Festo YXC Series Operating and installation instructions

Description
Mechanical
installation
8044168
1506a
[8044170]
YXC...
Handling system

YXC...
2 Festo – GDCP-YXC-EN – 1506a – Deutsch
Translation of the original instructions
GDCP-YXC-EN
Identification of hazards and instructions on how to prevent them:
Danger
Immediate dangers which can lead to death or serious injuries.
Warning
Hazards that can cause death or serious injuries.
Caution
Hazards that can cause minor injuries or serious material damage.
Other symbols:
Note
Material damage or loss of function.
Recommendations, tips, references to other documentation.
Essential or useful accessories.
Information on environmentally sound usage.
Text designations:
 Activities that may be carried out in any order.
1. Activities that should be carried out in the order stated.
– General lists.
èResult of an action/References to more detailed information.

YXC...
Festo – GDCP-YXC-EN – 1506a – English 3
1 Safety and requirements for product use 7......................................
1.1 Technical data 7............................................................
1.1.1 Ordered strokes [mm] 7.............................................
1.2 Safety 8..................................................................
1.2.1 General safety information 8..........................................
1.3 Intended use 8.............................................................
1.3.1 Possible misuse 8..................................................
1.4 Permitted mounting position 9................................................
1.5 Requirements for product use 9...............................................
1.5.1 Obligations of the operating company 10.................................
1.5.2 Qualified specialized personnel 10......................................
1.5.3 Range of application and certifications 10................................
2 Transport and storage 11.....................................................
2.1 Transport 11................................................................
2.2 Storage conditions 11........................................................
2.3 Unpacking 11...............................................................
2.4 Transport locks 12...........................................................
2.4.1 Securing in the transport protection crate 12.............................
2.4.2 Securing when lifting 12..............................................
2.4.3 Securing during transport and mounting 18...............................
3 Overview 20................................................................
3.1 Delivery status 20...........................................................
3.1.1 Completely mounted handling system 20.................................
3.1.2 Partially mounted handling system 20...................................
3.2 Module types 20............................................................
3.2.1 X-module EHMX (including motor) 20....................................
3.2.2 Y-module EHMY (including motor) 23....................................
3.2.3 Z-module EHMZ (including motor)/DHMZ 25..............................
3.3 Handling systems 27.........................................................
3.3.1 Single-axis system YXCS 27...........................................
3.3.2 Linear gantry YXCL 28................................................
3.3.3 Planar surface gantry YXCF 29..........................................
3.3.4 Three-dimensional gantry YXCR 30......................................
3.4 Handling systems without motors 31............................................

YXC...
4 Festo – GDCP-YXC-EN – 1506a – English
4 Installation of the single-axis systems and the linear gantries 32....................
4.1 Preparation 32..............................................................
4.1.1 Installation space 32.................................................
4.1.2 Number n of mounting components 32..................................
4.1.3 Preparation of the mounting surface 33..................................
4.2 Mounting components 34.....................................................
4.2.1 Mounting kit with adjustment possibility 34...............................
4.3 Mounting linear gantry (partially mounted) 39.....................................
4.3.1 Mounting of the Y-module EHMY-LP 40..................................
4.3.2 Mounting of the Z-module EHMZ/DHMZ 42...............................
4.4 Installation of single-axis system and linear gantry (completely mounted) 45............
5 Installation of the planar surface gantries and the three-dimensional gantries 47.......
5.1 Preparation 47..............................................................
5.1.1 Installation space 47.................................................
5.1.2 Number n of mounting components 47..................................
5.1.3 Preparation of the mounting surface 48..................................
5.2 Mounting components 52.....................................................
5.2.1 Mounting kit without adjustment possibility 52............................
5.2.2 Adjusting kit 55.....................................................
5.3 Mounting of the planar surface gantries and the three-dimensional gantries
(partially mounted) 59........................................................
5.3.1 Mounting of the X-module EHMX-RP 61..................................
5.3.2 Mounting of the Y-module EHMY-RP 68..................................
5.3.3 Mounting of the Z-module EHMZ/DHMZ 74...............................
5.4 Installation of the planar surface gantries and the three-dimensional gantries
(completely mounted) 77.....................................................
5.5 Check the alignment and structure 83............................................
5.6 Connecting shaft 84..........................................................
5.6.1 Mounting of the connecting shaft 84....................................
5.7 Motor with brake (EMMS-...-RSB/RMB) 94........................................
5.7.1 Dismounting 94.....................................................
5.7.2 Mounting 94.......................................................
6 Attachment components 95...................................................
6.1 Mounting to the Y-module 95..................................................
6.2 Mounting to the Z-module 95..................................................

YXC...
Festo – GDCP-YXC-EN – 1506a – English 5
7 Installation 96..............................................................
7.1 Safety instructions 96........................................................
7.2 Earthing 98.................................................................
7.2.1 Earthing points 98...................................................
7.2.2 Earthing points at the single-axis system 99..............................
7.2.3 Earthing points at the linear gantry 100...................................
7.2.4 Earthing points at the planar surface gantry 101............................
7.2.5 Earthing points at the three-dimensional gantry 102.........................
7.3 Cables and hoses 103.........................................................
7.3.1 Cables 103..........................................................
7.3.2 Hoses 103..........................................................
7.3.3 Energy chain subdivision Z-modules 105..................................
7.3.4 Energy chain subdivision Y-modules 106..................................
7.3.5 Energy chain subdivision X-modules 108..................................
7.3.6 Installation 108......................................................
7.3.7 Checking the energy chain 109..........................................
8 Commissioning 110...........................................................
8.1 Safety instructions 110........................................................
8.2 Limit switches 112............................................................
8.3 Test run 112.................................................................
9 Operation 113...............................................................
9.1 Safety instructions 113........................................................
9.2 Characteristic curve of the connecting shaft 113....................................
10 Maintenance and care 114.....................................................
10.1 Safety instructions 114........................................................
10.2 Cleaning 115.................................................................
10.3 Lubrication 115..............................................................
11 Decommissioning, disassembly, disposal 116.....................................
11.1 Safety instructions 116........................................................
11.1.1 General 116.........................................................
11.1.2 Dismantling 116.....................................................
11.1.3 Disposal 116........................................................
12 Fault clearance 117...........................................................
12.1 Malfunctions and remedy 117...................................................
12.2 Repair 118..................................................................

YXC...
6 Festo – GDCP-YXC-EN – 1506a – English
A Technical appendix 119........................................................
A.1 Technical data 119............................................................
A.1.1 Certifications 119....................................................
A.1.2 Materials 119........................................................

1 Safety and requirements for product use
Festo – GDCP-YXC-EN – 1506a – English 7
1 Safety and requirements for product use
1.1 Technical data
Note
The technical data are contained in a separate data sheet, depending on the order.
Damage to the product from incorrect use and non-compliance with the technical data.
The separate data sheet as well as the CAD model are components of the product docu
mentation and must be downloaded as follows.
 Determine order ID of the handling system (èproduct labelling on the Y-module).
 Download data sheet and CAD model from the Festo Support Portal by specifying
the order ID (èwww.festo.com/sp).
 Print out data sheet and keep it together with this description.
 Dimensions and other required measurements should be derived from the CAD model.
Illustrations in this description are shown as examples. The product can deviate, de
pending on the order.
1.1.1 Ordered strokes [mm]
For single-axis system and linear gantry:
 Determine stroke in Y-direction (Hy) (èproduct labelling on the Y-module):
– Hy = stroke in Y-direction e.g. B.: EHMY-LP-EGC-120-TB-KF-1000-...
For planar surface gantry and three-dimensional gantry:
 Determine width in Y-direction (By) and stroke in X-direction (Hx) (èproduct labelling on the
X-module):
– By = width in Y-direction e.g. B.: EHMX-EGC-120-TB-KF-1200-642-...
– Hx = stroke in X-direction e.g. B.: EHMX-EGC-120-TB-KF-1200-642-...

1 Safety and requirements for product use
8 Festo – GDCP-YXC-EN – 1506a – English
1.2 Safety
1.2.1 General safety information
 Observe all warnings in this documentation.
 Observe all warnings and safety instructions for the related accessories.
1.3 Intended use
This product is a handling system and executes positioning tasks within machines or automated sys
tems with a higher-order controller.
Warning
Unexpected risks in commissioning and operation of the product in a system.
Hazard for system safety as well as for persons within range of the system.
 Prepare risk evaluation of the complete system.
 Use product only as follows:
– in excellent technical condition
– in its original condition, without unauthorised modifications
– within the limits of the product defined in the technical data (è1.1 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.
1.3.1 Possible misuse
 Never use product as follows:
– with unauthorised modifications or alterations to the product
– outside of an industrial environment
– in an invalid mounting position
– with load limits exceeded
– without sufficient risk evaluation of the complete system
– without a safety concept for the complete system

1 Safety and requirements for product use
Festo – GDCP-YXC-EN – 1506a – English 9
1.4 Permitted mounting position
Use product only in the following mounting positions:
Handling system Mounting position1)
X-module Y-module Z-module
Single-axis system –Horizontal –
Linear gantry –Horizontal Vertical
Planar surface gantry Horizontal Horizontal –
Three-dimensional gantry Horizontal Horizontal Vertical
1) Related illustrations (è3.2 Module types).
Note
Deviating mounting positions or overhead mounting are not permitted. Energy chains
sag due to gravity. Cables and hoses are overloaded.
 Use product only in a permitted mounting position.
1.5 Requirements for product use
 Provide this documentation to the following persons:
– design engineer
– installer
– commissioner of the machine or system
 Comply with the specifications of the documentation. Follow all accompanying documentation and
the documentation of any associated accessories.
 Take the following into consideration for the destination:
– applicable legal regulations
– regulations and standards
– regulations of the testing organisations and insurers
– national specifications
 For correct and safe use, take the following into account:
– all warnings and notes
– all load limits of the product and the connected components (è1.1 Technical data)

1 Safety and requirements for product use
10 Festo – GDCP-YXC-EN – 1506a – English
1.5.1 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.
1.5.2 Qualified specialized personnel
Installation, mounting, commissioning, maintenance, repair and de-commissioning should only be per
formed by qualified personnel who are familiar with:
– installation and operation of electrical control systems
– installation and operation of pneumatic systems
– mounting and operation of mechatronic handling systems
– the applicable regulations for accident prevention and occupational safety
– the documentation and mode of operation of the product.
1.5.3 Range of application and certifications
Standards and test values that the product complies with and fulfills (è1.1 Technical data).

2 Transport and storage
Festo – GDCP-YXC-EN – 1506a – English 11
2 Transport and storage
2.1 Transport
The handling system is attached to the transport protection crate.
Note
Damage to the product due to incorrect transport.
 Observe the markings for transport on the transport-protection crate.
 Set the transport-protection crate on a firm and flat base.
2.2 Storage conditions
 Comply with storage conditions (è1.1 Technical data)
Storage conditions
Ambient conditions of the
storage location
Dry, solid and flat base, in original transport-protection crate
2.3 Unpacking
Note
Damage to the product due to incorrect unpacking.
 Observe the markings for unpacking on the transport-protection crate.
 Unpack product with at least 2 persons.
 Use correct tools.
 Parts of the transport-protection crate are large and heavy; do not let them fall onto
the product.
 Remove marked transport protection aids (è2.4.1 Securing in the transport protection crate).

2 Transport and storage
12 Festo – GDCP-YXC-EN – 1506a – English
2.4 Transport locks
Three different types of transport protection locks prevent uncontrolled movement of the product dur
ing unpacking, transport to the mounting location and installation.
Note
Keep the safety components for later use, e.g. for maintenance or dismantling.
2.4.1 Securing in the transport protection crate
The product is fastened in the transport protection crate by means of labelled screws.
Caution
Transport protection aids connected to the transport protection crate are not removed
completely. Transport protection crate breaks away when the product is lifted and falls
down.
Injury due to impact or pinching. Damage to the product.
Before the product is removed from the transport protection crate:
 Remove all transport protection aids marked with this symbol (screws).
2.4.2 Securing when lifting
Warning
Product is heavy. The centre of gravity is not in the middle.
Injury due to impact or pinching. Damage to the product.
When lifting the product, carry out the following actions:
 Use lifting points (e.g. lifting eye bolts) on the transport component kit.
 Attach transport belts as vertically as possible:
– Align lifting eye bolts in the lengthwise direction.
– Do not laterally stress lifting eye bolts.
– Apply load to lifting eye bolts evenly and in an angle of 45°.
 Use appropriate lifting gear (traverse) for safe handling.
 Take weight into account (èlabel on transport protection crate).
 Take adequate safety precautions.
 Assign sufficient number of people for mounting.
 Adjust lifting speed.

2 Transport and storage
Festo – GDCP-YXC-EN – 1506a – English 13
Align lifting eye bolts in the lengthwise direction apply load correctly.
Fig. 2.1
Adapt the lifting bolt orientation to the direction of force of the lifting gear:
 Loosen the nuts of the lifting eye bolts.
 Turn the lifting eye bolts in the respective direction of load.
 Tighten the nuts of the lifting eye bolts (tightening torque: M8 = 12 Nm; M12 = 24 Nm).

2 Transport and storage
14 Festo – GDCP-YXC-EN – 1506a – English
For the single-axis system and the linear gantry with EGC 50
To lift the handling system safely:
 Use mounted transport component kit.
For the single-axis system and the linear gantry with EGC80/120/185 and EGC-HD
To lift the handling system safely:
 Use mounted transport component kit.

2 Transport and storage
Festo – GDCP-YXC-EN – 1506a – English 15
For the planar surface gantry and the three-dimensional gantry
To lift the handling system safely:
 Use the following transport component kit.
aJ
1
2
3
4
5
6
7
89
1Mounting bracket (4x)
2Lifting eye bolt (4x)
3Slot nut (8 … 16x)
4Nut (4x)
5Screw (8x)
6Screw (2x)
7Cable guide (1x)
8Slot nut (2x)
9Stay (2x)
aJ Screw (8 … 16x)

2 Transport and storage
16 Festo – GDCP-YXC-EN – 1506a – English
 Fasten lifting eye bolts to mounting brackets
with the nut.
Screw size and tightening
torque
EHMX-EGC-
50 80 120 185
M 8 M12
[Nm] 12 24
 Attach the mounting bracket to the front sides
of the X-axes.
Screw size and tightening
torque
EHMX-EGC-
50 80 120 185
M4x10 M5x12 M8x16 M10x16
[Nm] 4.1 8.3 34 47
For clamping the Y-width (By):
 Fasten stays with the slot nuts to the mount
ing brackets.
Screw size and tightening
torque
EHMX-EGC-
50 80 120 185
M5x8
[Nm] 5.9

2 Transport and storage
Festo – GDCP-YXC-EN – 1506a – English 17
For clamping the cables and hoses:
 Position cable guide on the drive side at the
stay.
 Fasten the cable guide with the slot nuts.
 Wrap cables and hoses around the cable
guide and clamp them with cable ties.
Screw size and tightening
torque
EHMX-EGC-
50 80 120 185
M5x8
[Nm] 5.9

2 Transport and storage
18 Festo – GDCP-YXC-EN – 1506a – English
2.4.3 Securing during transport and mounting
Moving parts are secured during transport of the product to prevent them from sliding.
Danger
Moving parts are secured. Product is energised. Moving parts break free and run uncon
trollably and with high acceleration into the end position.
Injury (death) due to impact or pinching.
To place the product safely in operation:
 After mounting, remove all safety components marked with this symbol before ener
gising the product.
Safety component group at the Z-module
A Z-module with motor from Festo has a brake function. There are no moving parts to secure there.
For the Z-module without motor from Festo:
For the long-stroke Z-module (EMHZ-DGEA/EHMZ-EGC), the drive shaft is clamped through a safety
component group.
For the short-stroke Z-module (EHMZ-EGSL/DHMZ-DGSL), the moving parts do not need to be secured.
The slide can move.
When removing the safety component group at the Z-module:
Warning
Moving parts are secured. Safety component group is removed. Z-axis runs uncontrol
lably and with high acceleration into the end position.
Injury due to impact or pinching. Damage to the product.
Remove the safety component group as follows:
1. Support Z-axis from below.
2. Remove safety component group.
3. Bring Z-axis slowly into the lower end position.
4. Mount motor.

2 Transport and storage
Festo – GDCP-YXC-EN – 1506a – English 19
EHMZ-DGEA
1
2
1
2
1Safety component group 2Z-axis
EHMZ-EGC
11
2 2
1Safety component group 2Z-axis

3 Overview
20 Festo – GDCP-YXC-EN – 1506a – English
3Overview
The handling systems are based on 3 module types: X-module, Y-module and Z-module.
All illustrations show an example for the structure of the modules and handling systems.
The actual design differs depending on size and the order.
3.1 Delivery status
Depending on the order, the handling system is shipped as follows.
3.1.1 Completely mounted handling system
All modules are connected to each other. Motors are mounted onto the modules (exception: middle
motor position for the X-module). Cables and hoses are installed. Controllers and controller accessories
accompany the shipment.
3.1.2 Partially mounted handling system
The modules are not connected to each other. Motors are mounted onto the modules (exception:
middle motor position for the X-module). Cables and hoses, controllers and controller accessories
accompany the shipment.
3.2 Module types
3.2.1 X-module EHMX (including motor)
The X-module consists of 2 parallel linear axes with a shared electric drive.
The X-module moves the Y-module along the X-axes.
Adapters are mounted on the slides of the X-axes to connect the Y-module.
Structure
The motor is connected to both X-axes through a connecting shaft. The positions of the motor and en
ergy chain are dependent on the order.
The following components are located on the motor side:
 Energy chain
 Multi-pin plug for sensors (optional)