Festo EXCH-***-C series User manual

Description
Commissioning
8046380
1506a
[8046374]
EXCH-…-C…
Planar surface gantry with
control system

EXCH-…-C…
2 Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English
Translation of the original instructions
GDCP-EXCH-…-C… – INB-EN
CODESYS®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 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.

EXCH-…-C…
Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 3
Table of Contents – EXCH-…-C…
1 Safety and requirements for product use 5......................................
1.1 Safety 5..................................................................
1.1.1 General safety information 5..........................................
1.1.2 Intended use 7.....................................................
1.1.3 Foreseeable misuse 7...............................................
1.1.4 Specified standards/directives 7......................................
1.2 Requirements for product use 8...............................................
1.2.1 Qualified specialists 8...............................................
1.2.2 Range of applications and certifications 8...............................
2 Overview 9................................................................
2.1 System overview 9..........................................................
2.2 Accessories 9..............................................................
3 Commissioning 10...........................................................
3.1 General information 10.......................................................
3.1.1 Prior to commissioning 10.............................................
3.1.2 Delivery status 10...................................................
3.1.3 USB memory card 11.................................................
3.1.4 Axes and motors 13..................................................
3.1.5 Control elements 14.................................................
3.1.6 Operator unit/enabling button 16......................................
3.1.7 Emergency stop circuits 17............................................
3.1.8 Manual override/automatic operation 17................................
3.1.9 Release brakes 19...................................................
3.1.10 System inputs 20....................................................
3.2 Festo Configuration Tool (FCT) 20...............................................
3.2.1 Required software 20................................................
3.2.2 Installing the FCT 21.................................................
3.2.3 Starting the FCT 21..................................................
3.2.4 De-archiving an FCT project 21.........................................
3.3 Network configuration 22.....................................................
3.3.1 IP addresses 22.....................................................
3.3.2 Adapt IP address of the FCT-PC 23......................................
3.3.3 Adapting the IP address of the multi-axis controller 23......................
3.3.4 Changing IP addresses of the motor controllers 24.........................
3.3.5 Adapting IP address of the operator unit 25...............................

EXCH-…-C…
4 Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English
3.4 Creating kinematics-specific FCT project 25.......................................
3.4.1 Definition 25.......................................................
3.4.2 Requirements 25....................................................
3.4.3 Adapting stroke lengths 26............................................
3.4.4 Check direction of motor rotation 28....................................
3.4.5 Adding FCT component 28.............................................
3.5 Configuring the control system 29...............................................
3.5.1 Requirements 29....................................................
3.5.2 Preparation 29......................................................
3.5.3 Multi-axis controller with Codesys 29....................................
3.5.4 Motor controller 30..................................................
3.6 Homing and checking 31......................................................
3.6.1 Requirements 31....................................................
3.6.2 Drives: direction of movement, assignment and homing 31..................
3.6.3 Checking the toothed belt pretension at operating temperature 35............
3.6.4 Determining and adapting feed constants 36..............................
3.6.5 Safety circuits 39....................................................
3.7 Conclusion of commissioning 41................................................
3.8 Fault clearance 42...........................................................
4 Operation 44...............................................................
4.1 FCT projects 44..............................................................
4.1.1 Transfer control parameters in FCT project 44.............................
4.1.2 Saving and archiving FCT project 45.....................................
5 Repair 46..................................................................
6 De-commissioning and disposal 47.............................................

1 Safety and requirements for product use
Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 5
1 Safety and requirements for product use
1.1 Safety
1.1.1 General safety information
 Observe the safety instructions in the corresponding chapters.
Special safety regulations are placed immediately before the task instruction.
Danger
Serious injuries due to uncontrolled movements of the planar surface gantry.
 Perform risk assessment on operation of the planar surface gantry.
 Place planar surface gantry in operation only if the dangers to people identified in
the risk assessment can be excluded through appropriate measures.
Warning
Danger of electric shock even if power switch is shut off.
The control system is only completely voltage-free if all supply lines have been switched
voltage-free.
 Switch off all supply lines (also external voltage) prior to assembly, installation and/
or maintenance work and secure them from being restarted accidentally.
 Switch the voltages back on only after completion of work.
Warning
Severe injuries if installation and commissioning are not performed correctly.
 Commissioning only by specially trained personnel.
The following qualifications are required:
– knowledge of the Festo Configuration Tool (FCT) software
– experience with installation and operation of electrical control systems
For support in commissioning:
 Contact your regional Festo contact person (èwww.festo.com/sp).

1 Safety and requirements for product use
6 Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English
Warning
If the planar surface gantry is mounted vertically
Mortal danger and material damage due to falling traverse (Y-axis).
In the following cases, the traverse can drop in an uncontrolled manner:
– through release of the motor brakes.
– if the toothed belt breaks during operation or at rest.
– during operation without the required components.
 Make sure that all components required for vertical operation are mounted and
ready for operation:
– Drive with high-performance motors with brake:
EXCH-40-…-AB2-… : motors EMMS-…-100-S-…-RMB
EXCH-60-…-AB3-… : motors EMMS-…-140-S-…-RMB
– Control system with integrated safety switching device and power failure detec
tion (order characteristic: EXCH-…-AB…-C…-S2-…)
– Motor controller CMMP-AS-C5-11A-P3-M0 (order characteristic: B6, B7 or B8)
– Additional braking resistors CACR-KL2-40-W2000 (part no. 2882343).
Accessories (èwww.festo.com/catalogue)
 Ensure through appropriate protection devices that no persons are located in and
below the operating area of the planar surface gantry.
 Before releasing the motor brakes or switching off the power supply, ensure the
following:
– motors inactive (no rotation)
– traverse in the lower end position at the end caps
Note
Damage to the product from incorrect handling.
 Never pull or plug in the plug connectors and interfaces when powered.
 Observe the handling specifications for electrostatically sensitive devices.
Note
Unauthorised access to the device can cause damage or malfunctions.
When connecting the device to a network:
 Protect the network from unauthorised access.
Measures for protecting the network include:
– Firewall
– Intrusion Prevention System (IPS)
– Network segmentation
– Virtual LAN (VLAN)
– Virtual private network (VPN)
– Security at physical access level (port security)
Additional information: standards/guidelines for security in information technology.

1 Safety and requirements for product use
Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 7
1.1.2 Intended use
The planar surface gantry EXCH and the control system CMCA-...-B... are intended for installation in
machines or automation technology systems for moving payloads in combination with attachment
components.
Employ the planar surface gantry and the control system as follows:
– In perfect technical condition
– in original condition, without unauthorised modifications
– within the limits of the product defined through the technical data
(èAccompanying documentation)
– in an industrial environment
The safety circuit of the control system CMCA-...-B... is only one part of the safety concept for a
machine, whereby the safety concept must be based on a risk assessment of the entire machine to be
performed by the machine manufacturer.
Note
The removal of mechanical components (e.g. motor) causes referencing to be lost. At
the subsequent commissioning, a new referencing and adaptation of the feed constants
are required (è5 Repair).
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.
1.1.3 Foreseeable misuse
– The safety circuit of the control system CMCA-…-B… is changed in its function.
– With the control system CMCA-…-B…, safety functions are implemented that are not described in
this documentation.
– The safety circuit is not appropriate for the application.
– No verification and no validation of the switch in the machine have been performed.
– Operation without sufficient risk evaluation of the complete system.
– Operation without safety concept for the machine.
1.1.4 Specified standards/directives
Issue status
EN ISO 13849-1:2008-12
Tab. 1.1

1 Safety and requirements for product use
8 Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English
1.2 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:
 Observe all warnings and notes.
 Comply with all load limits of the product and the connected components
(èTechnical data of the corresponding documentation).
1.2.1 Qualified specialists
 The product should only be installed by specialized personnel with corresponding qualifications.
The following knowledge is required:
– installation and operation of electrical control systems
– applicable regulations for operating safety-engineering systems
– applicable regulations for accident prevention and operational reliability
– documentation and mode of operation of the product
1.2.2 Range of applications and certifications
Standards and test data of the products (èTechnical data of the corresponding documentation).
Certificates and declaration of conformity (èwww.festo.com/sp).

2 Overview
Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 9
2 Overview
2.1 System overview
The system EXCH-…-C… consists of the planar surface gantry and the control system CMCA-…-B… .
Planar surface gantry EXCH
The planar surface gantry has tow servo motors that drive a toothed belt arrayed in an H-shape.
The rotating toothed belt moves the traverse (Y-axis) and the slide unit on the Y-axis in the
2-dimensional space. The position of the slide is calculated by a controller.
The slide movement in the direction of an axis is reached through the controlled interplay of the two
motors.
Additional tasks can be taken over through attachment components (Z-axes).
Control system CMCA-…-B…
The control system CMCA-…-B…, subsequently called control system, includes the components
necessary for activation of the planar surface gantry
– multi-axis controller CMXR, subsequently called multi-axis controller, and
– motor controller CMMP, subsequently called motor controller.
A safety circuit is also integrated, which represents the basic functionality with
– the operator unit CDSA, subsequently called operator unit, or
– an enabling button in combination with the CDSA emulation.
2.2 Accessories
Needed for commissioning of the planar surface gantry together with the control system are:
– PC (laptop) with installed Festo Configuration Tool (FCT), including the plug-ins for the multi-axis
controller and the motor controller
– USB memory card with software and data (è3.1.3 USB memory card)
– accompanying documentation
– 2 zero point setting pieces (length 30 mm; included in scope of delivery)
– gauge for setting the feed constants (not included in the scope of delivery);
dimension recommendation: è3.6.4 Determining and adapting feed constants (step 5.)
– operator unit or enabling button
Commissioning can be carried in two ways:
– with the operator unit
or
– with the enabling button in combination with the CDSA emulation.
The CDSA emulation is a component of the CMXR plug-in.
The enabling button is not included in the scope of delivery.

3 Commissioning
10 Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English
3 Commissioning
This chapter describes commissioning of the system comprising the planar surface gantry and
controller system in the delivery status (è3.1.2 Delivery status).
Note
Commissioning requires knowledge of how to work with the following systems:
– control system and the components contained therein
– operator unit or enabling button with CDSA emulation
Specific instructions on the individual products and components required for commis
sioning are in the corresponding descriptions.
 Prior to commissioning of the system, make sure you have read and understood the
descriptions of these components.
The control system is available in various designs.
as a completely configured control cabinet or as a mounting plate for installation in a
control cabinet by the system manufacturer or operator. In this description, the control
elements are designated corresponding to the control cabinet version.
 In case of a user-specific or user-produced control cabinet:
Note the possibly deviating designations of the control elements.
3.1 General information
3.1.1 Prior to commissioning
Carry out the following steps to prepare for commissioning:
1. Mount kinematic system (èDescription of the planar surface gantry: EXCH “Mechanical Installa
tion”).
2. Connect control system
(èDescription of control system CMCA-…-B… “Electrical Installation”).
3.1.2 Delivery status
FCT basic projects for all available kinematics variants can be found on the USB memory card.
Note
At the factory, the control system is not yet configured for the planar surface gantry.
The following steps must also be performed during commissioning:
 Create a kinematic-specific FCT project from the FCT basic project that fits the kin
ematics (è3.4).
 Transfer control data of the kinematics-specific FCT project into the components of
the control system (è3.5).
In the case of user-specific or user-produced control systems:
 Adapt the corresponding FCT basic project or create a new one.

3 Commissioning
Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 11
3.1.3 USB memory card
The accompanying USB memory card includes software and data for commissioning (èTab. 3.1):
– documentation on planar surface gantry and control system
– FCT software and plug-ins
– FCT basic projects for various kinematics variants (èTab. 3.2)
Fold out interface
Fig. 3.1 Fig. 3.2
Content structure
Directories Contents
|– 1Documentation
|
|
|–
|
1Declaration of Incorpora
tion
– Declaration of incorporation in accordance with EC
Machinery Directive 2006/42/EC
|
|
|–
|
1Description Mechanical
Installation
– Description EXCH “Mechanical installation”
|
|
|–
|
1Description Electrical
Installation
– Description CMCA-…-B… “Electrical Installation”
||– 1Description Comissioning – Description EXCH-…-C…“Commissioning”
||– 1Description Accessories – Mounting instructions of the accessories
|– 1Software
|–
|
|
1CMMP – Installation file for FCT framework and CMMP plug-in
– Firmware file for motor controller (to install on it when a
motor controller is replaced)
|– 1
|
CMXR-C2 – Installation file for FCT framework and CMXR-C2 plug-in
|–
|
1Base_projects – FCT basic projects for various kinematics variants with
multi-axis controller CMXR-C2
|– 1Target – Installation files for Codesys
|– 1CoDeSys – Installation files for Codesys
|– 1FCT-Plugin
Tab. 3.1

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FCT basic projects
The basic projects have been prepared for various kinematics variants and differ in content regarding
the following characteristics and variants.
In the file name of the basic projects, the included characteristics and their variants are designated with
the following codes.
Characteristics Code in the basic project name Variants
EXCH-…-…-…
Size of planar surface gantry 40
60
Motor type and size AB1 With brake Size 70
AB2 Size 100
AB3 Size 140
AS1 Without brake Size 70
AS2 Size 100
AS3 Size 140
Motor attachment position B Bottom
TTop
Tab. 3.2 Code for file names of the basic projects
Note
The FCT basic projects do not yet include all kinematics-specific specifications.
For commissioning, the basic project that fits the kinematics must be selected and ex
panded to a kinematics-specific FCT project
(è3.4 Creating kinematics-specific FCT project).

3 Commissioning
Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 13
3.1.4 Axes and motors
The attachment position of the motors is determined when the planar surface gantry is
ordered.
1
34
2
5
6
1X-axis 1 (with energy chain)
2X-axis 2
3Motor 2
4Traverse (Y-axis)
5Slide unit of the Y-axis
(for fastening the attachment component)
6Motor 1
Fig. 3.3 Depicted as an example, planar surface gantry with motor attachment position underneath
(EXCH-…-B-…).
The motors are not assigned directly to an axis.
The directions of movement of the traverse and the slide unit of the Y-axis are achieved
through the interaction of both motors.

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3.1.5 Control elements
5
3
4
1
2
1Interlock for control cabinet doors
2Power switch
3Connection for operator unit or enabling
button
4Control and signal elements (èFig. 3.5)
5Emergency stop switches
Fig. 3.4 Control cabinet

3 Commissioning
Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 15
562341
1Illuminated push-button “acknowledge emergency stop”: confirms that the emergency stop
circuit is unlocked
2Indicator light “external emergency stop”: external emergency stop triggered
3Indicator light “automatic control”: automatic operation active
4Key switch “automatic/manual”: switches between automatic and manual operation.
The switch is only active when the “local” operating mode has been selected by means of link
plugs
(èDescription of control system CMCA-...-B... “Electrical installation”).
With “external” operating mode, the switch is without effect.
5Indicator light “manual control”: manual override active
6Key switch “brake release”: release motor brakes (è3.1.9 Release brakes).
Only possible in manual override and in combination with one of the enabling buttons on the oper
ator unit or a separate enabling button.
Fig. 3.5 Operating and signal elements
The labels for marking the control elements in German are also included with the control
cabinet.

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3.1.6 Operator unit/enabling button
Warning
Risk of injury/damage due to ineffective emergency stop.
A not-connected operator unit in reach of the user can result in ineffective use of the
emergency stop switch.
 Keep the not-connected operator unit outside the reach of the user.
Unplugging the connection cover or a connected device triggers an emergency stop.
 Put the system at rest before the connection cover or a connected device is plugged in
or unplugged.
Either a device must be connected or the connection cover mounted. Otherwise, the
emergency stop circuit is opened (emergency stop active).
Connect operator unit/enabling button
1. Switch off control system at the power switch.
2. Connect operator unit or enabling button at the connection on the left control cabinet door or,
for orders without control cabinet, on the mounting plate.
Warning
Risk of injury due to uncontrolled movements of the traverse or of the slide unit of the
Y-axis.
The enabling keys of the operator unit and the enabling button are operational immedi
ately after being connected.
 Note: Login is not required for the enabling keys to work.
3. Switch on control system at the power switch.
4. Switch control system to manual override (è3.1.8 Manual override/automatic operation).
Function of the enabling key
The operator unit has two enabling keys, which can be actuated alternatively.
The separate enabling button has an enabling key.
On both devices, the enabling key has the following three possible switch positions:
Switch position
(step)
Enabling key Function Switch contact
1Not actuated Off (neutral position) Off (opened)
2Actuated (up to pressure point) Permission On (closed)
3Pressed (end stop) Off (panic setting) Off (opened)
Tab. 3.3
The enabling function (switch position 2) of the enabling key is cancelled by
– releasing the enabling key (switch position 1) or
– pressing beyond the pressure point (switch position 3).
When the switch position is returned from 3 to 1, the enabling function is not effective.

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Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 17
3.1.7 Emergency stop circuits
The control system differentiates between two emergency stop circuits:
– internal emergency stop: triggered at the control system.
– external emergency stop: triggered, for example, by a higher-order controller.
The connection contacts for external emergency stop and safety door switch are open and not
bridged in the delivery status.
 Acknowledge the external emergency stop at the higher-order controller, in order to close the
contacts (èDescription of control system CMCA-…-B… “Electrical installation”; èCircuit dia
gram).
3.1.8 Manual override/automatic operation
The operating modes manual override and automatic operation differ primarily in the handling of safety
doors and the reduced speed of the kinematics in manual override.
Warning
Risk of injury/damage risk at high travel speed
of the traverse (Y-axis).
Setting up and checking may only be performed in manual override.
 To perform set up and checking work: Change the control system to manual override.
Automatic operation
Automatic operation corresponds to the configuration in production operation.
The following conditions must be met for the function (motor current enable):
– Contacts of the safety door switch closed.
– All emergency stop switches unlocked.
– All emergency stop circuits acknowledged.
– For local mode selection: key actuator “automatic/manual” set to “automatic”.
– For external mode selection: corresponding specification through the higher-order controller.
– Key switch “brake release” in position “0”.

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Manual override
In manual override, the kinematics system can be moved manually via the operator unit or an enabling
button, even with open safety doors. This operating mode of the multi-axis controller is used to check
the installed system, made up of the planar surface gantry and the control system, as well as for setting
up and commissioning the programs. The speed is limited during this mode.
Note
The speed limitation of the manual override is not reliable as defined by
EN ISO 13849-1. Additionally, external protective measures must be adopted for safety-
relevant control tasks or for the safety of persons.
The following conditions must be met to enable motor current with the enabling buttons on the
operator unit or the separate enabling button:
– All emergency stop switches unlocked.
– All emergency stop circuits acknowledged.
– For local mode selection: key actuator “automatic/manual” set to “manual”.
– For external mode selection: corresponding specification through the higher-order controller.
– Key switch “brake release” in position “0”.
Switching from manual override/automatic operation
Switching of the operating modes depends on the setting for the operating mode selection.
– Mode selector local: with the key switch “automatic/manual”.
– Operating mode selection, external: with the higher-order controller.
In this case, the “automatic/manual” key actuator has no function.
Information on setting the mode selection:
èDescription of control system CMCA-...-B... “Electrical installation”

3 Commissioning
Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English 19
3.1.9 Release brakes
This section is relevant if the motors of the planar surface gantry are equipped with a
brake (EXCH-…-AB…).
Releasing the motor brakes permits manual moving of the traverse and the slide unit of the Y-axis.
Releasing the brakes is possible only in manual override and only with the help of the operator unit or a
separate enabling button.
Danger
If the planar surface gantry is mounted vertically
Mortal danger and material damage due to falling traverse (Y-axis).
The traverse falls down in an uncontrolled manner due to release of the motor brakes.
 Before releasing the brakes, make sure that the traverse is located in the lower end
position at the end caps.
1. End all active programs.
2. Switch control system to manual override (è3.1.8 Manual override/automatic operation).
3. Connect operator unit or enabling button to the control system
(è3.1.6 Operator unit/enabling button).
Warning
Risk of injury due to uncontrolled movements of the traverse or of the slide unit of the
Y-axis.
The enabling keys of the operator unit and the enabling button are operational immedi
ately after being connected.
 Note: Login is not required for the enabling keys to work.
4. Rotate key switch “brake release” clockwise to the “2 o’clock position”.
5. Unlock brakes via an enabling key on the operator unit or the separate enabling button.
The brakes of the drives must unlock audibly.
The traverse and the slide unit of the Y-axis can now be shifted manually.
Connecting the operator unit or enabling button triggers an emergency stop
(èDescription of control system CMCA-...-B... “Electrical installation”).
 Before the start of commissioning: acknowledge emergency stop.

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20 Festo – GDCP-EXCH-…-C… – INB-EN – 1506a – English
3.1.10 System inputs
The system inputs of the multi-axis control system are configured for control of the following operating
statuses and user interventions.
Input Function
DI0 Emergency stop (active at status “0”)
DI1 Enabling keys on the operator unit or separate enabling button
DI2 Automatic operation selected
DI3 Manual override selected
DI4 –
DI5 Safety doors closed
DI6 Release brake active
DI7 External emergency stop active
Tab. 3.4
The status of the inputs can be observed over the I/O monitor of the operator unit or in the CDSA
emulation.
 Call up I/O monitor: Select key/button and then “IO-Monitor”.
3.2 Festo Configuration Tool (FCT)
The Festo Configuration Tool (FCT) is the software platform for configuring and commissioning different
components from Festo.
Information on installation and operation of the FCT can be found in the FCT description.
The description is on the USB memory card or, after installation of the program, in the
folder <FCT installation directory>\Help\FCT_<language>.pdf.
The following descriptions for the Festo Configuration Tool (FCT) refer to “English” as the
language setting.
The FCT language setting can be changed in the menu [Extra] [Language].
3.2.1 Required software
The files needed for installation of the FCT are on the accompanying USB memory card.
Required for commissioning are:
– FCT plug-in CMXR-C2, including FCT base program (Framework)
– FCT plug-in CMMP-AS
– Codesys