Festo YXC Series User manual

Description
Mechanical
installation
8030870
1502NH
[8030863]
YXC...
Handling system

YXC...
2 Festo – GDCP-YXC-EN – 1502NH – English
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 – 1502NH – English 3
Table of Contents – YXC...
1 Safety and requirements for product use 6......................................
1.1 Technical data 6............................................................
1.1.1 Ordered strokes [mm] 6.............................................
1.2 Safety 7..................................................................
1.2.1 General safety information 7..........................................
1.3 Intended use 7.............................................................
1.3.1 Possible misuse 7..................................................
1.4 Permitted mounting position 8................................................
1.5 Requirements for product use 8...............................................
1.5.1 Obligations of the operating company 9.................................
1.5.2 Qualified specialized personnel 9......................................
1.5.3 Range of application and certifications 9................................
2 Conveying and storage 10.....................................................
2.1 Conveying 10...............................................................
2.2 Storage conditions 10........................................................
2.3 Unpacking 10...............................................................
2.4 Transport protection aids 11...................................................
2.4.1 Securing in the transport protection crate 11.............................
2.4.2 Securing when lifting 11..............................................
2.4.3 Securing during transport and mounting 16...............................
3 Overview 18................................................................
3.1 Delivery status 18...........................................................
3.1.1 Completely mounted handling system 18.................................
3.1.2 Partially mounted handling system 18...................................
3.2 Module types 18............................................................
3.2.1 X-module EHMX (including motor) 18....................................
3.2.2 Y-module EHMY (including motor) 21....................................
3.2.3 Z-module EHMZ (including motor)/DHMZ 23..............................
3.3 Handling systems 25.........................................................
3.3.1 Single-axis system YXCS 25...........................................
3.3.2 Linear gantry YXCL 26................................................
3.3.3 Planar surface gantry YXCF 27..........................................
3.3.4 Three-dimensional gantry YXCR 28......................................
3.4 Handling systems without motors 29............................................

YXC...
4 Festo – GDCP-YXC-EN – 1502NH – English
4 Installation of the single-axis systems and the linear gantries 30....................
4.1 Preparation 30..............................................................
4.1.1 Installation space 30.................................................
4.1.2 Number n of mounting components 30..................................
4.1.3 Preparation of the mounting surface 31..................................
4.2 Mounting components 32.....................................................
4.2.1 Mounting kit with adjustment possibility 32...............................
4.3 Installation of single-axis system and linear gantry 37...............................
4.3.1 Installation YXCS/YXCL 37.............................................
5 Installation of the planar surface gantries and the three-dimensional gantries 39.......
5.1 Preparation 39..............................................................
5.1.1 Installation space 39.................................................
5.1.2 Number n of mounting components 39..................................
5.1.3 Preparation of the mounting surface 40..................................
5.2 Mounting components 44.....................................................
5.2.1 Mounting kit without adjustment possibility 44............................
5.2.2 Adjusting kit 47.....................................................
5.3 Completely mounted handling system 51.........................................
5.3.1 Installation YXCF/YXCR 51.............................................
5.4 Check the alignment and structure 57............................................
5.5 Connecting shaft 58..........................................................
5.5.1 Structure 58.......................................................
5.5.2 Mounting of the connecting shaft 58....................................
5.6 Motor with brake (EMMS-...-RSB/RMB) 67........................................
5.6.1 Dismantling 67.....................................................
5.6.2 Mounting 67.......................................................
6 Attachment components 68...................................................
6.1 Mounting to the Y-module 68..................................................
6.2 Mounting to the Z-module 68..................................................
7 Installation 69..............................................................
7.1 Safety instructions 69........................................................
7.2 Earthing 71.................................................................
7.2.1 Earthing points 71...................................................
7.2.2 Earthing points at the single-axis system 72..............................
7.2.3 Earthing points at the linear gantry 73...................................
7.2.4 Earthing points at the planar surface gantry 74............................
7.2.5 Earthing points at the three-dimensional gantry 75.........................

YXC...
Festo – GDCP-YXC-EN – 1502NH – English 5
7.3 Cables and hoses 76.........................................................
7.3.1 Completely mounted handling system 76.................................
7.3.2 Cables 76..........................................................
7.3.3 Hoses 76..........................................................
7.3.4 Energy chain subdivision Z-modules 77..................................
7.3.5 Energy chain subdivision Y-modules 78..................................
7.3.6 Energy chain subdivision X-modules 80..................................
7.3.7 Installation 80......................................................
7.3.8 Checking the energy chain 81..........................................
8 Commissioning 82...........................................................
8.1 Safety instructions 82........................................................
8.2 Proximity sensors 84.........................................................
8.3 Test run 84.................................................................
9 Operation 85...............................................................
9.1 Safety instructions 85........................................................
9.2 Characteristic curve of the connecting shaft 85....................................
10 Maintenance and care 86.....................................................
10.1 Safety instructions 86........................................................
10.2 Cleaning 87.................................................................
10.3 Lubrication 87..............................................................
11 De-commissioning, dismantling, disposal 88.....................................
11.1 Safety instructions 88........................................................
11.1.1 General 88.........................................................
11.1.2 Dismantling 88.....................................................
11.1.3 Disposal 88........................................................
12 Fault clearance 89...........................................................
12.1 Malfunctions and remedy 89...................................................
12.2 Repair 90..................................................................
A Technical appendix 91........................................................
A.1 Technical data 91............................................................
A.1.1 Certifications 91....................................................
A.1.2 Materials 91........................................................

1 Safety and requirements for product use
6 Festo – GDCP-YXC-EN – 1502NH – English
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.
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.: 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 (Hy) (èProduct labelling on the
X-module):
– By = width in Y-direction e.g.: EHMX-EGC-120-TB-KF-1200-642-...
– Hx = stroke in X-direction e.g.: EHMX-EGC-120-TB-KF-1200-642-...

1 Safety and requirements for product use
Festo – GDCP-YXC-EN – 1502NH – English 7
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 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
8 Festo – GDCP-YXC-EN – 1502NH – English
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
Festo – GDCP-YXC-EN – 1502NH – English 9
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 Conveying and storage
10 Festo – GDCP-YXC-EN – 1502NH – English
2 Conveying and storage
2.1 Conveying
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 Conveying and storage
Festo – GDCP-YXC-EN – 1502NH – English 11
2.4 Transport protection aids
Three different types of transport protection aids prevent uncontrolled movement of the product during
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 vertically to prevent the system from bending.
 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 Conveying and storage
12 Festo – GDCP-YXC-EN – 1502NH – 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 Conveying and storage
Festo – GDCP-YXC-EN – 1502NH – English 13
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 Conveying and storage
14 Festo – GDCP-YXC-EN – 1502NH – English
 Fasten lifting eye bolts to mounting brackets
with the nut.
Screw size and tightening
torque
EHMX-EGC-
50 80 120 185
M8 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
mounting brackets.
Screw size and tightening
torque
EHMX-EGC-
50 80 120 185
M5x8
[Nm] 5.9

2 Conveying and storage
Festo – GDCP-YXC-EN – 1502NH – English 15
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 Conveying and storage
16 Festo – GDCP-YXC-EN – 1502NH – 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 Conveying and storage
Festo – GDCP-YXC-EN – 1502NH – English 17
EHMZ-DGEA
1
2
1
2
1Safety component group 2Z-axis
EHMZ-EGC
11
2 2
1Safety component group 2Z-axis

3 Overview
18 Festo – GDCP-YXC-EN – 1502NH – 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 ac
company 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 position of the motor and en
ergy chain is dependent on the order.
The following components are located on the motor side:
 Energy chain
 Multi-pin plug for sensors (optional)

3 Overview
Festo – GDCP-YXC-EN – 1502NH – English 19
Motor position right (EHMX-...-R)
3
2
1
4
5
7
8
6
1Connecting shaft
2Motor (optional)
3Multi-pin plug/sensors (optional)
4Energy chain
5X-axis
6Adapter Y-module
7X-axis
8Adapter Y-module
Motor position left (EHMX-...-L)
1
2
3
4
6
7
8
5
1Motor (optional)
2Connecting shaft
3X-axis
4Adapter Y-module
5X-axis
6Adapter Y-module
7Energy chain
8Multi-pin plug/sensors (optional)

3 Overview
20 Festo – GDCP-YXC-EN – 1502NH – English
Motor position middle (EHMX-...-M)
1
2
3
4
5
6
7
1Connecting shaft with gear unit/motor1)
2X-axis
3Adapter Y-module
4X-axis
5Adapter Y-module
6Energy chain
7Multi-pin plug/sensors (optional)
1) Accompanying