on the slide unit EXCH-60

L18

L19

L15

L16

L22

L20

L21

B15

B16

B14

1 Thread M6 (8x)

3 Centring hole Ø 6 H7, depth 7 mm (4x)

2 Thread M8 (8x)

Fig. 4.16

Dimensions [mm] B14 B15 B16

132 _0.1 85 _0.03 106 _0.1

L13 L14 L15 L16 L18 L19 L20 L21 L22

75 _0.1 59 _0.1 22 12 _ 0.1 44 _0.1 32 _0.1 11 _0.1 13 5

Tab. 4.11

L14

L13

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4 Preparations for mounting

4.7.5 Power supply line

Without attachment component (EXCH-…-T0-…)

If ordered without attachment component, the following components in the energy chain are installed or mounted onto the product.

Components

Number

Compressed air tubing 2 Plug socket with cable 1 Earthing cable 2 Bulkhead fitting 2

Tab. 4.12

Components (without attachment component)

1 Energy chain of the Y-axis 2 Bulkhead fitting on top

(black compressed air tubing)

3 Bulkhead fitting underneath

4 Multi-pin plug distributor (6-fold) 5 Plug socket with cable 6 Silver compressed air tubing 7 Black compressed air tubing

(silver compressed air tubing)

Fig. 4.17

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4 Preparations for mounting

With electrical connection component (EXCH-…-E…)

The electrical cables for installation of the connection component are placed in the energy chains. The following components are mounted and connected.

Components Number

Adapter plate 1 Compressed air tubing 2 Bulkhead fitting 2 Motor cable 1 Encoder cable 1 Plug socket with cable 1 Earthing cable 2

Tab. 4.13

Components with electrical connection component

1 Energy chain of the Y-axis 2 Bulkhead fitting on top

(black compressed air tubing)

3 Bulkhead fitting underneath

4 Adapter plate 5 Electrical attachment component 6 Silver compressed air tubing 7 Black compressed air tubing

(silver compressed air tubing)

Fig. 4.18

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4 Preparations for mounting

With pneumatic attachment component (EXCH-…-P…)

The pneumatic cables for installation of the connection component are placed in the energy chains. The following components are mounted and connected.

Components Number

Adapter plate 1 Compressed air tubing 2 Bulkhead fitting 1 Solenoid valve 1 Proximity sensor 2 Pneumatic silencer 2 Plug socket with cable 2 Earthing cable 2

Tab. 4.14

Components with pneumatic attachment component

1 Energy chain of the Y-axis 2 Plug socket with cable for the solenoid valve 3 Solenoid valve 4 Silver compressed air tubing 5 Adapter plate 6 Pneumatic attachment component

Fig. 4.19

7 Compressed air tubing to the attachment

component

8 Bulkhead fitting

(black compressed air tubing)

9 Cable of a proximity sensor for end position

of the attachment component

aJ 2 compressed air tubings (black; silver)

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4 Preparations for mounting

Assignment at the multi-pin plug distributor

Fig. 4.20

Connection Function/assignment

1 Plug socket with cable for the solenoid valve

2 Proximity sensor1) for end position on top of the connection component 3 Proximity sensor1) for end position underneath the connection component 4 Proximity sensor2) for slide units of the Y-axis 5 – 6 – 7 Multi-pin plug connection: plug socket with cable from the energy chain

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

2) Optional (accessories)

Tab. 4.15

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4 Preparations for mounting

4.8 Accessories for position sensing

4.8.1 Proximity sensors at X-axis

Function

The sensor mounting EAPR-E12-… and the proximity sensor (type: SIES-…) are appropriate for: – position sensing of the carriage of the X-axis – protection against running into the stop in the X-direction

(e.g. if the toothed belt slips)

The sensor mounting and the proximity sensor are not included in the scope of delivery.

 Select the corresponding accessories from the Festo catalogue

(è www.festo.com/catalogue).

Position

Several sensor mountings and proximity sensors can be attached to the profile of the X-axis. The sensor mounting and the proximity sensor can be moved on the X-axis.

Mounting

Note

 Observe mounting instructions of the sensor mounting EAPR-E12-… and the proxim

ity sensor.

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4 Preparations for mounting

4.8.2 Proximity sensor at Y-axis

Function

The proximity sensor (type: SIES-…) is appropriate for: – position sensing of the slide unit of the Y-axis – protection against the slide unit of the Y-axis running into the stop

(e.g. if the toothed belt slips)

The proximity sensor is not included in the scope of delivery.

 Select the corresponding accessories from the Festo catalogue

(è www.festo.com/catalogue).

Position

The sensor slot for mounting the proximity sensor is located in the slide unit of the Y-axis. Premounted in the traverse (Y-axis) are 2 switch lugs for actuation of the proximity sensor. The positions of the proximity sensor and the switch lugs cannot be changed.

1 Switch lugs1) (2x)

3 Slide units of the Y-axis

2 Traverse (Y-axis)

1) Already premounted underneath the cover

Fig. 4.21 Depicted: EXCH-40-…-B-… (motor attachment position underneath).

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4 Preparations for mounting

Mounting of the proximity sensor

Note

 Observe documentation of the proximity sensor.

1. At the traverse (Y-axis): Unscrew screws 6 of the cover 4 (è Fig. 4.22).

2. Remove retaining plate 5 of the energy chain and the cover 4.

4 Cover of the Y-axis 5 Retaining plate (energy chain of the Y-axis) 6 Cover screws

7 Guide plate (energy chain of the Y-axis) 8 Screws (M5) (4x) 9 Cable ties

Fig. 4.22 Depicted: EXCH-40-…-B-… (motor attachment position underneath).

3. Unscrew the 4 screws 8 of the guide plate 7 of the energy chain (è Fig. 4.22).

4. Loosen or remove cable ties 9 (è Fig. 4.22).

5. Push the guide plate 7 with the energy chain to the side in the direction of the arrow (è Fig. 4.22) The lower slide plate aC with the sensor slot aA must be accessible (è Fig. 4.23).

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4 Preparations for mounting

6. On the upper slide plate of the Y-axis: Dismount cable cover aD (è Fig. 4.23).

7. Only EXCH-60: Unclip slot cover aF from the sensor slot aA.

8. Put proximity sensor aB with cable into the sensor slot aA and place it properly (è Fig. 4.23):

– EXCH-40: flush with the outer edge of the lower adapter plate – EXCH-60: with distance 23 … 30 mm from the outer edge of the lower slide plate

9. Fasten proximity sensor with the screw (tightening torque 0.3 Nm).

10.Lay cable of the proximity sensor into the slot aE of the upper slide plate.

11.Only EXCH-60:

Clip slot cover aF into the sensor slot aA over the cable of the proximity sensor.

Note

To avoid cable damage from the guide plate of the energy chain:  Place slot cover as close as possible to the upper slide plate.

12.Mount cable cover aD with the 2 screws (tightening torque 1.2 Nm). Make sure that the cable is laid completely within the two slots aA/aE.

EXCH-40 EXCH-60

aAaB

aJ Multi-pin plug distributor aA Sensor slot (T-slot) aB Proximity sensor with cable and plug

connector

aC Lower slide plate of the Y-axis aD Cable cover with 2 screws aE Slot in the upper slide plate aF Slot cover

Fig. 4.23

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4 Preparations for mounting

13.Push plug connecter of the proximity sensor into port 4 in the multi-pin plug distributor

(è Fig. 4.20).

Note

 Observe mounting instructions of the proximity sensor.

14.Mount guide plate 7 of the energy chain with the screws (è Fig. 4.22).

Use screw locking agent Loctite 243. Tightening torque 5.9 Nm.

15.Perform functional test of the proximity sensor.

16.Fasten cables between the energy chains with cable tie 9 for strain relief (è Fig. 4.22).

17.Mount the retaining plate 5 of the energy chain and the cover with the screws (è Fig. 4.22).

Tightening torque 1 Nm.

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5 Mounting (horizontal mounting position)

5.1 Mounting

5.1.1 Safety instructions

Warning

Inappropriate mounting material will cause the planar surface gantry mounting to come loose during mounting or operation. Danger of serious injuries.  Use mounting components and mounting surface with sufficient strength.  Observe weight of the planar surface gantry.

Warning

Danger of crushing when handling due to the weight or tilting of the planar surface gantry. The planar surface gantry has an asymmetrical centre of gravity. For stabilisation and to avoid distortions, two transport protection aids are attached to the X-axes.  Use only the transport lugs for transport.  Fasten the lifting gear to the 4 transport lugs.  No person may stand under the planar surface gantry during transport with lifting

gear.

 Observe the weight of the planar surface gantry, which depends on the size and

accessories.  Observe different weight distribution.  Remove transport protection aids on the X-axes only after mounting the planar sur

face gantry to the mounting surface.

Warning

Danger of crushing due to uncontrolled movements of the traverse (Y-axis).  Make sure that the traverse is located at the end caps in the end position (opposite

the motor side) and is secured against uncontrolled movements with the transport

attachments.

Note

For mounting, Festo recommends the adjusting kits as mounting accessories.  After alignment, the limits of the axis alignment must be complied with (è 5.2.2).

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5 Mounting (horizontal mounting position)

5.1.2 Requirements

– Transport crate at the mounting location (è 2.1 Transport). – Transport crate opened and transport screws removed (è 2.3 Unpacking). – Movable parts of the planar surface gantry still fixed with transport retainers (cable ties):

– Traverse (Y-axis) – Slide units of the Y-axis

– Pneumatic attachment component (Z-axis) – Requirements for the mounting surface complied with (è 4.2 Mounting requirements). – Note on the mounting position complied with (è 4.3.1 Horizontal mounting position). – Threaded holes in the mounting surface prepared (è 4.5.2 Mounting holes). – Planar surface gantry and mounting surface have the same temperature.

Note

If there are temperature differences between the planar surface gantry and the mount ing surface:  Adapt the temperature of the planar surface gantry to that of the mounting surface.  Observe permissible ambient temperature

(è A.1.6 Operating and environmental conditions).

5.1.3 Procedure

Definition of term: The term mounting accessories is used for the two possible types of mounting: adjusting kits or mounting plates.

1. For motors with brake:

Remove drive motors from the X-axes (è 4.6.4 Dismounting/mounting motors).

Danger

Severe injuries due to the motor falling down. For mounting and alignment of the planar surface gantry, motors with brakes must be removed.  On transport pallet: Remove motors before mounting the planar surface gantry.  Before loosening the motor attachment screws: secure motor from falling down.

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5 Mounting (horizontal mounting position)

2. Attach appropriate lifting device to the 4 transport lugs (è Fig. 5.1).

Danger

If the transport lugs are incorrectly loaded, the lifting eye bolts will break. Mortal danger and material damage due to falling planar surface gantry!  Load the 4 transport lugs evenly and in an angle of  45° (è Fig. 5.2).  Do not laterally stress lifting eye bolts of the transport lugs (è Fig. 5.3).

1 End cap 2 Transport lug (on transport plate) (2x) 3 Lifting gear with attachment points

5 Drive cover (motor side) 6 Transport lug (on transport protection aid)

(2x)

4 Transport protection aid (2x) Fig. 5.1 Depicted: EXCH-40-…-B (motor attachment position underneath).

45°

Fig. 5.2 Transport lugs: pattern of the permissible load direction

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5 Mounting (horizontal mounting position)

3. Align transport lugs.

Fig. 5.3 Lifting eye bolts of the transport lugs: lateral stress is not permissible.

Adapt the lifting bolt orientation to the direction of force of the lifting gear:

 Loosen the 4 nuts of the lifting eye bolts.

 Turn the 4 lifting eye bolts in the respective direction of load (è Fig. 5.1).

 Tighten the 4 nuts of the lifting eye bolts (tightening torque 24 Nm).

Warning

Danger of crushing at high lifting speed.  Lift and move planar surface gantry with adapted lifting speed.

4. Place planar surface gantry onto the mounting surface using the lifting gear.

5. Position mounting accessories on the threaded holes of the mounting surface

(è 4.4.1 Adjusting kits, Fig. 4.4).

6. Fasten X-axis 1 (with energy chain) using the mounting accessories (è 4.4.1 Adjusting kits, Fig. 4.5)

in the threaded holes of the mounting surface (è Fig. 5.4).

If required, move the traverse (Y-axis) in order to reach the mounting accessories.

To do this, remove the transport retainers (cable ties) of the traverse.

Only place the socket head screws 7 of the mounting accessories.

The X-axis must remain movable.

The socket head screw of the mounting accessories under the energy chain can only be mounted after loosening the energy chain (è next step 7.).

1 X-axis 1 (with energy chain)

7 Socket head screws (mounting accessories)

2 Traverse (Y-axis)

Fig. 5.4 Depicted EXCH-40 with 3 mounting accessories per X-axis.

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5 Mounting (horizontal mounting position)

7. Loosen energy chain attachment of the X-axis (è Fig. 5.5):

 Unscrew screws A 1 and nuts A 2 on the energy chain retainer.

Number of screws/nuts: EXCH-40 2 pieces each; EXCH-60 4 pieces each.

 Unscrew screw B 3 and nut B 5 on the retainer.  Remove metal sheet 4.

1 Screw A 2 Nut A

3 Screw B 4 Metal sheet 5 Nut B

Fig. 5.5 Presented EXCH-40

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5 Mounting (horizontal mounting position)

8. Fasten X-axis 2 using the mounting accessories to the threaded holes of the mounting surface

(è Fig. 5.6). If required, move the traverse.

Only place the socket head screws of the mounting accessories.

2 X-axis 2

Fig. 5.6

9. Move the traverse backwards and forwards over the entire stroke of the x-axes.

10.Align the profiles of the X-axes so that the socket head screws of the mounting accessories are

located as close as possible to the centres of the respective oblong holes.

11.Tighten socket head screws of all mounting accessories with reduced tightening torque

(10 … 20 Nm).

Reason for reduced tightening torque: The socket head screws are loosened and tightened again at the subsequent alignment. The correct tightening torque is 24 Nm.

12.Remove the 2 transport protection aids on the end caps and drive caps.

13.Remove the 2 transport plates (with transport lugs) on the X-axes.

Store the transport protection aids, transport plates and screws for later dismounting of the planar surface gantry.

14.For motor attachment underneath:

Note

For mounting the covers onto the drive cover:  Replace the longer screws for mounting the transport protection aid with the accom

panying shorter screws. EXCH-40: M5x40 EXCH-60: M6x40

 Mount covers onto the drive cover with the shorter screws.

Tightening torque EXCH-40: 8.3 Nm; EXCH-60: 10.0 Nm.

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5 Mounting (horizontal mounting position)

15.Remove the remaining label-marked transport protection aids from the moving parts.

Fig. 5.7 Cable tie (transport mounting)

Note

Mounting of the planar surface gantry on the mounting surface is completed. Next step: è 5.2 Align.

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5 Mounting (horizontal mounting position)

5.2 Align

5.2.1 Notes

Note

Transport and temperature differences during storage result in warping. A warped planar surface gantry causes malfunctions and increased wear.  Perform the following steps carefully in order to set up the planar surface gantry

exactly and dissipate warping.

 Note limit values of the axis alignment (è 5.2.2).

If not complied with, the service life of the planar surface gantry will be reduced.  Align X-axes on the guide rails.  Measure limit values on the guide rails.  Use appropriate tools, measurement and checking facilities.

Required aids:

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

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

– 2 inspection bases:

adjusting tools (magnetic) as accessories (è www.festo.com/catalogue) or final dimensions (height at least 10 mm, width max. 40 mm, accuracy

0.05 mm/m) Danger of tilting of inspection bases.  Make sure that the inspection base lies correctly on the guide rail.

Note

The alignment procedure depends on the type of attachment.

Alignment with adjusting kits

The adjusting kits are adjustable. The following describes alignment with adjusting kits.  Note handling of the adjusting kits (è 4.4.1 Adjusting kits).

Alignment with mounting plates

The mounting plates are not adjustable. To comply with the limit values of the axis alignment:  Use own adjustments,  Support mounting plates or  Align mounting surface. If the limit values with mounting plates are not complied with:  Use adjusting kits from Festo (è www.festo.com/catalogue) or  take other suitable measures.

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5 Mounting (horizontal mounting position)

5.2.2 Limit values of the X-axis alignment

Alignment characteristics of the guide rails

EXCH-40 EXCH-60

(A) Flatness [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. 5.1

1 Guide rails of the X-axes 2 Adjusting kit

Fig. 5.8

5.2.3 Requirements

– Planar surface gantry is fastened onto the mounting surface. – Motors with brakes are dismounted.

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5 Mounting (horizontal mounting position)

5.2.4 Preparation

Warning

The planar surface gantry loosens from the mounting surface if the mounting is insuffi cient. Danger of serious injuries.  Adjust only one screw of an adjusting kit at a time.  Ensure the screws have sufficient screw-in depth: for steel  8 mm.

1. Dismount profile covers on both x-axes:  Unscrew mounting screws of the profile covers.

If required, move the already loosened energy chain.

 Remove profile covers.

1 Mounting screw of the profile cover

3 Energy chain of the X-axis

2 Profile cover of the X-axis

Fig. 5.9

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5 Mounting (horizontal mounting position)

5.2.5 X-axis 1: Align evenness and tilting

Note

The procedure:  Place inspection base on the guide rail of the X-axis 1 (with energy chain).  Inspect guide rail of the X-axis 1 (with energy chain) at each position of an adjusting

kit.

 Align the guide rail with the respective adjusting kit of the inspection position.

2. Inspect guide rail of the X-axis 1 at the position of an adjusting kit for evenness and sideways tilting. Compare inspection results with the demanded limit values (è 5.2.2 Limit values of the X-axis alignment).

Check evenness Check sideways tilting

1 Guide rail of the X-axis 1 2 Adjusting kit

3 Inspection base 4 Precision spirit level

Fig. 5.10

3. Align the guide rail of the X-axis 1 with the adjusting kit of the inspection position (è 4.4.1 Adjusting kits, Fig. 4.6, and Fig. 4.7). Tightening torque of the socket head screws 24 Nm.

4. Repeat the steps 2. and 3. at each position of an adjusting kit of the X-axis 1.

5. 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 (with energy chain) is aligned and the basis for further alignment of the planar surface gantry.

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5 Mounting (horizontal mounting position)

5.2.6 X-axis 2: Align height offset, evenness and tilting

Note

The procedure:  Place inspection bases on the guide rails of the two X-axes (è Fig. 5.11).  Inspect guide rail of the X-axis 2 (without energy chain) at each position of an ad

justing kit.

 Align the guide rail with the respective adjusting kit of the inspection position.

1 Guide rail of the X-axis 1 2 Adjusting kit 3 Inspection bases 4 Precision spirit level 5 Steel straightedge 6 X-axis 1 (with energy chain)

7 Socket head screw of the adjusting kit 8 Guide rail of the X-axis 2 9 X-axis 2 aJ Traverse (Y-axis) aA Slide units of the Y-axis aB Drive cover (motor side)

Fig. 5.11

6. At the position of an adjusting kit:

Inspect guide rail of the X-axis 2 8 for: – height offset to the already aligned X-axis 1 (è Fig. 5.11) – evenness (corresponding to è Fig. 5.10) – sideways tilting (corresponding to è Fig. 5.10) Compare inspection results with the demanded limit values (è 5.2.2 Limit values of the X-axis alignment).

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The settings can be checked simultaneously with use of a second spirit level on the guide rail of the X-axis 2.

7. At the inspection position: Align the guide rail of the X-axis 2 with the adjusting kit of the X-axis 2 (è Fig. 5.11).

8. Repeat the steps 6. and 7. at each adjusting kit of X-axis 2. Move the checking facilities and steel straightedge to the position of the adjusting kit.

9. Inspect the guide rail of the X-axis 2 again for compliance with the limit values for evenness, tilting and height offset.

5.2.7 Align X-axes parallel

10.Loosen socket head screws of the adjusting kits at the X-axis 2 one ¼ turn (è Fig. 5.11). Make sure that the set adjusting bolt does not twist in the adjusting kit.

11.Move the traverse (Y-axis) backwards and forwards over the entire stroke of the X-axes to make the guide rails parallel. Make sure that there is sufficient play in the elongated holes of the adjusting kits on the X-axis 2 to adjust the parallelism.

12.Move traverse to the drive cover (motor side). Tighten socket head screws of the adjusting kit of the X-axis 2 located at this position (tightening torque 24 Nm).

When tightening the socket head screws: The traverse must be located at the position of the adjusting kit.

13.Move traverse in the direction of the end cap to the next adjusting kit. Tighten socket head screws of the adjusting kit of the X-axis 2 located at this position (tightening torque 24 Nm).

14.Repeat the step 13. for all fastening locations of the X-axis 2 until the traverse lies on the end caps.

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

16.If the limit values are not complied with: Repeat steps 2. to 15. until the limits are complied with or take other measures to comply with the limits.

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5 Mounting (horizontal mounting position)

5.2.8 Eliminate warping in the planar surface gantry

Note

Transport and mounting have caused warping in the planar surface gantry. Warping results in malfunctions and increased wear.  Relieve warping with the following steps.

17.At the X-axis 2 (without energy chain):

Loosen each of the 8 screws aC of the 2 guide carriages aD 1 turn (è Fig. 5.12).

9 X-axis 2 (without energy chain) aJ Traverse (Y-axis) aB Drive cover (motor side)

aC Screws of the guide carriages

(in elongated holes)

aD Guide carriage

aE Carriage of the X-axis

Fig. 5.12 Presented EXCH-40

18.Move the traverse (Y-axis) backwards and forwards over the entire stroke of the x-axes.

19.Unscrew the 8 screws aC individually one after the other and immediately screw each of them back

in tight with Loctite 243 screw locking agent (tightening torque 5.9 Nm).

For tension-free alignment of the axes:  Do not unscrew several screws at the same time.

Note

Alignment of the planar surface gantry is completed. Next step:  Adjust toothed belt pretensioning (è 5.3 Toothed belt pretensioning).

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5.3 Toothed belt pretensioning

5.3.1 Notes

Note

Expansion processes during transport and temperature differences during storage of the planar surface gantry can result in warping and overstretch the toothed belt. Tension on the toothed belt of the planar surface gantry has therefore been released for transport and does not have the required pretension on delivery.  Set the toothed belt pretensioning only in the following cases:

– at initial mounting of the planar surface gantry immediately after alignment – one time after the first commissioning of the planar surface gantry

(after approx. 30 strokes at operating temperature)

– after removal/installation or change of the toothed belt

Note

Incorrect toothed belt pretensioning has the following effects: – Service life of toothed belt, guides and ball bearings is reduced. – Performance of the planar surface gantry is influenced. – Positioning accuracy is worsened. – Toothed belt can slip.

Results: position errors and danger of collision.  Check toothed belt pretensioning carefully.  Use appropriate checking facilities.  Note frequency setpoint value of toothed belt pretensioning.  Do not overstretch toothed belt.

Slowly increase the toothed belt pretensioning to the correct value. If this procedure is not followed, the toothed belt and the planar surface gantry will be damaged.

The toothed belt pretensioning is determined by measuring the basic oscillation (self-gen erated frequency) of the toothed belt with a fixed and freely oscillating span length. The distance for the span length is set with the accompanying belt tensioning setting piece. A pulse is applied to the toothed belt to start it oscillating. The resulting self-generated frequency of the toothed belt must be measured with an acoustical frequency measuring device.

Only an acoustical frequency measuring device is appropriate for checking the toothed belt pretensioning.

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5.3.2 Checking the toothed belt pretension

Requirements

For motors with brake: – when inspecting before commissioning: motors dismounted (è 4.6.3 Mounting). – when checking after commissioning: motor brakes released

(è Description EXCH-…-C… “Commissioning”).

Procedure

1. Place belt tension setting piece on the X-axis 1 (with energy chain) between the drive cover and carriage of the X-axis.

The slot of the belt tensioning setting piece is intended for hanging and locking onto the profile of the X-axis. The toothed belt pretensioning can be inspected with mounted or dismounted profile cover of the X-axis.

1 Traverse (Y-axis) 2 X-axis 1 (with energy chain) 3 Drive cover (motor side)

4 Belt tension setting piece

(dimension L11=144.4 mm)

5 Carriage of the X-axis

Fig. 5.13 Depicted EXCH-40-…-B (motor attachment position underneath);

profile cover of the X-axis dismounted.

2. Push traverse (Y-axis) with the carriage onto the belt tension setting piece. The distance dimension L11 for checking is set (è Tab. 5.2).

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Distance dimension for checking the toothed belt pretensioning

Characteristic

EXCH-40 EXCH-60

Distance dimension L11 (belt tension setting piece) [mm] 144.4

Tab. 5.2

3. Align probe of the acoustic frequency meas urement device in the middle of the toothed belt underneath the belt tension setting piece.

Ensure there is a short distance between the probe and toothed belt.

4. Make the toothed belt vibrate by hitting it once with a slim, heavy object (e.g. an Allen key). The frequency measurement device shows the self-generated frequency of the toothed belt.

1 Acoustic frequency measurement device Fig. 5.14

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. Compare the measurement result with the frequency setpoint value (è Tab. 5.3).

Characteristic EXCH-40 EXCH-60

Frequency setpoint value of toothed belt pretensioning

with horizontal mounting position of the planar surface gantry [Hz] 173 +10 117 +10

Tab. 5.3

6. If the measurement result is outside the specified frequency range: è 5.3.3 Setting toothed belt pretensioning

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5.3.3 Setting toothed belt pretensioning

Note

The pretension of the toothed belt diminishes during storage and operation. This is normal and must not be changed by increasing the tension of the toothed belt. This reduced pretension must not be used for evaluating the wear condition of the toothed belt.

Belt tensioning device

1 End cap with belt tensioning device

Fig. 5.15 Depicted: EXCH-40-…-B (motor attachment position underneath)

1. Dismount cover of the belt tensioning device.

EXCH-40 EXCH-60

No dismounting (cover not present).  Unscrew the 4 screws of the cover. Remove

cover.

1 End cap with belt tensioning device 2 Cover (belt tensioning device) 3 Screw (4x)

Fig. 5.16

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2. Loosen locking of the belt tensioning device.

EXCH-40 EXCH-60

 Unscrew the 2 threaded pins.  Loosen the 4 socket head screws about 1 turn.

1 2

1 Threaded pin (2x) 2 Socket head screw M6x18 (4x)

Fig. 5.17

3. Change toothed belt pretensioning by evenly turning the 2 adjusting screws. Observe the following note.

EXCH-40 EXCH-60

1 Adjusting screw (2x)

Fig. 5.18

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Note

Turning the adjusting screws – clockwise: increases tension and frequency of oscillation of the toothed belt, – anti-clockwise: reduces tension and frequency of oscillation of the toothed belt.

4. Move or travel traverse (Y-axis) one time over the entire stroke of the X-axis This causes the toothed belt to fully settle and equalises differences in tension.

5. Check the toothed belt pretensioning (è 5.3.2).

6. If the measured self-generated frequency does not equal the setpoint value: Repeat steps 3. to 5.

7. If the measured self-generated frequency equals the setpoint value (è Tab. 5.3): Lock setting of the toothed belt pretensioning.

EXCH-40 EXCH-60

 Screw in the 2 threaded pins

(Tightening torque 1 Nm).

 Tighten the 4 socket head screws (tightening

torque 9.9 Nm ±10 %).

1 Threaded pin (2x) 2 Socket head screw (4x)

Fig. 5.19

8. Mount cover of the belt tensioning device.

EXCH-40 EXCH-60

No mounting (cover not present).  Mount cover with the 4 screws (corresponding

to è Fig. 5.16). Tightening torque 9.9 Nm.

9. Pull out belt tension setting piece.

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5.4 Assembly

1. Mount profile covers of both x-axes (è Fig. 5.9). Tightening torque 1 Nm.

2. Fasten energy chain to the retainers with the screws and nuts (è Fig. 5.5). Number of screws/nuts: EXCH-40 3 pieces each; EXCH-60 5 pieces each. Use locking agent LOCTITE 243. Tightening torque 2.9 Nm.

3. For motors with brake: Mount drive motors of the X-axes (è 4.6.4 Dismounting/mounting motors).

Danger

For motor attachment position underneath Severe injuries due to the motor falling down during mounting.  Secure motor against falling down.

Note

Temperature changes influence the toothed belt pretensioning. One time, only after the 1st commissioning at operating temperature (after ap prox. 30 strokes):  Check toothed belt pretensioning and correct it, if required

(è 5.3 Toothed belt pretensioning).

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6.1 Mounting

6.1.1 Safety instructions

Warning

Danger of crushing when handling due to the weight or tilting of the planar surface gantry. The planar surface gantry has an asymmetrical centre of gravity. For stabilisation and to avoid distortions, two transport protection aids are attached to the X-axes.  Use only the transport lugs for transport.  Fasten the lifting gear to the 2 transport lugs of the transport protection aid at the

drive covers (motor side).

 No person may stand under the planar surface gantry during transport with lifting

gear.

 Observe the weight of the planar surface gantry, which depends on the size and

accessories.  Observe different weight distribution.  Remove transport protection aids on the X-axes only after mounting the planar sur

face gantry to the mounting surface.

Warning

Danger of crushing due to uncontrolled movements of the traverse (Y-axis).  Make sure that the traverse is located at the end caps in the end position (opposite

the motor side) and is secured against uncontrolled movements with the transport

attachments.

Note

For mounting, Festo recommends the adjusting kits as mounting accessories.  After alignment, the limits of the axis alignment must be complied with (è 6.2.2).

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6.1.2 Requirements

– Traverse (Y-axis) – Slide units of the Y-axis

– Pneumatic attachment component (Z-axis) – Requirements for the mounting surface complied with (è 4.2 Mounting requirements). – All requirements and mounting specifications for vertical mounting position fulfilled

(è 4.3.2 Vertical mounting position) – Threaded holes in the mounting surface prepared (è 4.5.2 Mounting holes).

Warning

If the toothed belt breaks, the traverse (Y-axis) falls down in an uncontrolled manner. Danger of death and material damage.  Ensure through appropriate protection devices that no persons are located in and

below the operating area of the planar surface gantry.

– Planar surface gantry and mounting surface have the same temperature.

Note

(è A.1.6 Operating and environmental conditions).

– Up to three persons are required for some steps of the following work (mounting, aligning, toothed

belt tensioning).

If the mounting surface (for the planned vertical mounting position) can be brought into the horizontal position before mounting:

Recommendation for procedure

1. Mount the planar surface gantry onto the horizontal mounting surface and align it. Follow description: è 5 Mounting (horizontal mounting position).

2. Mount the mounting surface with the planar surface gantry in the vertical mounting position.

Benefits

– Mounting simpler and safer. – Alignment is possible without laser tracker.

Note

– All requirements for a vertical mounting position must be met.

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6.1.3 Procedure

Definition of term: The term mounting accessories is used for the two possible types of mounting: adjusting kits or mounting plates.

1. Dismount drive motors of the X-axes (è 4.6.4 Dismounting/mounting motors).

Danger

With mounted planar surface gantry, severe injuries due to motor falling from a high position.  On transport pallet: Remove motors before mounting the planar surface gantry.  Before loosening the motor attachment screws: secure motor from falling down.

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2. Fasten appropriate lifting gear to the 2 transport lugs of the transport protection aid at the drive covers (è Fig. 6.1). The traverse must be in the end position at the opposite end caps.

Warning

If the transport lugs are incorrectly loaded, the lifting eye bolts will break. Mortal danger and material damage due to falling planar surface gantry!  Load the 4 transport lugs evenly and in an angle of  45° (è Fig. 6.1).  Do not laterally stress lifting eye bolts of the transport lugs (è Fig. 6.2).

45°

1 Lifting gear with attachment points 2 Transport lug (2x) 3 Transport protection aid (2x)

1) Transport lugs for additional handling when mounting in horizontal mounting position

4 Transport plate with transport lugs 5 End cap 6 Drive cover (motor side)

Fig. 6.1 Depicted: EXCH-40-…-B (motor attachment position underneath).

(2x)

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3. Align transport lugs.

Fig. 6.2 Lifting eye bolts of the transport lugs: lateral stress is not permissible.

Adapt the lifting bolt orientation to the direction of force of the lifting gear:  Loosen the nuts of the lifting eye bolts at the 2 transport lugs used.  Turn the 2 lifting eye bolts in the respective direction of load (è Fig. 6.1).  Tighten the 2 nuts of the lifting eye bolts (tightening torque 24 Nm).

Warning

Danger of crushing at high lifting speed.  Lift and move planar surface gantry with adapted lifting speed.

4. Place planar surface gantry onto the mounting surface using the lifting gear.

5. Position mounting accessories on the threaded holes of the mounting surface (è 4.4.1 Adjusting kits, Fig. 4.4).

6. Fasten X-axis 1 (with energy chain) using the mounting accessories in the threaded holes of the mounting surface (è 4.4.1 Adjusting kits, Fig. 4.5). If required, move the traverse with 2 persons

in order to reach the mounting accessories. To do this, remove the transport retainers (cable ties) of the traverse. Only place the socket head screws of the mounting accessories.

The X-axis must remain movable.

The socket head screw of the mounting ac cessories under the energy chain can only be mounted after loosening the energy chain (è next step 7.).

1 X-axis 1 (with energy chain) 3 Traverse (Y-axis) 7 Socket head screws (mounting accessories)

Fig. 6.3 Depicted EXCH-40 with 3 mounting accessories per X-axis.

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7. Loosen energy chain attachment of the X-axis (è Fig. 6.4):

 Unscrew screws A 1 and nuts A 2 on the energy chain retainer.

Number of screws/nuts: EXCH-40 2 pieces each; EXCH-60 4 pieces each.

 Unscrew screw B 3 and nut B 5 on the retainer.

Remove metal sheet 4.

1 Screw A 2 Nut A

3 Screw B 4 Metal sheet 5 Nut B

Fig. 6.4 Presented EXCH-40

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8. Fasten X-axis 2 using the mounting accessor ies to the threaded holes of the mounting sur face. If required, lift the traverse with 2 persons. Only place the socket head screws of the mounting accessories.

2 X-axis 2 3 Traverse (Y-axis)

Fig. 6.5

9. Lift the traverse with two persons and move it backwards and forwards over the entire stroke of the x-axes.

10.Align the profiles of the X-axes so that the socket head screws of the mounting accessories are located as close as possible to the centres of the respective oblong holes.

11.Tighten socket head screws of all mounting accessories (tightening torque 24 Nm).

12.Remove the 2 transport protection aids on the end caps and drive caps.

13.Remove the 2 transport plates (with transport lugs) on the X-axes.

Store the transport protection aids, transport plates and screws for later dismounting of the planar surface gantry.

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6 Mounting (vertical mounting position)

14.For motor attachment underneath:

Note

For mounting the covers onto the drive cover:  Replace the longer screws for mounting the transport protection aid with the accom

panying shorter screws: EXCH-40: M5x40 EXCH-60: M6x40

 Mount covers onto the drive cover with the shorter screws.

Tightening torque EXCH-40: 8.3 Nm; EXCH-60: 10.0 Nm.

15.Remove the remaining label-marked transport protection aids from the moving parts.

Fig. 6.6 Cable tie (transport mounting)

Note

Mounting of the planar surface gantry on the mounting surface is completed. Next step: è 6.2 Align.

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6.2 Align

6.2.1 Notes

Note

Transport and temperature differences during storage result in warping. A warped products causes malfunctions and increased wear.  Perform the following steps carefully in order to set up the planar surface gantry

exactly and dissipate warping.

 Note limit values of the axis alignment (è 6.2.2).

Note

The alignment procedure depends on the type of attachment.

Alignment with adjusting kits

The adjusting kits are adjustable.  Note handling of the adjusting kits (è 4.4.1 Adjusting kits).

Alignment with mounting plates

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6 Mounting (vertical mounting position)

6.2.2 Limit values of the X-axis alignment

Alignment characteristics of the guide rails

EXCH-40 EXCH-60

(A) Flatness [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. 6.1

1 Guide rail of the X-axis 1 2 End cap

4 Guide rail of the X-axis 2 5 Drive cover (motor side)

3 Adjusting kit

Fig. 6.7

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6 Mounting (vertical mounting position)

6.2.3 Requirements

– Planar surface gantry is fastened to the mounting surface. – Motors are dismounted. – Three persons are required for alignment.

6.2.4 Preparation

1. Dismount profile covers on both x-axes:  Unscrew mounting screws of the profile covers.

If required, move the already loosened energy chain.

 Remove profile covers.

1 Mounting screw of the profile cover

3 Energy chain of the X-axis

2 Profile cover of the X-axis

Fig. 6.8

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6.2.5 Align X-axes

Danger

If several adjusting kits are adjusted at the same time, the planar surface gantry can loosen from the mounting surface and fall down.

Mortal danger and material damage due to falling planar surface gantry!

 Adjust only one screw of an adjusting kit at a time.  Ensure the screws have sufficient screw-in depth: for steel  8 mm.  Make sure that no one is located underneath the planar surface gantry.

 If you need support, contact the regional Festo contact person.

Additional information (è www.festo.com).

2. Align the guide rails of the X-axes with appropriate tools and measuring equipment for: – Flatness – Sideways tilting – Height offset – Parallelism

Note

 Comply with the limit values of the axis alignment

(è 6.2.2 Limit values of the X-axis alignment).

 Comply with the procedure for alignment with adjusting kits

(è 4.4.1 Adjusting kits).

 Check guide rails of the X-axes at each position of an adjusting kit.  Align guide rails with the respective adjusting kit of the inspection position.

3. Tighten socket head screws of the adjusting kits (tightening torque 24 Nm).

When tightening the socket head screws: The traverse must be located at the position of the adjusting kit.

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6.2.6 Eliminate warping in the planar surface gantry

Note

Transport and mounting have caused warping in the planar surface gantry. Warping results in malfunctions and increased wear.  Relieve warping with the following steps.

4. At the X-axis 2 (without energy chain):

Loosen the 8 screws aC of the 2 guide carriages aD 1 turn (è Fig. 6.9).

9 X-axis 2 (without energy chain) aJ Traverse (Y-axis) aB Drive cover (motor side)

aC Screws of the guide carriages

(in elongated holes)

aD Guide carriage

aE Carriage of the X-axis

Fig. 6.9 Presented EXCH-40

5. Move the traverse (Y-axis) with 2 persons upwards and downwards over the entire stroke of the X-axes.

6. Unscrew the 8 screws aC individually one after the other and immediately screw each of them back in tight with Loctite 243 screw locking agent (tightening torque 5.9 Nm).

For tension-free alignment of the axes:  Do not unscrew several screws at the same time.

Note

Alignment of the planar surface gantry is completed. Next step:  Adjust toothed belt pretensioning (è 6.3 Toothed belt pretensioning).

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6 Mounting (vertical mounting position)

6.3 Toothed belt pretensioning

6.3.1 Notes

Note

– at initial mounting of the planar surface gantry immediately after alignment – one time after the first commissioning of the planar surface gantry

(after approx. 30 strokes at operating temperature)

– after removal/installation or change of the toothed belt

Note

Slowly increase the toothed belt pretensioning to the correct value. If this procedure is not followed, the toothed belt and the planar surface gantry will be damaged.

Only an acoustical frequency measuring device is appropriate for checking the toothed belt pretensioning.

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6 Mounting (vertical mounting position)

6.3.2 Checking the toothed belt pretension

Requirements

– when inspecting before commissioning: motors dismounted (è 4.6.3 Mounting). – when checking after commissioning: motor brakes released

(è Description EXCH-…-C… “Commissioning”).

Danger

The traverse (Y-axis) falls down in an uncontrolled manner due to loosening of the brakes or dismounting of the motors. Mortal danger and material damage due to falling traverse!  Before loosening the brakes or dismounting the motors, position traverse in the

lower end position at the end caps.

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Procedure

1. Lift and hold traverse (Y-axis) with two persons approx. 20 cm.

2. By a third person: Place belt tension setting piece on the X-axis 1 (with energy chain) between the end cap and carriage of the X-axis.

1 Traverse (Y-axis) 2 X-axis 1 (with energy chain)

L11

5 Carriage of the X-axis 6 End cap

4 Belt tension setting piece

(dimension L11=144.4 mm)

Fig. 6.10 Depicted EXCH-40 profile cover of the X-axis dismounted.

3. Place traverse with the carriage onto the belt tension setting piece. The distance dimension L11 is set (è Tab. 6.2).

Warning

If the setting piece falls out, the traverse (Y-axis) falls downward. Danger of severe crushing and amputation of limbs!  Make sure that no one is located underneath the traverse.

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Distance dimension for checking the toothed belt pretensioning

Characteristic

EXCH-40 EXCH-60

Distance dimension L11 (belt tension setting piece) [mm] 144.4

Tab. 6.2

4. Align probe of the acoustic frequency meas urement device in the middle of the toothed belt at the belt tension setting piece. Ensure there is a short distance between the probe and toothed belt.

5. Make the toothed belt vibrate by hitting it once with a slim, heavy object (e.g. an Allen key). The frequency measurement device shows the self-generated frequency of the toothed belt.

1 Acoustic frequency measurement device

Fig. 6.11

Note

6. Compare the measurement result with the frequency setpoint value (è Tab. 6.3).

Characteristic EXCH-40 EXCH-60

Frequency setpoint value of toothed belt pretensioning

if the planar surface gantry is mounted vertically [Hz] 212 +10 117 +10

Tab. 6.3

7. If the measurement result is outside the specified frequency range: è 6.3.3 Setting of toothed belt pretensioning.

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6 Mounting (vertical mounting position)

6.3.3 Setting of toothed belt pretensioning

Note

The pretension of the toothed belt diminishes during storage time and operation. This is normal and must not be changed by increasing the tension of the toothed belt. This reduced pretension must not be used for evaluating the wear condition of the toothed belt.

Belt tensioning device

1 End cap with belt tensioning device

Fig. 6.12 Depicted: EXCH-40-…-B (motor attachment position underneath)

1. Dismount cover of the belt tensioning device.

EXCH-40 EXCH-60

No dismounting (cover not present).  Unscrew the 4 screws of the cover. Remove

cover.

1 End cap with belt tensioning device 2 Cover (belt tensioning device) 3 Screw (4x)

Fig. 6.13

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2. Loosen locking of the belt tensioning device.

EXCH-40 EXCH-60

 Unscrew the 2 threaded pins.  Loosen the 4 socket head screws about 1 turn.

1 2

1 Threaded pin (2x) 2 Socket head screw M6x18 (4x)

Fig. 6.14

3. Change toothed belt pretensioning by evenly turning the 2 adjusting screws. Observe the following note.

EXCH-40 EXCH-60

1 Adjusting screw (2x)

Fig. 6.15

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Note

Turning the adjusting screws – clockwise: increases tension and frequency of oscillation of the toothed belt, – anti-clockwise: reduces tension and frequency of oscillation of the toothed belt.

4. Move the slide unit of the Y-axis backwards and forwards 3 times over the entire stroke of the Y-axis. This causes the toothed belt to fully settle and equalises differences in tension.

5. Check the toothed belt pretensioning (è 6.3.2).

6. If the measured self-generated frequency does not equal the setpoint value: Repeat steps 3. to 5.

7. If the measured self-generated frequency equals the setpoint value (è Tab. 6.3): Lock setting of the toothed belt pretensioning.

EXCH-40 EXCH-60

 Screw in the 2 threaded pins

(Tightening torque 1 Nm).

 Tighten the 4 socket head screws (tightening

torque 9.9 Nm ±10 %).

1 Threaded pin (2x) 2 Socket head screw (4x)

Fig. 6.16

8. Mount cover of the belt tensioning device.

EXCH-40 EXCH-60

No mounting (cover not present).  Mount cover with the 4 screws (corresponding

to è Fig. 6.13). Tightening torque 9.9 Nm.

9. Lift traverse with two people and pull out the belt tension setting piece.

10.Place traverse on the end caps.

84 Festo – GDCP-EXCH-KM-KOMP-EN – 1506a – English

Page 85

6 Mounting (vertical mounting position)

6.4 Assembly

1. Mount profile covers of both X-axes (è Fig. 6.8). Tightening torque 1 Nm.

2. Fasten energy chain to the retainers with the screws and nuts (è Fig. 6.4). Number of screws/nuts: EXCH-40 3 pieces each; EXCH-60 5 pieces each. Use locking agent LOCTITE 243. Tightening torque 2.9 Nm.

3. Mount drive motors of the X-axes (è 4.6.4 Dismounting/mounting motors).

Danger

Severe injuries due to the motor falling down during mounting.  Secure motor against falling down.

Note

(è 6.3 Toothed belt pretensioning).

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7 Installation

7.1 Safety instructions

Warning

Danger of electric shock from voltage sources.  Switch off the supply voltage during the entire installation (switch voltage-free) and

secure it against being switched on again unintentionally. Only disconnection of the supply voltage in the supply line (fuse or separate switch) switches voltage off in the connected control system.

 Dangerous residual voltage even after the power supply is switched off:

Wait at least one minute after the supply voltage is switched off. Start work on plugs and interfaces only when the residual voltage has fallen below 60 V.

 Only use power sources which guarantee reliable electrical isolation of the operating

voltage in accordance with EN 60204-1.  Connect all PE protective conductors before commissioning.  Observe the regulations of EN 50178 and EN 60204-1 for protective earthing during

installation.  Installation must be performed by a trained technician.

The following qualifications are required:

– experience with installation and operation of electrical systems.

– experience with installation and operation of pneumatic systems

(if the pneumatic attachment component is used).

86 Festo – GDCP-EXCH-KM-KOMP-EN – 1506a – English

Page 87

7 Installation

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

The 2 drive motors of the X-axis and Y-axis are servo motors, each with one motor and encoder connec tion. The motor cable (è Tab. 7.1) and the encoder cable (è Tab. 7.2) are connected to it.

Overview of connections

1 Motor connection M23 (8-pin) 2 Encoder connection M12 (8-pin)

Fig. 7.1 Shown: motor of the planar surface gantry EXCH-40-…-AS1-… or EXCH-40-…AB1-…

Note

 To connect the motor cable and encoder cable to the controller, follow the accompa

nying mounting instructions and the motor controller description. When using third-party motors and controllers:  Take information on installation from the corresponding documentation.

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7 Installation

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

Motor side Colour1)Controller side Port Pin Function

1 U Line BK (1) Cables with wire end PE PE PROTECTIVE EARTH GNYE

sleeves (4x 1.5 mm2) 3 W Line BK (3) 4 V Line BK (2) A MT+Temperature sensor BN Cables with B MT–Temperature sensor WH C BR+ Brake (optional) GN

wire end sleeves

(4x 0.5 mm2) D BR– Brake (optional) YE

1) Specification of cable colour in accordance with IEC 757

Tab. 7.1

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

Motor side Controller side Port Pin Function Pin Port

1 –SENS 2

2 +SENS 9

SUB-D plug connector (15-pin)

3 DATA 12

4 DATA/ 5

5 0 V 3

6 CLOCK/ 6

7 CLOCK 13

8 UP 10

Tab. 7.2

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7 Installation

7.3 Electrical attachment component

The electrical attachment component has a servo motor with motor connection and encoder connection. The motor cable (è Tab. 7.3) and the encoder cable (è Tab. 7.4) are connected to it.

Note

 To connect the motor cable and encoder cable to the controller, follow the accompa

nying mounting instructions and the motor controller description. When using third-party controllers:  Take information on installation from the corresponding documentation.

Pin allocation for the motor cable (attachment component)

Motor side Plug

Port Pin Function

connector

Black (4-pin)

1 V Line BK (2) 2 W Line BK (3) 3 U Line BK (1)

PE PE Protective earth GNYE Blue (6-pin)

1 MT+Temperature sensor WH

2 MT–Temperature sensor BN

3 BR+ Brake GN

4 BR– Brake YE

5 n.c. – –

6 n.c. – –

1) Specification of cable colour in accordance with IEC 757

Tab. 7.3

Pin allocation for the encoder cable (attachment component)

Motor side Controller side Plug

Port Pin Function Pin Port

connector

Red (6-pin)

1 DATA 12

2 DATA/ 5

3 0 V 3

4 UP 10

5 CLOCK/ 6

6 CLOCK 13 Yellow (6-pin)

1 –SENS 2

2 +SENS 9

3 n.c. –

4 n.c. –

5 n.c. –

6 n.c. –

Tab. 7.4

Colour1)Controller side

Cables with wire end sleeves (4x 0.75 mm2)

Cables with wire end sleeves (4x 0.25 mm2)

SUB-D plug connector (15-pin)

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7 Installation

7.4 Earthing

Note

 Follow the national regulations for electrical earthing.

Earthing of the Y-axis and the attachment component

In the energy chain, 2 earthing cables are laid for earthing the Y-axis.  Connect the 2 earthing cables to the earthing point (e.g. in the control cabinet).

Earthing points of the Y-axis

1 X-axis 2 Earthing component of the Y-axis 3 Earthing point at the slide unit of the Y-axis

Fig. 7.2

The earthing point on the slide unit of the Y-axis 3 is used to earth an additional gripper on the attachment component, for example.

90 Festo – GDCP-EXCH-KM-KOMP-EN – 1506a – English

4 Traverse (Y-axis) 5 Slide units of the Y-axis

Page 91

7 Installation

Earthing the X-axis

Located on the underside of the X-axis with energy chain is the earthing component 2 (è Fig. 4.40).  Connect an additional earthing cable 6 to the earthing component:

– The earthing cable is not included in the scope of delivery. – Connect the cable lug of the earthing cable between the large disc 7 and the serrated wash

er 5.

– Tightening torque of the hex nut 3: 4 Nm.

 Connect the other end of the earthing cable to the earthing point (e.g. in the control cabinet).

Depicted: EXCH-40-…-T-… (motor attachment position on top); view from underneath

1 X-axis with energy chain 2 Earthing component of the X-axis 3 Hex nut

5 Serrated washer 6 Earthing cable 7 Large disc

4 Small disc

1) Not included in scope of delivery

Fig. 7.3

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8 Commissioning

Danger

Serious injuries due to uncontrolled movements of the planar surface gantry.  Perform risk assessment on operation the planar surface gantry.  Place planar surface gantry in operation only if the dangers to people identified in

the risk assessment can be excluded through appropriate measures.

Warning

If the planar surface gantry is mounted vertically Mortal danger and material damage due to falling traverse (Y-axis)! In the following cases, the traverse can drop in an uncontrolled manner: – if the power supply is interrupted during operation; if not all components for the

vertical mounting position are mounted.

– if the toothed belt breaks during operation or at rest.

 Make sure that all required components are mounted and ready for operation.  Ensure through appropriate protection devices that no persons are located in and

below the operating area of the planar surface gantry.

 Before switching off the power supply, ensure the following:

– motors inactive (no rotation) – traverse in the lower end position at the end caps

Warning

Severe injuries if installation and commissioning are not performed correctly.  Commissioning only by specially trained personnel.

The following qualifications are required: – knowledge of the Festo Configuration Tool (FCT) software – experience with installation and operation of electrical control systems

 Perform commissioning in conformity with the separate documentation

(è description EXCH-…-C… “Commissioning”). For support in commissioning:  Please contact your regional Festo contact person.  Additional information can be found in the Internet (è www.festo.com/sp).

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Page 93

9 Maintenance and care

Warning

Unintended starting can trigger unexpected movements. Injury (death) due to electric shock or severe crushing.  Before performing mounting work, switch off the power supply and secure it against

being switched on again. Dangerous residual voltage even after the power supply is switched off.  After the supply voltage is switched off, wait at least one minute.

Start work on plugs and interfaces only when the residual voltage has fallen below

60 V. When pneumatic attachment components are used, compressed air can be stored in the pneumatic system parts even after switch-off.  Vent pneumatic system parts through corresponding measures.

Warning

If the planar surface gantry is mounted vertically If the toothed belt breaks, the traverse (Y-axis), together with any tool load on it, falls down in an uncontrolled manner. Mortal danger and material damage due to falling traverse!  At each lubrication and every 6 months:

Check toothed belt for damage, increased wear and missing teeth.  Contact Festo Service if there are signs of wear or damage.

Warning

Serious injuries due to uncontrolled movements of the planar surface gantry.  Maintenance work may only be conducted by professional personnel with corres

ponding qualifications in accordance with these instructions.  The personnel assigned to perform maintenance must be familiar with commission

ing and manual operation of the planar surface gantry.

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9 Maintenance and care

9.1 Feed constant

Note

If the absolute exactness of the system worsens (for example, due to temperature fluc tuations):  Adjust the feet constant in conformity with the documentation

(è Description EXCH-…-C… “Commissioning”).

9.2 Cleaning

Note

Clean the system only in exceptional cases. Observe the following:  Do not clean the guide elements (e.g. guide rails).

9.3 Lubrication

The system is initially lubricated during production. Proper lubrication is required for trouble-free oper ation and to increase the service life of the linear guides.

Note

 Observe specifications for lubrication of the planar surface gantry (è Tab. 9.1).  Use an appropriate grease gun and corresponding accessories from the Festo cata

logue (è www.festo.com/catalogue).

Requirements

Lubricant ISOFLEX TOPAS NB 52 (K2011-009) Lubrication interval Amount of lubricant

1) Manufacturer: Klüber Co.

2) Path specification per axis

3) Per lubrication nipple (guide carriage)

[km] 2500 [g] 1

Tab. 9.1

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9 Maintenance and care

9.3.1 Lubrication points

1 Slide units of the Y-axis 2 Lubrication nipples (EXCH-40: 2x,

EXCH-60: 3x) on guide carriage of the Y-axis slide unit

3 Lubrication nipples (4x) on guide carriage of

the X-axis (at the carriages)

Fig. 9.1 Depicted: planar surface gantry EXCH-60

4 Carriage of the X-axis 5 Maintenance opening 6 Traverse (Y-axis)

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9 Maintenance and care

9.3.2 Procedure

Danger

Serious crushing due to axis movements of the planar surface gantry.  Slowly move or travel traverse and slide unit of the Y-axis.  Make sure that no one is located in the movement area during the axis movements.

Danger

If the planar surface gantry is mounted vertically Severe crushing from the traverse moving or falling down (Y-axis).  Make sure that no one is located underneath the traverse.  Recommendation: Use a mirror to find the lubrication nipple in the maintenance

opening on the underside of the traverse.

 Recommendation: Store lubrication nipple position in a maintenance program.

Note

For motors with brake, it is not possible to manually move the traverse and slide unit of the Y-axis.  The planar surface gantry must be connected and ready for operation.  Travel traverse and slide unit of the Y-axis in manual override.

Follow documentation (è description EXCH-…-C… “Commissioning”).

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

lubricant amount each (è Tab. 9.1, è Fig. 9.1).

2. Travel traverse into an appropriate position for access to the maintenance opening (è Fig. 9.1).

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

the maintenance opening (è Fig. 9.1). Number of lubrication nipples: – EXCH-40: 2 – EXCH-60: 3 Lubricate guide carriages of the Y-axis at the lubrication nipples with half of the specified lubricant amount each (è Tab. 9.1).

4. To ensure that the lubricant is evenly distributed in the linear guides: Travel traverse and slide unit of the Y-axis 1 time over the entire stroke.

5. Perform steps 1. to 4. again.

96 Festo – GDCP-EXCH-KM-KOMP-EN – 1506a – English

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9 Maintenance and care

9.3.3 Accessories

 Select the corresponding accessories from the Festo catalogue

(è www.festo.com/catalogue).

Designation Type

Lubricant ISOFLEX TOPAS NB 52 (K2011-009) One-hand grease gun LUB-1 Needle-pointed nozzle LUB-1-TR Lubrication adapter (female thread M10x1) LUB-1-KE

1) Manufacturer: Klüber Co.

Tab. 9.2

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Page 98

10 Dismounting and repair

10.1 Dismounting

Danger

If the planar surface gantry is mounted vertically Severe crushing from the motor or traverse falling down (Y-axis). The traverse is held in position with the holding brakes of the motors.  Before starting dismounting:

Position traverse in the lower end position at the end caps and secure it against uncontrolled movements.

 Make sure that no one is located underneath the planar surface gantry during dis

mounting.

 Dismount motors only with the planar surface gantry in the horizontal position.

Warning

Electric voltage or components separated when powered. Unintended starting can trigger unexpected movements. Injury (death) due to electric shock or severe crushing.  Before performing mounting work, switch off the power supply and secure it against

being switched on again. Dangerous residual voltage even after the power supply is switched off.  After the supply voltage is switched off, wait at least one minute.

Start work on plugs and interfaces only when the residual voltage has fallen below

60 V. When pneumatic attachment components are used, compressed air can be stored in the pneumatic system parts even after switch-off.  Vent pneumatic system parts through corresponding measures.

Note

If the product continues to be used after dismounting:  Place the planar surface gantry in the status at delivery: e.g. attach original trans

port protection aids.

1. Disconnect the planar surface gantry from the higher-order controller.

2. Mount the 2 transport protection aids: – horizontal mounting position (è 5.1 Mounting) – vertical mounting position (è 6.1 Mounting)

3. For the horizontal mounting position: Also mount the 2 transport plates with the 2 additional trans port lugs on the X-axes.

4. Dismount the planar surface gantry in reverse sequence, according to the mounting position: – horizontal mounting position (è 5.1 Mounting) – vertical mounting position (è 6.1 Mounting)

98 Festo – GDCP-EXCH-KM-KOMP-EN – 1506a – English

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10 Dismounting and repair

10.2 Repair

 Contact Festo Service.

Repair by Festo ensures that the required fine adjustments and checks will be carried out.

 Information about spare parts and accessories (è www.festo.com/spareparts).

10.3 Disposal

 Observe the warnings when dismounting parts (è 10.1 Dismounting).

 Observe the local regulations for environmentally friendly disposal of modules.

Some materials are listed in the technical data section to enable separate disposal of particular materials (è A.1 Technical data).

 Handle the lubricants (greases, oils) in accordance with the applicable regulations

governing health and safety and hazardous substances.

 Observe the local regulations regarding waste disposal and the environment.

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Page 100

A Technical appendix

A.1 Technical data

A.1.1 General

Characteristic EXCH-40 EXCH-60

Design Planar surface gantry Motor type Servo motors Guide Recirculating ball bearing guide Mounting position Vertical or horizontal Types of mounting (mounting accessories) – Adjusting kit

– Mounting plate

1) Observe requirements (è 4.3 Mounting position).

2) Some adjustments must be made for axis alignment.

Tab. A.1

A.1.2 Approvals

Characteristic EXCH-40 EXCH-60

Declaration of incorporation

in accordance with Machinery Directive 2006/42/EC

(è www.festo.com)

Tab. A.2

A.1.3 Materials

Component EXCH-40 EXCH-60

Profiles of the X-axis Aluminium Drive and end caps Guide pulley Profile of the Y-axis Slides Cover of the X-axis and Y-axis Coupling Aluminium with

elastomer ring gear

Clamping hub: aluminium Expanding mandrel hub: stainless steel

Collar: elastomer Guide Steel Drive pinion Ball bearing Toothed belt PU with steel cord

Tab. A.3

100 Festo – GDCP-EXCH-KM-KOMP-EN – 1506a – English

Festo EXCH-40-...-AS2, EXCH-40-...-AB1, EXCH-60-...-AB2, EXCH-60-...-W, EXCH-40-...-AS1 Mechanical Installation

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Safety and requirements for product use

1.1 Safety

1.1.1 General safety information

1.1.2 Intended use

1.2 Requirements for product use

1.2.1 Obligations of the operating company

1.2.2 Qualification of specialized personnel

1.2.3 Range of applications and certifications

2 Transport and storage

2.1 Transport

2.2 Storage conditions

2.3 Unpacking

2.4 Check the scope of delivery

3 Overview

3.1 Function and application

3.2 Operational principle

3.3 Design

4 Preparations for mounting

4.1 Dimensions

4.1.1 Dimensions EXCH-40-…-W-… (without motor)

4.1.2 Dimensions EXCH-60-…-W-… (without motor)

4.1.3 Dimensions of motors EXCH-40

4.1.4 Dimensions of motors EXCH-60

4.2 Mounting requirements

4.3 Mounting position

4.3.1 Horizontal mounting position

4.3.2 Vertical mounting position

4.4 Types of mounting

4.4.1 Adjusting kits

4.4.2 Mounting plates

4.5 Mounting

4.5.1 Number of mounting accessories

4.5.2 Mounting holes

4.6 Motors

4.6.1 Variants

4.6.2 Attachment positions

4.6.3 Mounting

4.6.4 Dismounting/mounting motors

4.6.5 Adapting the position of the motor cable outlets

4.6.6 Third-party motors

4.7 Attachment components

4.7.1 Fastening principle

4.7.2 Mounting of attachment components

4.7.3 Drill holes on the slide unit EXCH-40

4.7.4 Drill holes on the slide unit EXCH-60

4.7.5 Power supply line

4.8 Accessories for position sensing

4.8.1 Proximity sensors at X-axis

4.8.2 Proximity sensor at Y-axis

5 Mounting (horizontal mounting position)

5.1 Mounting

5.1.1 Safety instructions

5.1.2 Requirements

5.1.3 Procedure

5.2 Align

5.2.1 Notes

5.2.2 Limit values of the X-axis alignment

5.2.3 Requirements

5.2.4 Preparation

5.2.5 X-axis 1: Align evenness and tilting

5.2.6 X-axis 2: Align height offset, evenness and tilting

5.2.7 Align X-axes parallel

5.2.8 Eliminate warping in the planar surface gantry

5.3 Toothed belt pretensioning

5.3.1 Notes

5.3.2 Checking the toothed belt pretension

5.3.3 Setting toothed belt pretensioning

5.4 Assembly

6 Mounting (vertical mounting position)

6.1 Mounting

6.1.1 Safety instructions

6.1.2 Requirements

6.1.3 Procedure

6.2 Align

6.2.1 Notes

6.2.2 Limit values of the X-axis alignment