Linear gantry EXCT. Description. Mechanical installation NH [ ]

Linear gantry EXCT Description Mechanical installation 8059080 60NH [805908]

EXCT Translation of the original instructions EXCT-EN LOCTITE is a registered trademark of its respective trademark holder in certain countries. Identification of hazards and instructions on how to prevent them: Danger Immediate dangers which can lead to death or serious injuries Warning Hazards that can cause death or serious injuries Caution Hazards that can cause minor injuries Other symbols: Note Material damage or loss of function Recommendations, tips, references to other documentation Essential or useful accessories Information on environmentally sound usage Text designations: Activities that may be carried out in any order. Activities that should be carried out in the order stated General lists Result of an action/references to more detailed information Festo EXCT-EN 60NH English

EXCT Table of Contents EXCT Requirements for product use... 5. Target group... 5. Intended use... 5.3 Foreseeable misuse... 5.4 Applicable documents... 6.5 Obligations of the machine manufacturer... 6.6 Service... 6 Transport and storage... 7. Restraints in the packaging... 7. Axis lock... 8 3 Product overview... 9 3. Configuration... 9 3. Operational principle... 0 3.3 Permitted mounting position... 3.4 Motor attachment positions... 4 Mounting... 3 4. Safety instructions... 3 4. Preparation... 4 4.. Installation space... 4 4.. Mounting surface... 4 4..3 Types of mounting... 4 4..4 Mounting space and number of mountings... 5 4..5 Mounting kit dimensions... 6 4..6 Dimensions for slot nut mounting... 8 4..7 Removing transport restraints... 9 4.3 Installation... 0 4.3. Installation with mounting kits... 0 4.3. Installation with slot nuts... 4 4.4 Optional work... 9 4.4. Manually moving the Z-axis... 9 4.4. Dismantling/mounting motors... 30 4.4.3 Adapting cable outlets... 3 4.4.4 Dismantling/mounting the axis lock... 34 Festo EXCT-EN 60NH English 3

EXCT 4.5 Attachment components... 35 4.5. Overview... 35 4.5. Version without front unit (EXCT- -T0)... 36 4.5.3 Version with front unit (EXCT- -T to -T4)... 37 4.6 Accessories... 38 4.6. Sensing kit... 38 5 Installation... 39 5. Safety instructions... 39 5. Electrical installation... 40 5.. Multi-pin plug distributor... 40 5.. Drive motors... 4 5..3 Front unit attachment component (rotary drive)... 45 5..4 Earthing... 46 5.3 Pneumatic installation... 47 5.4 Cables and tubes... 48 5.4. Installing an additional cable (tube)... 48 6 Commissioning... 5 7 Maintenance... 5 7. Safety instructions... 5 7. Cleaning... 5 7.3 Lubrication... 53 7.4 Repair... 54 8 Dismantling... 55 8. Safety instructions... 55 8. Procedure... 56 8.3 Recycling... 56 A Technical appendix... 57 A. General product characteristics... 57 A. Evenness... 58 A.3 Dynamic... 59 A.4 Electrical... 59 A.5 Pneumatic... 59 A.6 Approvals... 59 A.7 Materials... 60 A.8 Operating and storage conditions... 60 4 Festo EXCT-EN 60NH English

Requirements for product use Requirements for product use. Target group Provide this documentation to the following persons: Design engineer/machine manufacturer Installer Commissioner Mounting, installation, commissioning, maintenance and disassembly should only be performed by qualified personnel who are familiar with: Mounting and operation of mechatronic systems Installation and operation of electrical control systems Installation and operation of pneumatic systems The applicable regulations for accident prevention and occupational safety The documentation and mode of operation of the product. Intended use This product is a handling system and executes positioning tasks within machines or automated systems with a higher-order controller. Only use the product as follows: In perfect technical condition In its original status, without unauthorised modifications Within the limits of the product defined by the technical data In an industrial environment Note In the event of damage caused by unauthorised manipulation or other than intended use, the guarantee is invalidated and the manufacturer is not liable for damages..3 Foreseeable misuse Never use the product as follows: With unauthorised modifications or alterations to the product In an invalid mounting position With load limits exceeded Without a risk assessment of the complete system Without a safety concept for the complete system Festo EXCT-EN 60NH English 5

Requirements for product use.4 Applicable documents Further information can be found in the support portal ( www.festo.com/sp)..5 Obligations of the machine manufacturer The product is an incomplete machine. Commissioning is prohibited until it has been established that the machinery in which the product will be installed is in compliance with the provisions of Machinery Directive 006/4/EC. Take the following into consideration for the destination: Regulations and standards Regulations of the testing organisations and insurers National specifications.6 Service Please consult your regional Festo contact if you have any technical problems. 6 Festo EXCT-EN 60NH English

Transport and storage Transport and storage Note Damage to the product due to incorrect transport. Observe the transport labelling and information on the packaging.. Transport the product to the installation/storage location in its packaging and set it down on a firm and flat base.. When storing the product please observe the storage conditions ( A.8 Operating and storage conditions). Note Damage to the product due to incorrect unpacking. Observe the labelling for unpacking on the packaging. Unpack the product with at least other persons present. Use appropriate tools. Parts of the packaging are large and heavy: Do not let any parts fall onto the product. Use suitable aids to raise and lower the product (e.g. crane). 3. Remove the packaging in accordance with the printed sequence. 4. Remove the plastic sheet and drying agent.. Restraints in the packaging Transport restraints prevent uncontrolled movement of the product in the packaging during transport and installation. The product is provided with the following designated transport restraints: Transport screws Cable ties Fig.. Festo EXCT-EN 60NH English 7

Transport and storage. Axis lock For product versions/orders without any motors An axis lock is mounted on each of the drive housings in place of the coupling housing and the motors. The axis locks function as a brake on the toothed belt and prevent uncontrolled movements of the Z-axis during transport and mounting procedures. Warning Products without motors or axis locks on the drive housings: Uncontrolled movements of the Z-axis during transport and mounting procedures. Risk of impact and crushing injuries. Remove the axis locks immediately prior to mounting the motors. Observe the instructions for dismantling ( 4.4.4 Dismantling/mounting the axis lock). EXCT-5 EXCT-30/00 Axis lock Fig.. Illustrated: EXCT-5 and EXCT-00: Without motors, intended motor attachment position at the front 8 Festo EXCT-EN 60NH English

3 Product overview 3 Product overview 3. Configuration ab aa aj 9 3 4 5 8 6 7 Drive housing Coupling housing ) 3 Motor (right) ) 4 Y-axis 5 Z-axis 6 Interface for attachment components ) optional Fig. 3. Example illustration of EXCT-5- -AB-VV 7 Multi-pin plug distributor ) 8 Motor (left) ) 9 Slide units of the Y-axis aj Mounting kit aa Energy chain of the Y-axis ab Energy chain of the Z-axis Festo EXCT-EN 60NH English 9

3 Product overview 3. Operational principle Two fixed servo motors drive a toothed belt arrayed in a T-shape. The toothed belt moves the slide of the Y-axis and the interface located on the Z-axis in a -dimensional space. A controller calculates the position of the interface. The controlled interaction of the motors results in the corresponding movement of the interface. Motor 6 Motor Motor Motor 5 4 3 Fig. 3. Directions of movement of the interface Fig. 3.3 Functional principle Toothed belt Y-axis 3 Interface for attachment components 4 Z-axis 5 Slide units of the Y-axis 6 Guide pulleys for toothed belt The depicted directions of movement of the interface (Fig. 3.) refer to the directions of rotation of the motor for the functional principle shown (Fig. 3.3). 0 Festo EXCT-EN 60NH English

3 Product overview 3.3 Permitted mounting position Note The product may only be mounted and operated with a vertical Z-axis. The interface for attachment components must be aligned at the bottom. Any other mounting position is not permitted. 3 Y-axis Z-axis 3 Interface for attachment components Fig. 3.4 Festo EXCT-EN 60NH English

3 Product overview 3.4 Motor attachment positions The motor attachment position depends on the order ( Tab. 3.). For an order without any motors: The drive housings are mounted according to the attachment position ordered. Product version Motor (left) Motor (right) EXCT- -VV -VH -HV -HH Tab. 3. Festo EXCT-EN 60NH English

4 Mounting 4 Mounting 4. Safety instructions Danger Unexpected movement of the product. Risk of impact and crushing injuries. Before working on the product, switch off the power supply and secure it against being switched on again. Before working on the product, switch off the compressed air supply, vent if necessary and secure it against being switched on again. Pneumatic system parts can still contain compressed air even when they are switched off. Vent pneumatic system parts accordingly. When lifting the product, perform the following measures: Secure movable components with transport restraints to prevent unexpected movement. Observe the product weight. Observe the position of the centre of gravity. Use suitable lifting gear. Use all of the transport brackets. Adjust the lifting speed. When securing the product, perform the following measures: Secure the product in a professional manner. Only use the supplied mounting components. Secure the screw connections. Make sure the mounting surface is sufficiently strong to absorb the maximum forces. Danger Risk of injury from electric shock. Before working on the product, switch off the power supply and secure it against being switched on again. Dangerous residual voltage even after the power supply is switched off: Start work on plugs and interfaces only when the residual voltage has fallen below 60 V. Festo EXCT-EN 60NH English 3

4 Mounting 4. Preparation 4.. Installation space The installation space required for the product depends on the following: Size of the product Stroke of the Y- and Z-axis ( www.festo.com/catalogue) Attachment position of the motors ( 3.4 Motor attachment positions) Sufficient free space for movement of the interface (Z-axis) and the attachment component Sufficient space for the cable outlet on the connection side of the energy chain: This may be on the left or right depending on the product version 4.. Mounting surface The mounting surface must exhibit the following characteristics: Torsionally rigid Free of stress Sufficient strength to absorb the maximum forces Sufficient evenness ( A. Evenness) 4..3 Types of mounting The product can be secured to the mounting surface with the following types of mounting. Types of mounting With mounting kits on the backwall of the Y-axis With slot nuts on the backwall of the Y-axis or on the underside of the Y-axis (Observe the following note.) Instructions 4.3. Installation with mounting kits 4.3. Installation with slot nuts Tab. 4. Note The procedure for mounting With slot nuts on the underside of the Y-axis is only permissible for a Y-stroke 500 mm by using the third/central mounting position ( 4..4 Mounting space and number of mountings). When the product is delivered, the required number of mounting kits are mounted. Alternative types of mounting with accessories ( www.festo.com/catalogue). 4 Festo EXCT-EN 60NH English

4 Mounting 4..4 Mounting space and number of mountings Prepare mounting points (e.g. threaded holes) in the mounting surface. When doing this observe the following: Determine the required number of mounting positions ( Tab. 4.). Observe mounting space L ( Tab. 4. and Fig. 4.). Hole spacing according to the type of mounting: With mounting kits ( 4..5 Mounting kit dimensions) With slot nuts ( 4..6 Dimensions for slot nut mounting) With 3 mounting positions: 3rd mounting located centrally between the outer mountings (L/). Mounting space and number of mountings Mounting space L (outer mountings) [mm] L = Y-stroke Number of mounting positions where Y-stroke 500 mm where Y-stroke 500 mm 3 Tab. 4. Mounting space L outer mountings with spacing L 3rd mounting (where Y-stroke 500 mm) Fig. 4. Illustrated: 3 mounting positions with 3 mounting kits as type of mounting Festo EXCT-EN 60NH English 5

4 Mounting 4..5 Mounting kit dimensions Number of required mounting points/drill holes per mounting kit: 4 drill holes ( above and below the Y-axis) Observe the dimensions of the mounting kit: EXCT-5: Fig. 4. EXCT-30/00: Fig. 4.3 Mounting kit EXCT-5 3 Slot nut (4x) Stop edge for profile of the Y-axis bottom Fig. 4. 3 Drill holes for M6 mounting screws Size Dimensions [mm] B B B3 D D H H H3 EXCT-5 4 0 7 6. 5 80 30 60 H4 H5 L L L3 L5 L6 L7 EXCT-5 55 45 30 80 00 80 30 60 Tab. 4.3 6 Festo EXCT-EN 60NH English

4 Mounting Mounting kit EXCT-30/00 3 Slot nut (4x) Stop edge for profile of the Y-axis bottom Fig. 4.3 3 Drill holes for M8 mounting screws Size Dimensions [mm] B B D D H H H3 H4 EXCT-30 4 0 6. 8 00 35 60 70 EXCT-00 L L L3 L4 L5 L6 L7 EXCT-30 470 430 30 300 30 40 85 EXCT-00 60 00 Tab. 4.4 Festo EXCT-EN 60NH English 7

4 Mounting 4..6 Dimensions for slot nut mounting The slots for slot nut mounting are located on the backwall and underside of the profile of the Y-axis. Number of drill holes per mounting position ( 4..4 Mounting space and number of mountings): slot nuts are required for each mounting position and each slot. Example calculation: 3 mounting positions x slots x slot nuts/slot = slot nuts. EXCT-5 EXCT-30/00 3 3 4 Backwall slot, top Backwall slot, bottom 3 Underside slot, rear 4 Underside slot, front (EXCT-30/00 only) Size Dimensions [mm] c a b x y EXCT-5 0 60 8 80 EXCT-30 0 85 0 30 8 EXCT-00 0 00 0 60 50 Tab. 4.5 8 Festo EXCT-EN 60NH English

4 Mounting 4..7 Removing transport restraints. Prior to starting assembly only remove the following, designated transport restraints: Transport screws on the mounting kits Mounting brackets and transport screws on the interface of the Z-axis Retain the mounting brackets and transport screws for future use.. Attach lifting gear to all of the transport brackets on the product. Note Risk of damage to the Z-axis if lifted at an angle. The Z-axis must not be stressed during lifting or mounting procedures. Do not lift the product by the Z-axis. Attach suitable lifting gear to all of the mounting kits on both sides via the transport brackets. Lift the product without exerting any stress on the Z-axis. 3 4 Mounting kit (each with transport brackets) Transport brackets for lifting gear Fig. 4.4 3 Interface for the Z-axis 4 Z-axis Illustrated: EXCT-5 with front motor attachment positions and mounting kits Festo EXCT-EN 60NH English 9

4 Mounting 4.3 Installation 4.3. Installation with mounting kits 3 Transport brackets for lifting gear 3 Slot nut (4x for each mounting kit) Mounting kit Fig. 4.5 Illustrated: EXCT-5 with front motor attachment positions and two mounting kits When the product is delivered, the required number of mounting kits are mounted with slot nuts on the backwall of the Y-axis. Note Motors with brakes or axis locks are mounted on the product in a delivery status to prevent the Z-axis from moving. To move the Z-axis: 4.4. Manually moving the Z-axis.. Observe the safety instructions ( 4. Safety instructions).. Remove the transport restraints ( 4..7 Removing transport restraints). 0 Festo EXCT-EN 60NH English

4 Mounting Note Risk of damage to the Z-axis if subjected to stress. When handling and setting down the product, do not subject the interface or Z-axis to any stress. Caution Risk of tipping over. Risk of impact and crushing injuries Place the product on sturdy supports (e.g. mounting benches) and secure it from falling/tipping over. 3. Place the underside of the Y-axis on supports and secure the product in place. 4 3 Mounting kit Slot nut screws (4x for each mounting kit) Fig. 4.6 3 Interface (Z-axis) 4 Support (e.g. mounting bench) Festo EXCT-EN 60NH English

4 Mounting 4. If required, align the mounting kits with the prepared mounting points on the mounting surface: Loosen the slot nut screws approx. one rotation. Slide the mounting kits in the direction of the arrow. Unscrew the slot nut screws one after the other and tighten with Loctite 43 screw locking agent (tightening torque 0 Nm). 5. Check whether the lifting gear can be used on the transport brackets of the mounting kits for mounting purposes. Distance between transport bracket and backwall of mounting kit: approx. 6 mm. Use suitable lifting gear. Alternatively, attach the lifting gear to the drive housings on the left and right-hand side. 3 3 Mounting kit Transport bracket for lifting gear Fig. 4.7 3 Drive housing 6. Use the lifting gear, or ask other people for assistance, to position the product on the mounting points of the mounting surface. Festo EXCT-EN 60NH English

4 Mounting 7. Secure the product to the mounting surface by using suitable screws ( Tab. 4.6). Screws are not included in the scope of delivery. Warning Incorrect mounting. Risk of impact and crushing injuries. Use screws with a strength class of at least 8.8. Select screws suitable for the installation situation. EXCT-5 EXCT-30 EXCT-00 Screws for mounting kit M6 M8 M8 Tab. 4.6 Mounting kit Screws (4x for each mounting kit) Fig. 4.8 8. If used, remove the lifting gear. 9. If present: Remove the labelled transport restraints (cable ties) from the moving parts. Festo EXCT-EN 60NH English 3

4 Mounting 4.3. Installation with slot nuts There are two options on the Y-axis for mounting with slot nuts: on the backwall of the profile (example: Fig. 4.9) on the underside of the profile (example: Fig. 4.0) Fig. 4.9 Example: Mounting with slot nuts on the backwall of the Y-axis profile Fig. 4.0 Example: Mounting with slot nuts on the underside of the Y-axis profile 4 Festo EXCT-EN 60NH English

4 Mounting Note The procedure for mounting With slot nuts on the underside of the Y-axis is only permissible for a Y-stroke 500 mm by using the third/central mounting position ( 4..4 Mounting space and number of mountings). Note Motors with brakes or axis locks are mounted on the product in a delivery status to prevent the Z-axis from moving. To move the Z-axis: 4.4. Manually moving the Z-axis.. Observe the safety instructions ( 4. Safety instructions).. Remove the transport restraints ( 4..7 Removing transport restraints). Note Risk of damage to the Z-axis if subjected to stress. When handling and setting down the product, do not subject the interface or Z-axis to any stress. Caution Risk of tipping over. Risk of impact and crushing injuries Place the product on sturdy supports (e.g. mounting benches) and secure it from falling/tipping over. 3. Place the underside of the Y-axis on supports and secure the product in place. Festo EXCT-EN 60NH English 5

4 Mounting 4 3 Mounting kit Slot nut screws (4x for each mounting kit) Fig. 4. Illustrated: EXCT-5 with front motor attachment positions 3 Interface (Z-axis) 4 Support (e.g. mounting bench) When mounting on the underside of the profile: The assembled mounting kits can be used to transport the product to the mounting surface. Only remove the mounting kits when the product has been mounted. Order the required slot nuts as accessories ( www.festo.com/catalogue). 4. Only applicable for mounting on the backwall of the profile: Dismantle the mounting kits: Unscrew four slot nut screws from each mounting kit ( Fig. 4.). Remove the mounting kits. Leave the slot nuts in the slot. 6 Festo EXCT-EN 60NH English

4 Mounting Note Retain the mounting kits for future use. 5. Position the slot nuts into the slots in accordance with the prepared drill holes in the mounting surface. When mounting on the backwall of the profile: Number of slots: Total number of slot nuts required: mounting positions: 8x 3 mounting positions: x When mounting on the underside of the profile: Number of slots: EXCT-5: ; EXCT-30/00: Total number of slot nuts required: mounting positions: EXCT-5: 4x; EXCT-30/00: 8x 3 mounting positions: EXCT-5: 6x; EXCT-30/00: x Slot nut Slot in the profile of the Y-axis Fig. 4. Illustrated: Mounting on the underside of the profile 6. Place the product on the mounting surface. When mounting on the backwall of the profile: Attach suitable lifting gear to the drive housings on the left and right-hand side or ask other people for assistance. When mounting on the underside of the profile: Attach suitable lifting gear to the transport brackets of the mounting kits. Festo EXCT-EN 60NH English 7

4 Mounting 7. Select suitable M6 screws for mounting into the slot nuts. Warning Incorrect mounting. Risk of impact and crushing injuries. Use screws with a strength class of at least 8.8. Select screws suitable for the installation situation. Screw length: Observe the screw-in depth in the profile and the thickness of the mounting surface. 8. Tighten the screws into the slot nuts with Loctite 43 screw locking agent (tightening torque 0 Nm). Fig. 4.3 9. If used, remove the lifting gear. 0.When mounting on the underside of the profile: Remove the mounting kits ( step 4.). Remove the slot nuts from the slots in the backwall of the profile..if present: Remove the labelled transport restraints (cable ties) from the moving parts. 8 Festo EXCT-EN 60NH English

4 Mounting 4.4 Optional work 4.4. Manually moving the Z-axis Depending on the order, the Z-axis (slide of the Y-axis) is secured against uncontrolled movements when delivered. For product versions with motors: Motors with brakes are mounted. For product versions without motors: Axis locks are mounted on the drive housings. The Z-axis can be moved for mounting with the following procedure. Note Altered centre of gravity when dismantling the motors or a displaced Z-axis. Risk of damage to the product when handling or as a result of it falling. Secure the product to the mounting surface ( 4.3 Installation) or Place the product with the underside of the Y-axis on sturdy supports (e.g. mounting benches): Do not stress the Z-axis. Secure the product on the supports to prevent it from falling and tipping over.. If present: Remove the labelled transport restraints (cable ties) from the moving parts.. If motors are mounted: Dismantle the motors ( 4.4. Dismantling/mounting motors). If axis locks are mounted: Dismantle the axis locks ( 4.4.4 Dismantling/mounting the axis lock). 3. Manually move the Z-axis to the desired position. Festo EXCT-EN 60NH English 9

4 Mounting 4.4. Dismantling/mounting motors Note Third-party motors with a driving torque that is too high can damage the product. When using third-party motors observe the following: Only use motors with a brake. Maximum permissible driving torque ( www.festo.com/catalogue) Mounting dimensions of motor interface ( www.festo.com/catalogue) Use a suitable combination of coupling, coupling housing and motor flange. Product version with motors Motors with a brake secure the Z-axis (slide of the Y-axis) against uncontrolled movements. Motor attachment position, front Motor attachment position, rear 5 4 3 3 4 5 Motor Mounting screw (4x) 3 Motor flange Fig. 4.4 Illustrated: EXCT-5, motor (left) 4 Coupling housing 5 Drive housing 30 Festo EXCT-EN 60NH English

4 Mounting Dismantling the motors Note Altered centre of gravity when dismantling the motors. Risk of damage to the product when handling or as a result of it falling. Secure the product to the mounting surface ( 4.3 Installation) or Place the product with the underside of the Y-axis on sturdy supports (e.g. mounting benches): Do not stress the Z-axis. Secure the product on the supports to prevent it from falling and tipping over. Warning When motors are removed, the Z-axis can move uncontrollably in direction Y and Z under its own weight. Risk of impact and crushing injuries. Before dismantling the motors please ensure the following: The Z-axis is secured against uncontrolled movements and The interface (Z-axis) is in the lower end position.. Disconnect all of the cables from the motor.. Unscrew the four mounting screws from the motor. 3. Remove the motor. 4. Repeat steps. to 3. for the other motor. Mounting the motors. Place the motor flange and motor in position.. Tighten the mounting screws (for the tightening torque refer to the table). Tightening torque EXCT-5 EXCT-30 EXCT-00 Mounting screws (motor) [Nm] 8.3 8 8 Tab. 4.7 3. Connect the cables to the motor. 4. Repeat steps. and 3. for the other motor. Note Dismantling and mounting the motors will result in homing settings being lost. Perform homing ( Description EXCT commissioning ). Festo EXCT-EN 60NH English 3

4 Mounting 4.4.3 Adapting cable outlets When delivered, the cable outlets on the motors are in the top mounting position. The position can be adapted to the installation situation by turning the motors in 90 increments. Requirement: The product is secured to the mounting surface ( 4.3 Installation). 3 4 5 Motor (left) Mounting screws (4x for each motor) 3 Cable outlet (motor connection) Fig. 4.5 4 Motor (right) 5 Interface (Z-axis) Illustrated: EXCT-5 with front motor attachment positions Warning The interface (Z-axis) will fall to the lower end position when the mounting screws are unscrewed from the motors. Risk of impact and crushing injuries. Make sure that the interface (Z-axis) is located in the lower end position. Note Position the interface (Z-axis) so that a free moving space of approx. 0 cm is available to the left and right (direction Y). To move the interface: ( 4.4. Manually moving the Z-axis). 3 Festo EXCT-EN 60NH English

4 Mounting. If connected, disconnect the cables from the motor.. Unscrew the mounting screws from the motor. 3. Turn the motors to the desired position in accordance with the directions illustrated ( Fig. 4.5): Motor (left): Clockwise Motor (right): Anti-clockwise For a rear motor attachment position: The direction of rotation of the motors is identical to the directions illustrated in Fig. 4.5. The interface (Z-axis) performs a minor diagonal upward movement in each case. 4. Tighten the mounting screws (for the tightening torque refer to the table). Tightening torque EXCT-5 EXCT-30 EXCT-00 Mounting screws (motor) [Nm] 8.3 8 8 Tab. 4.8 5. Connect the cables to the motor. Note Altering the position of the cable outlets will result in homing settings being lost. Perform homing ( Description EXCT commissioning ). Festo EXCT-EN 60NH English 33

4 Mounting 4.4.4 Dismantling/mounting the axis lock For a product version/order without motors, the axis locks will be mounted on the two drive housings when delivered. The axis locks function as a brake on the toothed belt and prevent uncontrolled movements of the Z-axis during transport and mounting procedures. Warning Products without motors or axis locks on the drive housings: Uncontrolled movements of the Z-axis during transport and mounting procedures. Risk of impact and crushing injuries. Prior to dismantling the axis locks, please observe the following: The product is secured to the mounting surface or The product is placed with the underside of the Y-axis resting on sturdy supports. Do not stress the Z-axis. Do not place the product on the Z-axis. Secure the product to prevent it from falling and tipping over. Make sure that the Z-axis is secured against uncontrolled movements. Make sure that the interface (Z-axis) is located in the lower end position. Dismantling. Loosen the clamping screw approx. rotations.. Unscrew the mounting screws 3. 3. Remove the axis lock from the drive housing 4. 4. Repeat steps. to 3. for the second axis lock. 4 Fig. 4.6 Illustrated: EXCT-5, drive housing left 3 Retain the axis locks for future use. Mounting. Make sure that the interface (Z-axis) is located in the lower end position.. Mount the axis locks on both drive housings in reverse order. For tightening torques please refer to the table. Tightening torques Mounting screws 3 [Nm].9 Clamping screw Tighten until the Z-axis can no longer be moved. 34 Festo EXCT-EN 60NH English

4 Mounting 4.5 Attachment components 4.5. Overview Attachment components (e.g. grippers, suction cups, etc.) can be attached to the interface of the Z-axis via the prepared mounting holes with female threads. Z-axis Interface Fig. 4.7 Interface of the Z-axis; illustrated product version without front unit (EXCT-5- -T0) Note Observe the following when designing and mounting attachment components: Defined limit values ( A. General product characteristics) Maximum screw-in depth at the interface: EXCT-5/-30: 0 mm EXCT-00: 4 mm Documentation of the attachment component When mounting and connecting the attachment component: Switch off the power supply to the system and secure it from being restarted accidentally. Product versions EXCT- Attachment component on the interface Notes/power supply -T0 4.5. -T ERMH-8-E7- Front unit 4.5.3 -T ) ERMH-8-P-E7- with electric rotary drive -T3 ERMH--E7- -T4 ) ERMH--P-E7- ) Front unit with additional pneumatic through-feed (ERMH- -P- ) Tab. 4.9 Festo EXCT-EN 60NH English 35

4 Mounting 4.5. Version without front unit (EXCT- -T0) An attachment component is not mounted on the interface. Mounting holes (4x) for front unit with electric rotary drive ERMH- -E7- Fig. 4.8 Illustrated: EXCT-5 Mounting holes (6x) for connecting plate of the attachment component EGSL-... Dimensions of the mounting holes ( www.festo.com/catalogue). When mounting the attachment components please observe the corresponding documentation. Power supply The energy chain contains the following cables for connecting attachment components. Components Quantity Tubing Earthing cable Connecting cable ) ) Optional; only when ordering the product with multi-pin plug (EXCT- -MP) Tab. 4.0 Note When installing other cables or tubes in the energy chain, please observe: 5.4 Cables and tubes. 36 Festo EXCT-EN 60NH English

4 Mounting 4.5.3 Version with front unit (EXCT- -T to -T4) The front unit is mounted and connected to the electric rotary drive ERMH- -E7-... at the interface of the Z-axis. 8 3 4 7 5 6 Air port (variant T and T4) Connection for encoder cable 3 Connection for motor cable 4 Rotary drive ERMH- -E7- Fig. 4.9 5 Connection for sensor cable 6 Connecting plate for the front unit 7 Interface 8 Z-axis When mounting other attachment components to the front unit or interface: Observe the documentation for the attachment component. Power supply The energy chain contains the following cables for connecting attachment components. Components Quantity Tubing Motor cable Encoder cable Earthing cable Sensor cable Connecting cable ) ) Optional; only when ordering the product with multi-pin plug (EXCT- -MP) Tab. 4. Note When installing other cables or tubes in the energy chain, please observe: 5.4 Cables and tubes. Festo EXCT-EN 60NH English 37

4 Mounting 4.6 Accessories 4.6. Sensing kit Accessories ( www.festo.com/catalogue) The sensing kit includes a proximity switch and is suitable for sensing the position of the slide on the Y-axis. Several sensing kits can be attached to the profile of the Y-axis. Observe the assembly instructions for the sensing kit. 38 Festo EXCT-EN 60NH English

5 Installation 5 Installation 5. Safety instructions Danger Unexpected movement of the product. Risk of injury due to electric shock, impact, crushing. Before working on the product, switch off the power supply and secure it against being switched on again. Before working on the product, switch off the compressed air supply, vent if necessary and secure it against being switched on again. Pneumatic system parts can still contain compressed air even when they are switched off. Vent pneumatic system parts accordingly. Danger Risk of injury from electric shock. Before working on the product, switch off the power supply and secure it against being switched on again. Dangerous residual voltage even after the power supply is switched off: Start work on plugs and interfaces only when the residual voltage has fallen below 60 V. Festo EXCT-EN 60NH English 39

5 Installation 5. Electrical installation 5.. Multi-pin plug distributor For product version EXCT- -MP, an electrical multi-pin plug distributor is mounted on the interface of the Z-axis ( 3. Configuration). The connecting cable is connected to the multi-pin plug connection 5 ( Tab. 5.). The connecting cable is routed through the energy chains and it is intended for connection to a control system. Sensors can be connected to the sensor connections 4. Pin allocation 4 3 5 Sensor connections 4 Multi-pin plug connection 5 Pin Function/assignment Pin Colour ) 4 Operating voltage 5 GY 3 0 V 7 BU 4 Unassigned for customer applications WH 4 Unassigned for customer applications BN 3 4 Unassigned for customer applications 3 GN 4 4 Unassigned for customer applications 4 YE ) Colour code in accordance with IEC 60757:983-0, at the loose end of the cable Tab. 5. Note Unsealed sensor connections influence the degree of protection ( A.8 Operating and storage conditions). Seal any unused sensor connections with cover caps. 40 Festo EXCT-EN 60NH English

5 Installation 5.. Drive motors Note Before installing the motor and encoder cables - especially with regard to non-festo products: Refer to the corresponding documentation for installation information. For product versions/orders with motors: The two drive motors are servo motors with holding brakes, each with a motor and encoder connection. Motor connection M3 (8-pin) Encoder connection M (8-pin) Fig. 5. Illustrated: Motor of the EXCT-30 Festo EXCT-EN 60NH English 4

5 Installation Installing and connecting motor and encoder cables The product version with the Y-axis energy chain on the right-hand connection side is described in the following procedure. For product versions with the Y-axis energy chain on the left-hand connection side (not described here), please note the following deviations: Each of the mountings are located on the other side of the Y-axis. The motor and encoder cables for motor (right) are to be installed in the Y-axis.. Unscrew the two screws on the connection side of the Y-axis energy chain ( Fig. 5.). EXCT-5 EXCT-30/00 5 3 3 5 3 4 4 3 4 4 Screw (x) Energy chain of the Y-axis 3 Encoder cables Fig. 5. 4 Motor cables 5 Profile slot in the Y-axis Illustrated: Motor (right) on EXCT-5 and EXCT-00: Front motor attachment position, Y-axis energy chain on the right-hand connection side 4 Festo EXCT-EN 60NH English

5 Installation. On the side cover of the Y-axis (opposite the connection side of the energy chain) unscrew the two screws from the retaining plate ( Fig. 5.3). EXCT-5 EXCT-30/00 3 4 3 4 5 5 Screw (x) Retaining plate 3 Encoder cable Fig. 5.3 4 Motor cable 5 Profile slot in the Y-axis Illustrated: Motor (left) on EXCT-5 and EXCT-00: Front motor attachment position, energy chain on the right-hand connection side 3. Remove the retaining plate. 4. Lift the energy chain of the Y-axis. 5. For the motor opposite the connection side of the Y-axis energy chain: Insert the motor and encoder cables fully into the profile slot of the Y-axis ( Fig. 5., Fig. 5.3). Note Protruding cables will be damaged by the energy chain. Make sure that the cables do not protrude beyond the profile slot. 6. Secure the retaining plate with the two screws ( Fig. 5.3). For the tightening torque refer to the table. Tightening torques EXCT-5 EXCT-30 EXCT-00 Screws on the retaining plate [Nm].5.9 4.0 for mounting the energy chain [Nm] Tab. 5. 7. Secure the energy chain with the two screws ( Fig. 5.). Tightening torque Tab. 5.. 8. Connect the motor and encoder cables to motor and motor ( Tab. 5.3 and Tab. 5.4). Festo EXCT-EN 60NH English 43

5 Installation Pin allocation for the motor cable Motor side Colour ) Controller side Connection Pin Function U Phase BK () Cables with PE PE Protective earth GNYE wire end sleeves 3 W Phase BK (3) (4x.5 mm ) 4 V Phase BK () A M T+ Temperature sensor BN Cables with ) Colour code in accordance with IEC 60757:983-0 Tab. 5.3 B M T Temperature sensor WH C BR+ Brake GN D BR Brake YE wire end sleeves (4x 0.5 mm ) Pin allocation for the encoder cable Motor side Controller side Connection Pin Function Pin Connection SENS +SENS 9 SUB-D plug connector (5-pin) Tab. 5.4 3 DATA 4 DATA/ 5 5 0 V 3 6 CLOCK/ 6 7 CLOCK 3 8 UP 0 44 Festo EXCT-EN 60NH English

5 Installation 5..3 Front unit attachment component (rotary drive) Note Before installing the motor and encoder cables: Refer to the corresponding documentation for installation information. Connecting the front unit (product version EXCT- -T T4). Variant T or T4: Connect the air port for the pneumatic rotary throughfeed.. Connect the motor and encoder cables ( Fig. 5.4 and Fig. 5.5). 3. Connect the sensor cable for SIEN position sensing ( Fig. 5.6). Pin allocation for the motor cable (attachment component) Connection U Pin Function Colour ) Operating voltage W WH Operating voltage U BN 3 Operating voltage V GN 4 Protective earth conductor PE YE ) Colour code in accordance with IEC 60757:983-0 Fig. 5.4 Pin allocation for the encoder cable (attachment component) Connection ENC Pin Function Colour ) Signal trace A WH Signal trace A\ BN 3 Signal trace B GN 4 Signal trace B\ YE 5 Signal trace Z GY 6 Signal trace Z\ PK 7 Signal trace U BU 8 Signal trace V RD 9 Signal trace W BK 0 GND encoder VT 5 V supply GYPK Screening RDBU ) Colour code in accordance with IEC 60757:983-0 Fig. 5.5 Pin allocation for the sensor cable (attachment component) SIEN connection Pin Function Circuit diagram Operating voltage +0... +30 V DC Fig. 5.6 4 Switching output A (Out A) 3 0 V Festo EXCT-EN 60NH English 45

5 Installation 5..4 Earthing Note Observe the national regulations for electrical earthing. Earthing points are marked on the product. Connect the earthing cable to the side cover earthing point on the connection side of the energy chain: Place the serrated washer on the side cover earthing point. Place the cable lug of the earthing cable between the serrated washer and the washer. Tighten the screw (tightening torque.5 Nm). Connect the earthing cable to the earthing point of the control system (e.g. in the control cabinet). When using an electrical attachment component: Connect the earthing cable for the attachment component to the interface earthing point. Earthing points 3 4 5 Interface earthing point for electrical attachment component Fig. 5.7 Screw 3 Washer 4 Serrated washer 5 Side cover earthing point (right or left, depending on the connection side of the energy chain) Illustrated: EXCT-5 with Y-axis energy chain on the right-hand connection side 46 Festo EXCT-EN 60NH English

5 Installation 5.3 Pneumatic installation 3 Z-axis Interface supply ports 3 Interface Fig. 5.8 Within the profile of the Z-axis are two integrated air ducts. These air ducts connect the tubing installed in the energy chains with the two supply ports of the interface. The supply ports are intended for the connection of pneumatic attachment components. Festo EXCT-EN 60NH English 47

5 Installation 5.4 Cables and tubes 5.4. Installing an additional cable (tube) Note Tubes that are permanently in contact with cables can be damaged by the cable material. Install tubes separately from the cables (e.g. in separate chambers of the energy chain). When installing cables and tubes also ensure that: They are not twisted and are free of mechanical stress They can be moved freely in the bending radius of the energy chain They are secured at the end pieces of the energy chain with cable ties Requirement: There is no plug mounted on at least one end of the cable or tube being installed.. Dismantle the motors ( 4.4. Dismantling/mounting motors). Cover of the Z-axis. Slide the Z-axis upwards and secure it from falling at the interface. 3. Unscrew the accessible screws of the Z-axis cover above the Y-axis. The number of accessible screws depends on the size and stroke of the Z-axis. Total number of screws ( Tab. 5.5) Illustrated: EXCT-5- -00 Cover of the Z-axis Z-axis stroke EXCT-5 EXCT-30 EXCT-00 Total number of screws (dependent on the size and stroke of the Z-axis) Tab. 5.5 00 mm 3 00 mm 4 50 mm 4 4 500 mm 6 6 800 mm 8 48 Festo EXCT-EN 60NH English

5 Installation 4. Position the Z-axis at the lower end position. 5. Unscrew the remaining screws underneath the Y-axis from the cover of the Z-axis. 6. Remove the cover of the Z-axis. Energy chain cover 7. Unscrew four screws: left: x right: x 8. Remove the cover. Festo EXCT-EN 60NH English 49

5 Installation 9. Insert the open end of the cable through the energy chain. 0.Lay the cable flush in the profile of the Z-axis..Installation is performed in reverse order. Also note: Energy chain cover: Tighten the screws with Loctite 43 screw locking agent. For tightening torques please refer to the table. Tightening torques Screws on the Z-axis cover [Nm].5 Screws on the energy chain cover [Nm].9 Tab. 5.6 50 Festo EXCT-EN 60NH English

6 Commissioning 6 Commissioning The commissioning process is described in separate documents ( www.festo.com/sp). If you require assistance during commissioning: Please contact your regional Festo contact person. Additional information can be found online ( www.festo.com/sp). Festo EXCT-EN 60NH English 5

7 Maintenance 7 Maintenance 7. Safety instructions Danger Unexpected movement of the product. Risk of impact and crushing injuries. Before working on the product, switch off the power supply and secure it against being switched on again. Before working on the product, switch off the compressed air supply, vent if necessary and secure it against being switched on again. Pneumatic system parts can still contain compressed air even when they are switched off. Vent pneumatic system parts accordingly. Danger Risk of injury from electric shock. Before working on the product, switch off the power supply and secure it against being switched on again. Dangerous residual voltage even after the power supply is switched off: Start work on plugs and interfaces only when the residual voltage has fallen below 60 V. Warning If the toothed belt breaks, the interface (Z-axis) will fall down. Risk of impact and crushing injuries. During each lubrication procedure and every 6 months: Check the toothed belt for damage, increased wear and missing teeth. If there are signs of wear or damage: Contact Festo Service. 7. Cleaning Note Only clean the product in exceptional circumstances by using non-abrasive cleaning agents and a soft cloth. Do not clean the guide elements (e.g. guide rails). 5 Festo EXCT-EN 60NH English

7 Maintenance 7.3 Lubrication The product is lubricated initially upon delivery. Lubrication is required on a regular basis to ensure trouble free operation. Use appropriate accessories from Festo ( www.festo.com/spareparts). Specifications Lubricant ISOFLEX TOPAS NB 5 (K0-009) ) Lubrication interval [km] 500 ) Amount of lubricant per lubrication nipple [g] ) Manufacturer: Klüber ) Total traversing path (Y- and Z-axis) Tab. 7. Lubrication points of the Y- and Z-axis 3 Foldable covers Lubrication nipple, left Fig. 7. Illustrated: EXCT-5 3 Lubrication nipple, right Lubrication nipples EXCT-5 EXCT-30 EXCT-00 Position left right left right left right Quantity 3 3 3 Axis allocation Z Y Z Y x Z, x Y Y Tab. 7. Festo EXCT-EN 60NH English 53

7 Maintenance Danger Serious crushing due to axis movements of the product. Slowly move the slide of the Y-axis and the interface of the Z-axis. Make sure that no one is located in the movement area during the axis movements. Note Since the attached motors are equipped with integrated brakes, it is not possible to manually move the slide of the Y-axis and the interface of the Z-axis. The product must be connected and ready for operation. Move the slide of the Y-axis and the interface of the Z-axis in manual override mode ( description EXCT commissioning ).. Fold the covers upwards ( Fig. 7.).. Lubricate each of the lubrication nipples with half of the specified amount of lubricant. 3. Move the slide of the Y-axis and the interface of the Z-axis once along the entire stroke to evenly distribute the lubricant. 4. Perform steps. to 3. again. 7.4 Repair Warning Incorrect sequence of repair steps: Risk of impact and crushing injuries Only carry out repairs in accordance with the repair instructions. If repairs are required, contact the Festo Service department ( www.festo.com/sp). 54 Festo EXCT-EN 60NH English

8 Dismantling 8 Dismantling 8. Safety instructions Danger Uncontrolled movements of the Z-axis. Risk of impact and crushing injuries. Prior to dismantling move the Z-axis to a safe position (delivery status): At the lower end position and a roughly central position on the Y-axis Danger Unexpected movement of the product. Risk of impact and crushing injuries. Before working on the product, switch off the power supply and secure it against being switched on again. Before working on the product, switch off the compressed air supply, vent if necessary and secure it against being switched on again. Pneumatic system parts can still contain compressed air even when they are switched off. Vent pneumatic system parts accordingly. When lifting the product, carry out the following actions: Secure movable components with transport restraints to prevent unexpected movement. Observe the product weight. Observe the position of the centre of gravity. Use suitable lifting gear. Use all of the transport brackets. Adjust the lifting speed. Danger Risk of injury from electric shock. Before working on the product, switch off the power supply and secure it against being switched on again. Dangerous residual voltage even after the power supply is switched off: Start work on plugs and interfaces only when the residual voltage has fallen below 60 V. Festo EXCT-EN 60NH English 55

8 Dismantling 8. Procedure Danger When disassembling the motors: Uncontrolled movements of the Z-axis. Risk of impact and crushing injuries. After disassembling the motors and prior to dismantling the product: Mount the axis locks ( 4.4.4 Dismantling/mounting the axis lock).. Disconnect all of the electric cables and pneumatic tubing from the product.. Mount transport restraints onto the moving parts (e.g. slide of the Y-axis, etc.). 3. Dismantle the product in reverse order ( 4 Mounting). 4. When storing the product: Secure cables and tubes to prevent them from being touched ( 5.4 Cables and tubes). 8.3 Recycling Incorrect disposal is harmful to the environment. Observe the local regulations for disposal of modules. Handle the lubricants (greases, oils) in accordance with the applicable regulations for health and safety and hazardous substances. Observe the local regulations regarding waste disposal and the environment. 56 Festo EXCT-EN 60NH English

A Technical appendix A Technical appendix A. General product characteristics Characteristic Design Linear gantry Motor type ) Servo motor, with brake Guide Recirculating ball bearing guide Mounting position Vertical Z-axis: Interface at the bottom Types of mounting ) with mounting kits with slot nuts ) Motors optionally available ) Alternative types of mounting with accessories ( www.festo.com/catalogue) Tab. A. Festo EXCT-EN 60NH English 57

A Technical appendix A. Evenness Mounting surfaces Mounting surfaces for mounting kits left/right Mounting surface for 3rd mounting kit Fig. A. Illustrated: EXCT-00 with three mounting kits Limit values of the mounting surfaces (A) Evenness of each mounting surface [mm] 0. (B) Parallel alignment of the mounting surfaces to one another [mm] 0.5 Tab. A. 58 Festo EXCT-EN 60NH English

A Technical appendix A.3 Dynamic For specific dynamic data: Observe catalogue specifications ( www.festo.com/catalogue). The dynamic data is based on the reference stroke specified in the table and motors from Festo. Characteristic EXCT-5 EXCT-30 EXCT-00 Operation with max. dynamic response Rated load for max. dynamic response ) [kg].5 3.0 0.0 max. acceleration ) [m/s ] 50 50 30 Operation with reduced dynamic response Rated load for reduced dynamic response ) [kg] 3.0 6.0 5.0 reduced acceleration ) [m/s ] 30 30 5 Max. speed [m/s] 4.8 3) 5 3) 4 Repetition accuracy (at rated load) [mm] ± 0. Max. process force in Z direction [N] 00 300 500 Reference stroke Y-axis [mm] 500 000 500 Z-axis [mm] 00 500 500 ) Rated load = tool load (attachment components, e.g. front unit and gripper) + payload (workpiece) ) The specified acceleration values are permissible for movements in direction Y in the upper third of the maximum Z-stroke. 50 % of the specified acceleration values is permissible in the lower third of the maximum Z-stroke. 3) The maximum speed is reached by a version with maximum Y-stroke: EXCT-5: 000 mm; EXCT-30: 500 mm. Tab. A.3 A.4 Electrical Observe the data sheet ( www.festo.com/catalogue). A.5 Pneumatic Characteristic Operating medium Filtered compressed air, lubricated or unlubricated Operating pressure ) [bar] 0.95 +8 ) Also observe the technical data for the attachment components. Vacuum for suction cup permissible. Tab. A.4 A.6 Approvals Characteristic CE marking (see declaration of conformity) ( www.festo.com) Declaration of incorporation ( www.festo.com/sp) in accordance with EU EMC Directive in accordance with Machinery Directive 006/4/EC Tab. A.5 Festo EXCT-EN 60NH English 59

A Technical appendix A.7 Materials Contains paint-wetting impairment substances RoHS-compliant Component EXCT-5 EXCT-30 EXCT-00 Profile of the Y- and Z-axis Drive and coupling housing Guide pulley Slide units of the Y-axis Covers of the Y- and Z-axis Coupling Guide Drive pinion Ball bearing Toothed belt Aluminium Aluminium with elastomer ring gear Steel Polyurethane with steel cord Clamping hub: Aluminium Expanding mandrel hub: Stainless steel Collar: Elastomer Tab. A.6 A.8 Operating and storage conditions Characteristic EXCT-5 EXCT-30 EXCT-00 Storage temperature [ C] 0 +60 Storage location (requirement) Dry, solid and flat base, in original packaging Maximum shelf life 4 months Relative air humidity [%] 0 90 Ambient temperature [ C] +0 +40 Degree of protection (in accordance IP40 with EN 6059) Duty cycle [%] 00 Noise level L ) pa [db(a)] 70 78 77 ) Energy-equivalent A-weighted noise level at m distance determined locally over the measurement surface. Tab. A.7 60 Festo EXCT-EN 60NH English