Festo EGC-TB-KF User manual

en Operating
instructions
8076268
2017-11c
[8076270]
Toothed belt axis
EGC-TB-KF, EGC-HD-TB

EGC-TB-KF, EGC-HD-TB
2 Festo – EGC-TB-KF, EGC-HD-TB – 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 – Toothed belt axis EGC-TB-KF, EGC-HD-TB
Table of contents
1 Control sections and connections 4............................................
2 Function and application 5...................................................
3 Transport and storage 5.....................................................
4 Requirements for product use 6...............................................
5 Installation 7..............................................................
5.1 Mechanical assembly 7......................................................
5.1.1 Mount axis 7......................................................
5.1.2 Installation of the effective load 9.....................................
5.1.3 Installing external accessories 10.......................................
6 Commissioning 11...........................................................
7 Operation 12...............................................................
8 Maintenance and care 13.....................................................
9 Repair 14..................................................................
10 Accessories 15..............................................................
11 Troubleshooting 15..........................................................
12 Technical data 16............................................................
13 Characteristic curves 19......................................................

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Documentation on the product
For all available product documentation èwww.festo.com/pk
1 Control sections and connections
EGC-...-TB-KF EGC-HD-...-TB
1342567
8
9
aJ
aAaBaC aC aB aA
aJ
9
1Thread and centring holes for foot mounting
2Cover cap
3Drive hollow shaft
4Thread for motor mounting kit
5Guide rail (2x with EGC-HD-...-TB)
6Thread and centring holes for mounting the
effective load
7slide
8Surface for profile mounting
9Thread for optional switch lug
(with EGC-HD-...-TB, both sides)
aJ Groove for proximity switch
(with EGC-HD-...-TB, both sides)
aA Grooves for slot nut mounting and
accessories
aB Relubrication opening (both sides,
2xEGC-...-TB-KF, 4xEGC-HD-...-TB)
aC Toothed belt
Fig. 1

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2 Function and application
A toothed belt on a drive hollow shaft 3converts the rotation of a motor into a linear movement. The
slide 7then moves backwards and forwards.
The slide is bearing mounted. The reference position of the slide can be detected using proximity
sensors in the slots aJ.
The EGC-...-TB-KF toothed belt axis is intended to be used to quickly
position effective loads with large dimensions. It is approved for
slide operating mode.
The EGC-...-TB-KF and EGC-HD-...-TB are not approved for operating
conditions in which vegetable water-soluble greases or oils could
penetrate into the axis.
Fig. 2
Note
The EGC toothed belt axis is not braked: If the input torque is not applied, the slide is
freely movable.
Generally self-locking of the complete system can be achieved with motors with an
integrated spring-loaded holding brake or with high self-braking torque (e.g. for vertical
operation).
 Please select the corresponding motors from our catalogue
(èwww.festo.com/catalogue).
You will then be operating a mated pair, which are especially adapted to each other.
When using other motors:
 Observe the limit values for forces, torques and speeds
(è12 Technical data and 13 Characteristic curves).
3 Transport and storage
 Take the product's weight into account. Depending on the version, the EGC can weigh up to 350 kg.
For transport, the transport belts must be positioned at the permissible support distances
(support distances è13 Characteristic curves).
 Ensure the following storage conditions:
– Storage times should be kept to a minimum
– cool, dry, shaded, corrosion-protected storage locations
– no oils, greases or grease-dissolving vapours.
In this way you ensure the performance of the toothed belt.

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4 Requirements for product use
Warning
Unexpectedly fast moving masses can harm people or property items (crushing).
 Apply power to the drive motor, at first limited to low speeds and torques.
Note
Malfunctions will occur if the device is not used correctly.
 Make sure that the specifications contained in this chapter 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 (è12 Technical data).
 Use the product in its original status, without any unauthorised modification.
 Take into consideration the environmental conditions at the location of use.
Corrosive environments reduce the service life of the product (e.g. ozone).
 Compare the limit values in these operating instructions with those of your application (e.g. forces,
torques, temperatures, masses, speeds).
Only if the load limits are observed is it possible to operate the product in compliance with the rel
evant safety regulations.
 Take the tolerance of the tightening torques into account. Unless otherwise specified,
the tolerance is ±20 %.

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5 Installation
5.1 Mechanical assembly
 Do not modify the screws and threaded pins.
Exception: Direct request to do so in these operating instruc
tions.
 Mount the motor onto the axis in accordance with the assembly
instructions for the motor mounting kit recommended in the
catalogue.
Fig. 3
5.1.1 Mount axis
Requirements
 Position the product in such a way that its control sections are accessible (e.g. relubrication open
ings).
 Make sure that the mounting components are outside the positioning range of the slide.
 Install product without tension or distortions.
 Fasten product to a mounting surface with flatness of 0.05 % of
the stoke length, but max. 0.5 mm.
For gantry applications, attention must also be paid to parallel
alignment or product heights in alignment of the axes.
For additional information, contact your local Festo Service.
 Take the required support spacing into account
(è13 Characteristic curves).
Fig. 4
 Attach the EGC (èTab. 1).

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Interfaces for mounting components
on the cover on the profile
e.g. with foot mounting HPE1)
(only for EGC-...-TB-KF)
e.g. with slot nuts NST1) e.g. with profile mounting MUE1)
1) èwww.festo.com/catalogue
Tab. 1
Note
Danger of screws being pulled out if the axis is only mounted to the covers and the
torque load around the longitudinal axis is too great.
 If there are heavy loads, mount the axis to the profile with additional mounting
components.
 Tighten the mounting screws evenly with the following tightening torque.
Size 50 70 80 120 185
Screw (cover) M4 M5 M5 M8 M10
Tightening torque [Nm] 2.9 5.9 5.9 24 47
Tab. 2
For installation in a vertical or inclined position:
Warning
Injury to people and material damage!
If there is a power failure or if the toothed belt
breaks, the work load will slide down.
 Make sure that you only use motors with an
integrated spring-loaded holding brake. Fig. 5
 Check whether additional external safety measures against damage due to breaking
of the toothed belt are required (e.g. toothed latches, moving bolts or emergency
buffers).

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5.1.2 Installation of the effective load
 Place the effective load so that the tilting torque resulting from
force F (parallel to the axis of motion) and lever arm “a” remains
low.
Fig. 6
aF
 Fasten the effective load to the slide with the screws and cent
ring sleeves.
 Make sure that the maximum screw-in depth D is adhered to.
Fig. 7
Size 50 70 80 120 125 160 185 220
Screw (side/top) M4 M5 M5/M6 M5 M6 M6/M8 M6
Max. screw-in depth D [mm] 4.2 8.4 9.5 10 8.4 9.5 15 10
Centring (H7) [mm] 557/95/9999
Tightening torque [Nm] 2.9 5.9 5.9/9.9 5.9 9.9 9.9/24 9.9
Tab. 3
Effective loads with own guide:
 Adjust the guides of the effective load and of the EGC so that they are exactly parallel.
You will then avoid overloading the guide and increased wear.
With hard and stiff effective loads (e.g. steel):
Note
If the aluminium slide becomes bent against a curved
effective load, the service life of the guide will be re
duced.
 Make sure that the mounting surface of the
effective loads is even to within t=0.01 mm.
If additional slides are used, possible differences in
height must be compensated for. Fig. 8
t
Effective loads projecting in the longitudinal direction of the slide:
 Make sure that the effective load does not strike against the
motor.
Fig. 9

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5.1.3 Installing external accessories
To protect the end positions against uncontrolled overrunning:
 Check whether proximity sensors are required (hardware limit switches).
If proximity sensors are used as limit switches:
 Preferably use proximity switches with normally-closed function.
These will protect an EGC with a fractured proximity switch cable from overrunning the end position.
If proximity switches are used as reference switches:
 Use proximity switches that correspond to the input of the controller being used.
 Use inductive proximity switches with switch lug aE (èassembly instructions of the accessory
used).
Mounting
in the grooves aJ (èFig. 1) with mounting bracket aD
aJ
aE aD
aE
Tab. 4
 Avoid external influence caused by magnetic or ferrite parts in the vicinity of the proximity switches
(minimum distance of 10 mm to the slot nuts).
To protect the end positions:
 Use emergency buffer or shock absorber (èAssembly instructions of the accessory used).
To avoid contamination:
 Use slot covers in all unused grooves.

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6 Commissioning
Warning
Moving masses can cause personal injury or dam
age to material items (crushing).
 Make sure that, in the positioning 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.
It should not be possible to touch the EGC until
the mass has come to a complete standstill.
Fig. 10
Note
Incorrect specification values of the braking ramp in STOP statuses
(e.g. EMERGENCY OFF, Quick Stop) result in an overloading of the linear axis and can
destroy it or drastically reduce the 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 linear axis used is not ex
ceeded.
 Use the “PositioningDrives” design software to design the linear axis
(èwww.festo.com).
Note
Block-shaped acceleration profiles (without smoothing) cause high peaks in the drive
force that can lead to overloading of the drive. In addition, positions outside the per
missible range may occur as a result of overswing effects. A jolt-limited acceleration
specification reduces vibrations in the entire system and has a positive effect on stress
in the mechanical system.
 Check which closed-loop controller settings can be adapted (e.g. jerk limitation,
smoothing of the acceleration profile).
Note
The elasticity of the toothed belt delays the acceleration behaviour of the EGC and res
ults in larger accelerations than are set on the controller (spring effect).
 Take into account possible deviations from the acceleration set at the controller.

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Check travel Homing run Test run
Determining the approach direc
tion of the motor
Comparison of the real situation
with the figure in the controller
Checking the overall behaviour
Tab. 5
1. Start check travel with low dynamic response.
In spite of equal control, motors of the same design sometimes turn in the opposite direction due to
different wiring.
2. Start homing in accordance with the operating instructions for your motor drive system with low
dynamic response to the reference switch.
The homing run may only take place toward the reference switch.
3. Start a test run with low dynamic response.
4. Check whether the EGC fulfils the following conditions:
– The slide runs through the complete intended positioning cycle.
– The slide stops as soon as it reaches a limit switch.
7 Operation
Warning
Moving masses can cause personal injury or damage to material items (crushing).
 Make sure that, in the positioning range
– nobody can place his/her hand in the path of the moving components
(e.g. through protective guards)
– there are no foreign objects.
It should not be possible to grasp the EGC until the mass has come to complete rest.
Note
The reference position is lost when the motor is dis
mounted (e.g. turning of the motor).
 Start homing (è6 Commissioning) in order to de
termine the new reference position.
Fig. 11

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8 Maintenance and care
Warning
Uncontrolled moving masses can cause injury to people or damage to property (squeez
ing). If a toothed belt breaks in combination with a vertically or diagonally installed EGC,
the work mass will fall down.
 In case of signs of wear, return the EGC to Festo for repairs.
Controller signals can cause the EGC to make unintended movements.
 Switch off the controller for all maintenance work on the EGC and secure it to pre
vent it from being restarted unintentionally.
On cleaning and maintenance:
 If required, clean the guide axis with a soft cloth. All media gentle to the material may be used as
cleaning agents.
Note
The lubrication interval Sint is dependent on the product load.
 Cut the lubrication interval Sint (èFig. 12) in half if the following situations are
present:
– dusty and dirty environment
– nominal strokes 2000 mm
– at speeds 2 m/s
– positioning profile Zdelta operation (frequent acceleration and braking)
– ambient temperatures 40 °C
– product has been in operation for 3 years.
If several situations occur simultaneously, the lubrication interval must be divided by
four.
 Grease the following components:
Bearing guide Guide rail
Lubricating point (èFig. 1) Relubrication opening aB Surface 5
Lubrication interval (èFig. 12) As required 1)
Grease 2) Roller bearing grease
1) or if the component no longer has a layer of grease
2) Grease gun, blast pipe and grease (è10 Accessories)
Tab. 6

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For greasing the bearing guide (not possible for
EGC-...-GP/GQ):
1. Calculate the load comparison factor fv with
the aid of the formula for combined loads
(è12 Technical data) and determine the lub
ricating interval Sint from it (èFig. 12).
Fig. 12
fv
2. Grease the bearing guide on both sides at all
relubrication openingsaB.
3. Move the slide over the complete travel dis
tance during lubrication in order to distribute
the grease equally inside.
Fig. 13 aB
9 Repair
Note
Retensioning of the toothed belt reduces its service life considerably. In addition, the
technical data, e.g. the feed constant, change.
 Make sure that the toothed belt is not retensioned.
The toothed belt is pretensioned so that it does not have to be retensioned during
its service life.
 Recommendation: Send the EGC to our repair service.
This way the fine tuning and tests that are required will be taken into particular consideration.
 Information about spare parts and auxiliary means can be found at:
(èwww.festo.com/spareparts).

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10 Accessories
Designation Part number/type
Grease gun with needle-pointed nozzle
Nozzle, outlet axial
Nozzle, outlet radial
647958/LUB-1 1)
647959/LUB-1-TR-I 1)
647960/LUB-1-TR-L 1)
Roller bearing grease LUB-KC1 from Festo 1)
1) (èSpare-parts catalogue at www.festo.com/spareparts)
Tab. 7
11 Troubleshooting
Malfunction Possible cause Remedy
Squeaking
noises, vibrations
or the axis is not
running smoothly
The coupling is moun
ted too tight
Comply with the permissible coupling spacing
dimensions
(èassembly instructions of the motor mounting kit)
Distortions Fit the EGC free of tension (evenness of the bearing
surface: è5 Installation)
Align the EGC so that it is exactly parallel to the second
axis
Grease the EGC (è8 Maintenance and care)
Modify travel speed
Incorrect regulator set
tings
Change the regulator parameters
Roller bearing/bearing
guide defective
Send EGC to Festo for repair
Toothed belt worn Send EGC to Festo for repair
Slide does not
move
Coupling hub slipping Check mounting of motor mounting kit
(èassembly instructions of the motor mounting kit)
Loads too high Reduce mass of the effective load/travel speed
Mounting screws for
effective load too long
Observe max. screw-in depth
(è5.1.2 Installation of the effective load)
Slide travels bey
ond the end posi
tion
The proximity switches
do not react
Check the proximity switches, connections and con
troller
Toothed belt
jumps off
Toothed belt preten
sioning too low
Send EGC to Festo for repair
(è9 Repair)
Incorrect regulator set
tings
Change the regulator parameters
Tab. 8

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12 Technical data
Size 1) 50 70 80 120 125 160 185 220
Design Electromechanical axis with toothed belt
Guide Recirculating ball bearing guide
Mounting position Any
Max. feed force Fx [N] 50 100 350 800 450 1000 2500 1800
Max. driving torque [Nm] 0.46 1.24 5 16 7.3 19.9 93 59.6
Max. no-load driving
torque 2)
[Nm] 0.072 0.18 0.4 1.4 0.5 2.1 4.05 4.1
Max. speed [m/s] 3 5 3 53)
Max. acceleration [m/s2] 50 40 50
Repetition accuracy [mm] ±0.08 ±0.1
Feed constant [mm/rev.] 58 78 90 125 102 125 232 208
Ambient temperature [°C] –10 … +60
Protection class IP40
1) The following tool is available for sizing: PositioningDrives design software (èwww.festo.com)
2) Measured at a speed of 0.2 m/s
3) For variant GP with BG160/220: max. speed 3 m/s
Tab. 9

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EGC-...-TB-KF
Size 50 70 80 120 185
Maximum permitted forces on the slide
Fy = Fz [N] 650 1850 3050 6890 15200
Maximum permitted torques on the slide
Mx [Nm] 3.5 16 36 144 529
My = Mz
(EGC-GK,EGC-GP)
[Nm] 10 51 97 380 1157
My = Mz
(EGC-GV, EGC-GQ)
[Nm] – 132 228 680 1820
Condition for combined loads:
fv+|Mx|
Mxmax
)
|My|
Mymax
)|Mz|
Mzmax
)
|Fy|
Fymax
)|Fz|
Fzmax
v1
Materials
Profile, cover, slide Anodised aluminium
Ball bearing, guide, screws Steel
Cover caps Polyacetal
Toothed belt Fibreglass-reinforced polychloroprene
Buffer Nitrile rubber
Sealing disc Acrylic butadiene styrene
Weight
0-stroke [kg] 0.62 1.85 3 10.5 32.6
per 100 mm stroke [kg] 0.19 0.44 0.62 1.5 3
Tab. 10

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EGC-HD-...-TB
Size 125 160 220
Maximum permitted forces on the slide
Fy = Fz [N] 3650 5600 13 000
Maximum permitted torques on the slide
Mx [Nm] 140 300 900
My = Mz [Nm] 275 500 1450
Condition for combined loads:
fv+|Mx|
Mxmax
)
|My|
Mymax
)|Mz|
Mzmax
)
|Fy|
Fymax
)|Fz|
Fzmax
v1
Materials
Profile, cover, slide Anodised aluminium
Ball bearing, guide, screws Steel
Cover caps Polyacetal
Toothed belt Fibreglass-reinforced polychloroprene
Buffer Nitrile rubber
Sealing disc Acrylic butadiene styrene
Weight
0-stroke [kg] 4.72 9.05 25.51
per 100 mm stroke [kg] 0.73 1.07 2.1
Tab. 11

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13 Characteristic curves
Maximum permissible support span L as a function of the force F for EGC-...-TB-KF
LL
EGC-50
EGC-70
EGC-80
EGC-120
EGC-185
EGC-50
EGC-70
EGC-80
EGC-120
EGC-185
Fig. 14

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Maximum permissible support span L as a function of the force F for EGC-HD-...-TB
LL
EGC-HD-125
EGC-HD-160
EGC-HD-220
EGC-HD-125
EGC-HD-160
EGC-HD-220
Fig. 15