Festo EXCH-40-...-AB1 Series Mechanical Installation Download Page 86

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Installation

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

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).

Summary of Contents for EXCH-40-...-AB1 Series

Page 1: ...Description Mechanical installation 8046388 1506a 8046382 EXCH Planar surface gantry ...

Page 2: ...ous 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 Acti...

Page 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 positio...

Page 4: ... 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 axi...

Page 5: ...e 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 Lub...

Page 6: ...M KOMP EN 1506a English 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 ...

Page 7: ...r 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 caus...

Page 8: ...omply 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 Qualifica...

Page 9: ...lanar 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 Dry solid and flat base in original packaging Tab 2 1 ...

Page 10: ...unting 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 th...

Page 11: ...ry EXCH1 1 Adjusting kits2 or mounting plates3 with screws and discs Dependent on the stroke of the X axis è 4 4 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 instructions2 2 Encoder cable with mounting instructions2 2 Attachment component2 4 1 1 Basic filling of the energy chains compres...

Page 12: ...ed 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 Motor 2 Motor 1 Y axis X axis 1 2 3 1 4 Fig 3 1 Directions of movement slide units of the Y axis Fig 3 2 Operational principle 1 Guide pulleys for toothed belt 2 Toothed belt rotating 3 Traverse Y axis 4 ...

Page 13: ...pling housing and motor flange3 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 a...

Page 14: ...re 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 D...

Page 15: ... 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 P3 337 34 8 39 8 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 adjus...

Page 16: ...e 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 P3 366 P4 416 34 8 39 8 1 Depending on the motor version L1 increases by the dimensions L8 und L9 è 4 1 4 Dimensions of motors EXCH 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...

Page 17: ...5 H6 L8 B4 1 2 3 4 5 6 1 B10 B9 H4 1 H4 H5 H6 H3 L8 L9 1 Cover1 2 Drive cover 3 Coupling housing axial kit 4 Motor flange axial kit 5 Motor 6 Motor cable outlet 1 Not applicable if motor attachment position on top 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 5...

Page 18: ... H6 H3 L8 B4 B9 1 2 3 4 5 6 1 B10 H4 1 H4 H5 H6 H3 L8 L9 1 Cover1 2 Drive cover 3 Coupling housing axial kit 4 Motor flange axial kit 5 Motor 6 Motor cable outlet 1 Not applicable if motor attachment position on top 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 ...

Page 19: ...ction 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 ...

Page 20: ...ice 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 po...

Page 21: ...for height differences in the mounting surface of up to 5 mm Reordering adjusting kits è www festo com catalogue Overview 1 2 3 4 5 6 7 1 Slot nut1 2 Adjusting plate1 3 Hexagon head screw1 M6x30 2x 4 Square nut1 2x 5 Adjusting bolt1 2x 6 Washer2 2x 7 Socket head screw2 M8x40 2x 1 Mounted to the profiles of the axes if ordered 2 Enclosed separately if ordered Fig 4 3 Note Incorrect mounting can cau...

Page 22: ...h socket head screws 7 onto the mounting surface 3 Tighten socket head screws 7 tightening torque 24 Nm 7 7 6 2 Fig 4 5 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...

Page 23: ...e 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 accessori...

Page 24: ... B8 B8 B7 2 3 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 L1 L6 L7 B6 B7 B8 Size Depth EXCH 40 M8 14 Stroke X axis 141 n 1 37 5 2 30 5 2 Stroke Y axis 385 8 0 5 78 0 0 2 13 0 EXCH 60 Stroke X axis 328 n 1 42 5 2 30 5 2 Stroke Y axis 531 6 0 5 98 0 0 2 13 02 1 For stroke of the X axis 9...

Page 25: ...1 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 under...

Page 26: ... on top 1 2 3 4 5 6 5 4 3 2 6 1 Cover 2 Drive cover1 with drive pinion 3 Coupling housing 4 Motor flange 5 Mounting screws 6 Motor 1 With motor attachment position on top with sealing disc 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 ...

Page 27: ...y 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 2 3 3 2 1 1 M...

Page 28: ...en 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 sequ...

Page 29: ...g 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 c...

Page 30: ...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 Dismountin...

Page 31: ... 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 j D2 j D3 D4 j 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...

Page 32: ...omponents 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 ma...

Page 33: ...OMP EN 1506a English 33 4 7 3 Drill holes on the slide unit EXCH 40 L16 1 2 B15 B14 L13 L15 L14 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 ...

Page 34: ...ide unit EXCH 60 3 2 B14 1 B16 B15 L18 L19 L15 L16 L22 L21 L20 L14 L13 1 Thread M6 8x 2 Thread M8 8x 3 Centring hole Ø 6 H7 depth 7 mm 4x 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 ...

Page 35: ...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 2 3 4 5 6 7 1 Energy chain of the Y axis 2 Bulkhead fitting on top black compressed air tubing 3 Bulkhead fitting underneath silver compressed air tubing 4 Multi pin plug distributor 6 fold 5 Plug socket with cable 6 Silver compressed...

Page 36: ...nts 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 2 4 3 5 6 7 1 Energy chain of the Y axis 2 Bulkhead fitting on top black compressed air tubing 3 Bulkhead fitting underneath silver compressed air tubing 4 Adapter plate 5 Electrical attachment compo...

Page 37: ...1 Proximity sensor 2 Pneumatic silencer 2 Plug socket with cable 2 Earthing cable 2 Tab 4 14 Components with pneumatic attachment component 1 2 3 4 5 6 7 8 9 aJ 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 7 Compressed air tubing to the attachment component 8 Bulkhead fi...

Page 38: ... cable for the solenoid valve1 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 ...

Page 39: ...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 ...

Page 40: ...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 2 3 1 Switch lugs1 2...

Page 41: ...r 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 dire...

Page 42: ...able 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 ...

Page 43: ...s 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 ...

Page 44: ...ids 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 mounti...

Page 45: ...nd 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 t...

Page 46: ...ace 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 2 3 4 1 5 6 4 5 6 2 1 End cap 2 Transport lug on transport plate 2x 3 Lifting gear with attachment points 4 Transport protection aid 2x 5 Drive cover motor side 6 Transport lug on transport protection aid 2x Fig 5 1 Depicted EXCH 40 B motor attachm...

Page 47: ...sing 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 ret...

Page 48: ...achment 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 3 2 1 4 5 1 Screw A 2 Nut A 3 Screw B 4 Metal sheet 5 Nut B Fig 5 5 Presented EXCH 40 ...

Page 49: ...nting 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 transp...

Page 50: ... EXCH KM KOMP EN 1506a English 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 ...

Page 51: ... 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 adjustin...

Page 52: ...gnment 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 1 2 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 ...

Page 53: ...er 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 2 3 1 Mounting screw of the profile cover 2 Profile cover of the X axis 3 Energy chain of the X axi...

Page 54: ...esults with the demanded limit values è 5 2 2 Limit values of the X axis alignment Check evenness Check sideways tilting 3 4 1 2 1 2 3 4 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 he...

Page 55: ...2 3 aB 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 offs...

Page 56: ... 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...

Page 57: ...out 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 s...

Page 58: ...all 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 ...

Page 59: ...arriage 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 2 4 5 3 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...

Page 60: ...key The frequency measurement device shows the self generated frequency of the toothed belt 1 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 measurem...

Page 61: ...he toothed belt This reduced pretension must not be used for evaluating the wear condition of the toothed belt Belt tensioning device 1 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 2 3 1 End cap wi...

Page 62: ...sioning 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 1 1 Adjusting screw 2x Fig 5 18 ...

Page 63: ...oothed 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 2 1 Threaded...

Page 64: ...t 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 tem...

Page 65: ...e 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 o...

Page 66: ... located in and below the operating area of the planar surface gantry 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 ...

Page 67: ...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 ...

Page 68: ...ak 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 1 2 3 4 45 45 5 6 3 5 2 4 1 Lifting gear with attachment points 2 Transport lug 2x 3 Transport protection aid 2x 4 Transport plate with transport lugs1 2x 5 End cap 6 Drive cover motor si...

Page 69: ...ting 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 t...

Page 70: ...chment 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 3 2 1 4 5 1 Screw A 2 Nut A 3 Screw B 4 Metal sheet 5 Nut B Fig 6 4 Presented EXCH 40 ...

Page 71: ... 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 Remo...

Page 72: ...port 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 ...

Page 73: ...reduced Align X axes on the guide rails Measure limit values on the guide rails Use appropriate tools and measuring equipment e g laser tracker 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 The mounting plates are not adjustable ...

Page 74: ... 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 2 3 4 5 1 Guide rail of the X axis 1 2 End cap 3 Adjusting kit 4 Guide rail of the X axis 2 5 Drive cover motor side Fig 6 7 ...

Page 75: ...face 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 2 3 1 Mounting screw of the profile cover 2 Profile cover of the X axis 3 Energy chain of the X axis Fig 6 8 ...

Page 76: ... 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 C...

Page 77: ...hain 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 sc...

Page 78: ...ll 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 t...

Page 79: ...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 ...

Page 80: ...toothed belt pretensioning can be inspected with mounted or dismounted profile cover of the X axis 1 2 4 5 L11 6 1 Traverse Y axis 2 X axis 1 with energy chain 4 Belt tension setting piece dimension L11 144 4 mm 5 Carriage of the X axis 6 End cap 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 dime...

Page 81: ...ey The frequency measurement device shows the self generated frequency of the toothed belt 1 1 Acoustic frequency measurement device Fig 6 11 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 6 Compare the measureme...

Page 82: ...f the toothed belt This reduced pretension must not be used for evaluating the wear condition of the toothed belt Belt tensioning device 1 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 2 3 1 End cap...

Page 83: ...ioning 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 1 1 Adjusting screw 2x Fig 6 15 ...

Page 84: ...g 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 2 1 Threaded pin 2x 2 Socket head sc...

Page 85: ...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 Temperature changes influence the toothed belt pretensioning One time only after the 1st commissioning at operating temperature after ap prox 30 strokes...

Page 86: ... 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 protecti...

Page 87: ... 7 2 are connected to it Overview of connections 1 2 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 informat...

Page 88: ...W Line BK 3 4 V Line BK 2 A MT Temperature sensor BN Cables with wire end sleeves 4x 0 5 mm2 B MT Temperature sensor WH C BR Brake optional GN 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 SUB D plug connector 15 pin 2 SENS 9 3 DATA 12 4 DATA...

Page 89: ...location for the motor cable attachment component Motor side Colour1 Controller side Plug connector Port Pin Function Black 4 pin 1 V Line BK 2 Cables with wire end sleeves 4x 0 75 mm2 2 W Line BK 3 3 U Line BK 1 PE PE Protective earth GNYE Blue 6 pin 1 MT Temperature sensor WH Cables with wire end sleeves 4x 0 25 mm2 2 MT Temperature sensor BN 3 BR Brake GN 4 BR Brake YE 5 n c 6 n c 1 Specificati...

Page 90: ... 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 2 3 4 5 1 X axis 2 Earthing component of the Y axis 3 Earthing point at the slide unit of the Y axis 4 Traverse Y axis 5 Slide units 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 attac...

Page 91: ...ery 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 1 2 3 4 5 6 7 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 4 Small ...

Page 92: ...eration 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 instal...

Page 93: ...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...

Page 94: ...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 Requirement...

Page 95: ... 5 6 4 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 4 Carriage of the X axis 5 Maintenance opening 6 Traverse Y axis Fig 9 1 Depicted planar surface gantry EXCH 60 ...

Page 96: ... 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 po...

Page 97: ... Select the corresponding accessories from the Festo catalogue è www festo com catalogue Designation Type Lubricant ISOFLEX TOPAS NB 52 K2011 009 1 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 ...

Page 98: ...ain 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 correspo...

Page 99: ...l 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 subs...

Page 100: ...ting 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 è www festo com in accordance with Machinery Directive 2006 42 EC 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 A...

Page 101: ...g 2 7 EXCH AS2 kg 4 8 6 9 EXCH AS3 kg 9 6 with brake EXCH AB1 kg 2 9 EXCH AB2 kg 5 3 7 5 EXCH AB3 kg 10 4 Mounting accessories2 Adjusting kit kg 0 78 0 89 Mounting plate kg 0 26 0 30 Attachment component Electrical EXCH E1 kg 3 4 5 3 EXCH E2 kg 4 0 6 2 Pneumatic EXCH P1 kg 1 8 2 7 EXCH P2 kg 2 4 3 6 EXCH P3 kg 2 7 4 3 EXCH P4 kg 5 0 1 Rated load tool load attachment component Z axis gripper for ex...

Page 102: ...ng position Horizontal m s2 50 50 Vertical m s2 30 30 Speed max Mounting position Horizontal m s 5 5 Vertical m s 4 3 1 Rated load tool load attachment component Z axis gripper for example payload Tab A 6 Note The specified dynamic data apply only under ideal conditions For specific data see the catalogue è www festo com catalogue Permissible forces and torques Note Comply with catalogue specifica...

Page 103: ...eristic EXCH 40 EXCH 60 Ambient temperature C 10 50 Degree of protection in accordance with EN 60529 IP40 Storage temperature C 10 60 Air humidity 0 90 non condensing Noise level1 dB A 74 81 Duty cycle 100 1 Energy equivalent A weighted noise level at 1 m distance determined locally over the measurement surface Tab A 7 ...

Page 104: ...ation is prohibited Offenders will be liable for damages All rights re served in the event that a patent utility model or design patent is registered Copyright Festo AG Co KG Postfach 73726 Esslingen Germany Phone 49 711 347 0 Fax 49 711 347 2144 e mail service_international festo com Internet www festo com Original de ...

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