Festo EPCO-16 User manual

en Operating
instructions
8076277
2017-11c
[8076279]
Electric cylinder
EPCO

EPCO
2Festo – EPCO – 2017-11c
Translation of the original instructions
Symbols: Installation and commissioning may only be per
formed in accordance with these instructions by
technicians with appropriate qualifications.
Warning
Caution
Note
Environment
Accessories
English 3.........................................................................

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English – Electric cylinder EPCO
Table of contents
1 Operating elements and connections 4.........................................
2 Function and application 4...................................................
3 Transport and storage 5.....................................................
4 Prerequisites for use 5......................................................
5 Installation 6..............................................................
5.1 Mechanical assembly 6......................................................
5.2 Electrical installation 8.......................................................
5.3 Installing circuitry 9.........................................................
6 Commissioning 10...........................................................
7 Operation 12...............................................................
8 Maintenance and care 12.....................................................
9 Repair 13..................................................................
10 Accessories 13..............................................................
11 Troubleshooting 13..........................................................
12 Technical data 14............................................................
12.1 Mechanical data 14..........................................................
12.2 Electrical data 16............................................................
13 Characteristic curves 17......................................................

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Documentation on the product
For all available product documentation èwww.festo.com/pk
1 Operating elements and connections
EPCO-16 EPCO-25/40
67543211 3
1Motor/holding brake connection
2Piston rod (propulsive tube)
3Encoder connection
4Cylinder housing
5Internal thread for fastening
6Wrench flats for counter holding
7Groove for mounting
Fig. 1
2 Function and application
A rotating ball screw converts the rotary movement of a motor into a linear movement. This moves the
piston rod 2backwards and forwards.
The piston rod is guided in a non-rotating manner. The position of the piston rod can be optionally quer
ied as follows:
– EPCO-...ST-E: by using an integrated, incremental positional transducer after a homing run
– EPCO-...ST: enables open-loop operation (without positional transducer and without positional
feedback)
– EPCO-...-A: with an integrated ring magnet and optional proximity sensors.
The EPCO electric cylinder is designed for accurately positioning effective loads in combination with the
CMMO-ST or CMMS-ST controller (permissible controllers è10 Accessories).

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The device is intended for use in an industrial environment. Measures may need to be implemented in
residential areas for interference suppression.
Note
The EPCO is non-braking. When the supply voltage is not applied, the piston rod can be
moved freely. Automatic locking of the complete system can be optionally achieved with
a holding brake in the EPCO-...-ST-B.
3 Transport and storage
 Consider the weight of the electric cylinder.
Depending on the version, the EPCO can weigh up to 5 kg.
 The following should be observed with regard to storage:
– Storage times should be kept to a minimum
– Store in cool, dry, well-shaded locations that do not present a risk of corrosion.
4 Prerequisites for use
Warning
Unexpectedly fast-moving masses can harm people or property (risk of crushing).
 Initially, only apply limited power to the drive motor to ensure low speeds and
torques.
Note
Malfunctions will occur if the device is not used correctly.
 It is vital that the stipulations contained in this section are adhered to at all times.
 Take into consideration the legal regulations applicable for the destination, as well as:
– regulations and standards,
– regulations of the testing organizations and insurers,
– national specifications.
 Note the warnings and instructions on the product and in the relevant operating instructions.
 Remove all transport packaging, such as foils, caps and cardboard.
The material used in the packaging is intended for recycling (exception: oil paper = residual
waste).
 Observe the local regulations for environmentally friendly waste management of electronic compon
ents.
 Take into account the material specifications (èTechnical data chapter).
 Use the product in its original state, without any unauthorised product modifications.
 Take into consideration the ambient conditions at the location of use.
Corrosive environments reduce the service life of the product (e.g. ozone).

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 Compare the limit values specified in these operating instructions with those of your application
(e.g. forces, torques, temperatures, masses, speeds). The relevant safety regulations can only be
adhered to by ensureing the product is operated in compliance with the load limits.
 Take the tolerance of the tightening torques into account. Unless otherwise specified, the tolerance
is ±20 %.
5 Installation
5.1 Mechanical assembly
 Do not modify the screws and threaded pins if not directly requested to do so in these operating
instructions.
Note
Excessive tensile loads may cause the threaded holes to be pulled out.
 In the event of high loads make sure that the EPCO is secured at other mounting
points in the grooves 7in addition to the front mounting threads 5.
 Make sure that the device is fitted free of mechanical stress
and distortion (evenness of the bearing surface: ≤ 0.2 mm).
 Position the EPCO so that all of the control sections are
accessible.
 Secure the EPCO with the mounting accessories
(è10 Accessories).
 Tighten the screws evenly.
Fig. 2
57
Size 16 25 40
Direct mounting 5
Female thread front side M4 M5 M6
Max. tightening torque [Nm] 3 4 5
Slot nut mounting 7
Spanner Size ß2.5 2.5 4
Max. tightening torque [Nm] 1.2 1.2 5.9
Tab. 1

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Fitting in a vertical or sloping position:
Warning
Uncontrolled moving loads can cause personal
injury and material damage (risk of crushing).
If a spindle nut fracture occurs inside the EPCO,
the loads will slide down.
 Check whether additional external safety
measures to protect against spindle nut frac
ture are necessary (e.g. toothed latches or
moveable bolts). In this way you can prevent
the load from sliding down.
Fig. 3
Installing the effective load
 Place the centre of gravity of the effective load, if possible,
centrally to the piston rod.
 When securing the effective load make sure that no torque
is transferred to the piston rod.
The wrench flat 6can be used to exert counter pressure.
 Secure the effective load to the piston rod.
The piston rod will bend depending on the effective load
(èAppendix 13 Characteristic curves). Fig. 4
6
Size 16 25 40
Piston rod thread
Male thread (EPCO-...) M6 M8 M10x1.25
Female thread (EPCO-...-F) M4 M6 M8
Spanner Size 6 ß 7 9 10
Tab. 2

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Installation of external accessories
To protect the end positions against uncontrolled overrunning:
 Check whether proximity sensors are necessary (as safety limit switches or hardware limit
switches). This is only possible for the EPCO-...-A with integrated magnet.
If proximity switches (sensors) are used:
 Use proximity sensors with normally-closed function.
These protect the EPCO from overrunning the end position if the proximity sensor cable is fractured.
 To mount the proximity sensors use a mounting kit or a sensor
rail (è10 Accessories). These are bonded directly to the cylin
der profile (èAssembly instructions for the accessories).
 Avoid external influences from magnetic or ferritic parts in the
vicinity of the proximity sensors (minimum distance of 20 mm
from ferritic parts).
Fig. 5
5.2 Electrical installation
Warning
If the piston rod is moved externally, open, dangerous voltages may occur across the
electrical connections (generator principle).
 Make sure that the piston rod is only moved with wired connections.
Note
If unused plug connectors are touched, there is a danger that damage may occur to the
EPCO or to other parts of the system as a result of ESD (electrostatic discharge). Place
protective caps on unused terminals to prevent such discharges.
Note
To maintainEMC security:
The maximum length of the individual connection cables must not exceed 30 m.
1. Make sure the controller is switched off and that it is prevented from being restarted. Cancelling the
enable signal on the controller is not sufficient.
2. Connect the motor on the EPCO completely to the controller as shown in the following tables. The
pre-assembled cables from Festo (è10 Accessories) offer sufficiently large cable cross sections as
well as screening of the motor/encoder cable with earth contact on both sides.

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Motor connection/holding brake: round plug (8-pin)/D-sub plug connector (9-pin) 1
Pin Allocation EPCO-16 EPCO-25/40
1String A
2String A/
3String B
4String B/
5 n.c.
6 n.c.
7Holding brake +24 V1)
8Holding brake GND1)
9 n.c.
1) Only for motors with holding brake EPCO−...−ST-B
Tab. 3
Encoder connection: round plug (8−pin) 22)
Pin Allocation EPCO-16 EPCO-25/40
1Signal trace A
2Signal trace A/
3Signal trace B
4Signal trace B/
5GND encoder
6Signal trace N
7Signal trace N/
8VCC auxiliary supply 5 V3)
2) Only for motors with encoder EPCO−...−ST-E
3) Short circuit proof, max. load 100 mA
Tab. 4
5.3 Installing circuitry
Note
Additional measures are necessary if used in safety relevant applications, e.g. in Europe
the standards listed under the EC machinery directive must be observed. Without
additional measures in accordance with statutory minimum requirements, the product
is not suitable for use in safety-related sections of control systems.

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6 Commissioning
Warning
Moving masses can cause personal injury and
material damage (risk of crushing).
 Make sure that, in the travel range,
– nobody can place his/her hand in the path
of the moving components (e.g. through a
protective guard),
– there are no foreign objects in the path of
the moving components
It should not be possible to touch the EPCO
until the mass has come to a complete stand
still.
Fig. 6
Note
The motor can unexpectedly be started if the brake is released. Depending on the type
of device, the controller will unlock the holding brake automatically.
 Before releasing the holding brake, make sure that the EPCO cannot move
unexpectedly.
 Complete the commissioning of the motor in conjunction with the controller in
accordance with the controller manual.
Note
Incorrect set values for the braking ramp in STOP statuses (e.g. EMERGENCY OFF, Quick
Stop) result in an overloading of the spindle axis and can destroy it or drastically reduce
its service life.
 Check the settings for all braking ramps in your controller or the higher-order control
system (deceleration values and jerk).
 Taking the travel speed, moving mass and mounting position into account, make
sure that the delay values (brake delay and time delays) are set in such a way that
the maximum actuation moment or feed force of the spindle axis used is not
exceeded.
 To design the spindle axis use the Festo sizing software PositioningDrives
(èwww.festo.com).

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Note
Block-shaped acceleration profiles (without jolt limitation) cause high peaks in the
motive force that can lead to an overloading of the drive. In addition, positions outside
the permissible range may occur as a result of overswing effects. A jolt-limited accelera
tion specification reduces vibrations in the entire system and reduces stress in the
mechanical system.
 Check which closed-loop controller settings can be adapted (e.g. jerk limitation,
smoothing of the acceleration profile).
Check travel Homing run Test run
Ascertaining the direction of
movement of the piston rod
Comparing the real situation
with the image in the controller
Checking the overall behaviour
Tab. 5 Definitions
1. Start a Check travel and limit it to low dynamic response.
Despite identical control, motors of the same design can turn in the opposite direction due to differ
ent wiring.
2. Start a Homing run up to the reference switch in accordance with the controller description and
limit it to low dynamic response.
Providing the permissible impact energy is not exceeded, the homing run may be executed directly
against the end position.
Maximum impact energy (= ½ mass x speed2):
– EPCO-16: max. 0.1 x 10-3 J
– EPCO-25: max. 0.2 x 10-3 J
– EPCO-40: max. 0.4 x 10-3 J
3. Start a Test run and limit it to low dynamic response.
4. Check whether the EPCO fulfils the following requirements:
– The piston rod must move through the complete intended positioning cycle.
– The piston rod must stop as soon as it reaches a limit switch.
5. If the proximity sensors fail to respond:
(è11 Troubleshooting and èProximity sensor operating instructions).

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7 Operation
Warning
Hot parts of the housing can cause burning.
 Make sure that people and objects cannot come into direct contact with the motor.
Warning
Moving masses can cause personal injury and ma
terial damage (risk of crushing).
 Make sure that, in the travel range,
– nobody can place his/her hand in the path
of the moving components (e.g. through a
protective guard),
– there are no foreign objects in the path of
the moving components
It should not be possible to touch the EPCO
until the mass has come to a complete stand
still.
Fig. 7
Fitting in a vertical or sloping position:
Warning
Injury to people and damage to property. Excessive loads can result in slippage of the
holding brake.
 Only actuate the holding brake when the motor is at a standstill.
 Only release the holding brake if the motor secures the piston rod in position in a
controlled manner.
8 Maintenance and care
Warning
Layers of dust can catch fire.
 Clean the motor housing of dust regularly.
 Clean the EPCO with a soft cloth if required. The drive must have cooled down to room temperature
before it is cleaned. The instructions for the cleaning agents must be observed. Only media which
will not damage the material may be used as cleaning agents.
 Lubricate the piston rod with lubricating grease LUB-KC1 from Festo as soon as the grease-film is no
longer visible.

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9 Repair
 Send the EPCO to our repair service if required.
 Information about spare parts and accessories can be found at:
(èwww.festo.com/spareparts).
10 Accessories
Note
 Please select the appropriate accessories from our catalogue
(èwww.festo.com/catalogue).
11 Troubleshooting
Malfunction Possible cause Remedy
Running
noises or
vibrations
Tension Install the EPCO free of tension
(evenness of the bearing surface: ≤ 0.2 mm)
Lubricate the piston rod
(è8 Maintenance and care)
Modify travel speed
Incorrect regulator settings Modify control parameters
(in closed loop operating mode)
Resonance point of the actuator Modify travel speed or load mass
Piston rod
does not move
Loads too high – Reduce load mass
– Reduce travel speed
– Send the EPCO to Festo for repair
Ambient temperature too low
(increased breakaway torque in
initial run due to increasing
viscosity of the lubricants in the
spindle system)
– Reduce load mass
– Reduce travel speed
– Adjust ambient temperature
Tab. 6

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12 Technical data
12.1 Mechanical data
Size 16 25 40
Spindle pitch 3P 8P 3P 10P 5P 12.7P
Design Electric cylinder with rotating spindle and stepper motor
Mounting position Any
Ambient temperature [°C] 0 … +50
Storage temperature [°C] –20 … +60
Relative air humidity [%] 45 … 80 (non-condensing)
Protection class IP40
Max. speed [mm/s] 125 300 150 500 180 460
Max. acceleration [m/s2] 10
Feed constant
(spindle pitch)1)
[mm/rev.] 3 8 3 10 5 12.7
Repetition accuracy [mm] ±0.02
Axial play (new) [mm] 0.1
Max. torsion angle
of the piston rod
[°] ±2.0 ±1.5 ±1.0
Note on materials Contains PWIS (paint-wetting impairment substances)
Information on material
Cylinder profile, end cap Aluminium
Spindle, ball bearing, piston rod Steel
Spindle nut Steel
Weight
at 0 mm stroke2) [kg] 0.62 … 0.68 1.04 … 1.28 2.49 … 2.77
per 100 mm stroke [kg] 0.17 0.34 0.55
1) Nominal value, varies due to component tolerances
2) Depending on motor version

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Size/thread type 16 25 40
Spindle pitch 3P 8P 3P 10P 5P 12.7P
Maximum forces and torques
Max. effective load in hori
zontal mounting position3)
[kg] 24 8 60 20 120 40
Max. effective load in
vertical mounting position
[kg] 12 4 30 10 60 20
Max. feed force Fx [N] 125 50 350 105 650 250
Maximum permissible force on the piston rod
Fx [N] 125 50 350 105 650 250
Fy = Fz [N] è13 Characteristic curves (in the appendix)
Maximum permissible torques on the piston rod
Mx [Nm] 0 0 0
My = Mz [Nm] 0.6 1.0 3.3
Condition for combined loads:
|My|
Mymax
)|Mz|
Mzmax
)
|Fy|
Fymax
)|Fz|
Fzmax
v1and|Fx|vFxmax,|Mx|vMxmax
1) Observe the max. lateral force, è13 Characteristic curves (in the appendix)
Tab. 7

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12.2 Electrical data
Size 16 25 40
Motor EPCO-…-ST
Operating mode Continuous operation (S1)
Nominal voltage [V] 24
Nominal current [A] 1.4 3.0 4.2
Holding torque [Nm] 0.09 0.5 1.13
Stepper angle [°] 1.8 ± 5 %
Insulation class B (130 °C)
Brake EPCO-…ST-B
Nominal voltage [V] 24 ± 10 %
Performance [W] 8 8 8
Holding torque [Nm] 0.2 0.4 0.4
Mass moment of inertia [kgmm2] 0.69 1.3 1.3
Encoder EPCO-…ST-E
Pulses/revolution 500
Zero pulse Yes
Line driver RS422 protocol
Operating voltage of encoder [V] 5
CE mark (see declaration of conformity)1)2) According to EU EMC Directive
1) Measures may need to be implemented in residential areas for interference suppression
2) The maximum length of the individual connection cables must not exceed 30 m.
Tab. 8
UL certification information
Product category code PRHZ2 (USA) or PRHZ8 (Canada)
Certificate number E342973
Standards taken into account UL 1004-1/-6, C22.2 No.100
UL test symbol
Tab. 9

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13 Characteristic curves
Permissible lateral force Fy and Fz as a function of the cantilever load l
EPCO-16
EPCO-25
EPCO-40
y,z
Fig. 8
Total deflection f of the piston rod as a function of the cantilever load l and lateral force F
EPCO-16 (F = 2 N)
EPCO-25 (F = 3 N)
EPCO-40 (F = 6 N)
Fig. 9

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EPCO-16-3P
Vertical installation
Positioning time t as a function of the travel distance l and effective load m
t = 0,6 s
t = 1,2 s
t = 1,8 s
t = 2,4 s
t = 3,0 s
Acceleration a and speed v as a function of the effective load m and travel distance l
l = 0 mm
l = 200 mm
m = 0 kg
m = 12 kg
Fig. 10

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EPCO-16-3P
Horizontal installation
Positioning time t as a function of the travel distance l and effective load m
t = 0,3 s
t = 0,6 s
t = 0,9 s
t = 1,2 s
t = 1,5 s
t = 1,8 s
Acceleration a and speed v as a function of the effective load m and travel distance l
l = 0 mm
l = 200 mm
m = 0 kg
m = 24 kg
Fig. 11

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EPCO-16-8P
Vertical installation
Positioning time t as a function of the travel distance l and effective load m
t = 0,3 s
t = 0,6 s
t = 0,9 s
t = 1,2 s
t = 1,5 s
Acceleration a and speed v as a function of the effective load m and travel distance l
l = 0 mm
l = 200 mm
m = 0 kg
m = 4 kg
Fig. 12