Festo DGE-25 ZR RF Series, Repair Instructions

Page 1: ...Repair instructions en Toothed belt axis DGE 25 ZR KF DGE 40 ZR KF DGE 63 ZR KF 7DGE_25 63_ZR_KFb_en...

Page 2: ...n and utilisation of this document as well as the communication of its contents to others without explicit authorisation is prohibited Offenders will be liable for damages All rights reserved in parti...

Page 3: ...eviations into consideration if necessary These repair instructions have been prepared with care Festo AG Co KG does not however accept liability for any errors in these repair instructions or their c...

Page 4: ...the guide rail with slide 22 4 3 Drive covers 24 4 3 1 Clamp pieces 24 4 3 2 Clamping sleeves DGE 25 and DGE 40 only and buffers 24 4 3 3 Toothed drive shafts 24 4 4 Replacing the toothed belt 26 4 5...

Page 5: ...etc Can be found on the Festo website www Festo com Spare parts documentation Contains an overview of the spare and wearing parts as well as infor mation on their installation Can be found in the onli...

Page 6: ...the locally valid environmental protection regulations 2 General product description 2 1 Functional description The DGE ZR is a toothed belt axis based on the operational principle of a circulating to...

Page 7: ...verview of the mounting directions and variants for the toothed belt axis H H H Drive shaft on left Drive shaft on right Versions GK Standard slide GV Extended slide KL Additional slide on left KR Add...

Page 8: ...Component overview 3 1 DGE 25 ZR This diagram is intended only to provide an overview of the individual components To order spare and wearing parts please use the online spare parts catalogue on the F...

Page 9: ...drive trunnion with pressed on deep groove ball bearings 20 Gear drive 2 drive trunnions with pressed on deep groove ball bearings 21 Cylinder barrel 22 25 Cover strip 26 28 Slot nut 29 30 Guide rail...

Page 10: ...R_KFb_en 3 2 DGE 40 ZR This diagram is intended only to provide an overview of the individual components To order spare and wearing parts please use the online spare parts catalogue on the Festo websi...

Page 11: ...drive trunnion with pressed on deep groove ball bearings 20 Gear drive 2 drive trunnions with pressed on deep groove ball bearings 21 Cylinder barrel 22 24 Cover strip 25 27 Slot nut 28 29 Guide rail...

Page 12: ...R_KFb_en 3 3 DGE 63 ZR This diagram is intended only to provide an overview of the individual components To order spare and wearing parts please use the online spare parts catalogue on the Festo websi...

Page 13: ...drive 2 drive trunnions with pressed on deep groove ball bearings 20 Cylinder barrel 21 22 Cover strip 23 26 Slot nut 27 28 Guide rail 29 Socket head screw DIN 912 M5 20 8 8 Tightening torque 5 9 Nm u...

Page 14: ...arrel Drive cover with toothed belt pulley and drive as well as clamp for the cover strip Piston with adapter and cover strip guide Slide with recirculating ball bearings only with version DGE KF on g...

Page 15: ...vers from the clamp pieces on the drive covers using a small knife or thin screwdriver Loosen the threaded pins in the centre of the clamp pieces at both ends of the axis Note The adapter in the pisto...

Page 16: ...Pull the cover strip from the clamping jaws 4 1 3 Removing the drive covers and the toothed belt Move the piston to the stop at one end of the cylinder barrel Remove the cover cap in the drive cover G...

Page 17: ...tain ing pin Remove the retaining pin from the clamp piece Pull the toothed belt with the clamping plate from the clamp piece Pull the toothed belt out of the drive cover Repeat the last steps on the...

Page 18: ...ur Pitting on the bearing surface of the guide rail can be observed visually as the bearing surface is noticeably un even This can result in perceptible bearing clearance impaired roll off and increas...

Page 19: ...guide rail Carefully push the slide from the guide rail Remove the covers of the screw holes in the guide rail by inserting a small screwdriver into them and levering them out Note The covers must be...

Page 20: ...pins on the side of the slide using a tapping drill M3 to remove the residue of the locking agent Note Make sure that the stop side arrows and the mounting surface of the slide do not exhibit any sur...

Page 21: ...difficult to feel what is happening when setting the roller bearing cartridge pairs Pretension the three threaded pins using the appropriate torque see table Type Torque DGE 25 10 Ncm DGE 40 10 Ncm D...

Page 22: ...ed pins and repeat the setting procedure Then tighten the screws of the roller bearing cartridges using the appro priate torque see table Fill the guide system with the specified grease see section 5...

Page 23: ...VR Apply Loctite 243 to all socket head screws and tighten these from the inside out using the appropriate torque see table Type Torque DGE 25 2 9 Nm 10 DGE 40 2 9 Nm 10 DGE 63 5 9 Nm 10 Note The sli...

Page 24: ...10 DGE 63 2 0 Nm 10 4 3 2 Clamping sleeves DGE 25 and DGE 40 only and buffers The clamping sleeves not included on the DGE 63 are inserted into the drive covers Pull out these parts to replace them B...

Page 25: ...t If a bearing is not fitting securely replace the module Installing the toothed drive shaft Apply a light coating of grease to the outside of the deep groove ball bear ings and push the toothed drive...

Page 26: ...rds the acceleration and braking behaviour of the toothed belt axis and results in greater acceleration and deceleration than set in the controller spring effect Block shaped acceleration and decelera...

Page 27: ...DGE 40 GV2 659 mm 1 998 DGE 40 HD3 40 398 mm 1 998 DGE 63 785 mm 1 996 DGE 63 GK1 785 mm 1 996 DGE 63 GV2 1 035 mm 1 996 1 GK Standard slide 2 GV Extended slide 3 HD Heavy duty version Example DGE 25...

Page 28: ...contain a magnet see chapter 3 Component overview Note The north pole of a new magnet is indicated with a red dot The north pole must be pointing towards the clamp piece during installation If necess...

Page 29: ...be screwed in and unscrewed before inserting a new piston for the first time This screw should not be used for final assembly 4 5 4 Inserting the piston clamp pieces and toothed belt Note In the case...

Page 30: ...n to the position of the clamping plate The flattened side of the slot and the chamfered end must be pointing away from the toothed belt Warning The toothed belt must be placed correctly on the clampi...

Page 31: ...d must be aligned centrally with respect to the cylinder barrel before being tightened Tighten the flange screws using the appropriate torque see table Type Torque DGE 25 6 0 Nm 10 DGE 40 11 0 Nm 10 D...

Page 32: ...h a washer Move the piston as far as possible to the right Insert the clamp piece a few millimetres into the piston Place the right hand drive cover on the cylinder barrel Note DGE 25 and DGE 40 only...

Page 33: ...when checking it Before the toothed belt pretension can be measured the piston must be moved back and forth a number of times so that the toothed belt can fully settle and differences in tension can b...

Page 34: ...z1 DGE 63 153 6 Hz 358 6 Hz1 1 Alternatives for toothed belt axes with very short stroke Setting the toothed belt pretension If the measured natural frequency of the toothed belt is outside the specif...

Page 35: ...toothed belt pretension again at the other end of the toothed belt axis as described above Repeat the procedure until the measured value corresponds to the value in the table Warning The pretension of...

Page 36: ...m FV Pretension force N m Weight per metre of the toothed belt kg m The frequency to be set can be calculated using the data from the following table Type Weight per metre m Freely oscillating strand...

Page 37: ...mm from the edge of the drive block Clamp the cover strip by tightening the threaded pins using the appropriate torque see table Type Torque DGE 25 2 0 Nm 10 DGE 40 2 0 Nm 10 DGE 63 3 0 Nm 10 Place t...

Page 38: ...e more and adjust the tension of the cover strip if necessary Seal the threaded pins at both ends of the toothed belt axis with locking paint Press the adapter down until it is flush with the top edge...

Page 39: ...que see table Type Torque DGE 25 5 9 Nm 10 DGE 40 9 9 Nm 10 DGE 63 24 Nm 10 Place the toothed belt axis on the work surface as shown with the linear guide facing upwards Support the piston to the side...

Page 40: ...Type Minimum distance Y Maximum distance Y DGE 25 19 mm 23 mm DGE 40 30 mm 35 mm DGE 63 44 mm 51 mm If the distance Y is smaller than the specified minimum the buffer may not have been correctly assem...

Page 41: ...all bearing guide must be relubricated at set intervals using a grease gun Note The press fitted lubrication nipples are funnel type lubrication nipples based on DIN 3405 Festo offers a one hand high...

Page 42: ...trates all the spaces in the roller bearing cartridges 5 3 Toothed belt pretension Warning The toothed belt is set to the specified value in the factory and is thus maintenance free over its entire se...

Page 43: ...0 62 mm Ruler Internal hexagon screwdriver Allen key 2 8 mm Torque wrench 1 25 Nm Torque screwdriver 10 Ncm Screwdriver bits Internal hexagon socket Allen socket 2 8 mm Flat pliers Sturdy general purp...

Page 44: ...bonding of the test probe for use with the test equip ment Order alternatives Type Optibelt TT mini S plus Available exclusively from Schaefer Technik GmbH www schaefer technik de Acoustic belt tensi...

Page 45: ...l with the cylinder barrel Material Aluminium a 30 mm b 50 mm c 40 5 mm d 30 mm e 23 25 0 2 mm f 45 1 0 2 mm g 70 mm a 30 mm b 67 mm c 55 mm d 42 mm e 42 1 0 2 mm f 64 1 0 2 mm g 90 mm a 30 mm b 105 m...

Page 46: ...anty 1 Festo products are being continuously developed with regard to hardware and soft ware The hardware status and where appli cable the software status of the product can be found on the name plate...

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Page 49: ...Operating instructions en Toothed belt pretension test equipment 7Tension01_TBb_en...

Page 50: ...nd utilisation of this document as well as the communication of its contents to others without explicit authorisation is prohibited Offenders will be liable for damages All rights reserved in particul...

Page 51: ...sion and take any deviations into consideration These operating instructions have been prepared with care Festo AG Co KG does not however accept liability for any errors in these operating instructio...

Page 52: ...stance DGE ZR KF only 8 6 1 2 Inserting clamp pieces DGE 25 40 ZR RF only 8 6 2 Preparing the test equipment 9 6 2 1 Attaching the extension sleeves 9 6 2 2 Attaching the stop bolts 10 6 2 3 Attaching...

Page 53: ...ams used in these operating instructions Warning This sign indicates a dangerous situation for persons and or the product Failure to observe this warning can result in injury to persons and or damage...

Page 54: ...ce with the locally valid envi ronmental protection regulations 2 Control elements and connections 2 1 Test equipment 6 7 8 1 2 3 4 5 9 aJ aA aC aD aE aF aB 1 Position stop for DGE 25 40 63 2 Extensio...

Page 55: ...pment in a dry place where it is protected from corrosion ideally in the match ing Systainer see section 9 Accessories and ordering data 5 Test requirements Warning Checking and setting the toothed be...

Page 56: ...a fixed and freely oscillating strand length L The distance from the clamping body to one of the drive covers L1 is set by inserting the test equipment and the corresponding stop bolt The oscillation...

Page 57: ...rent distances are compensated by the extension sleeves to optimise the force stimulus applied by the plunger Loosen the plunger housing and then unscrew it from the test equipment Screw the appropria...

Page 58: ...ns that the slide piston is attached on the left of the test equipment S R means that the slide piston is attached on the right of the test equipment The designations are engraved into the test equipm...

Page 59: ...LGA TB G 80 S L or S R 1 ELGA TB G 120 S L or S R 1 1 Note the position of the stop bolt Depending on the design of the toothed belt axis the following methods can be used to ensure the correct positi...

Page 60: ...t at the position E using the 7 mm stop bolt Place the test equipment to the left or right of the slide piston S L or S R as appropriate to the position of the distance piece must be facing the slide...

Page 61: ...op bolt or the front side of the test equipment is touching the piston the clamping body or the clamp piece with no visible gap Move the holder for the plunger housing so that the plunger is centred a...

Page 62: ...tion using the acoustic operating principle In addition to the basic oscillation natural frequency harmonic oscillation can also occur From experience it is always the first harmonic oscillation In ot...

Page 63: ...ed in the relevant chapter in the respective operating instructions 6 3 3 Additional information on checking the toothed belt pretension The correct toothed belt pretension is of critical importance f...

Page 64: ...Preparing the toothed belt axis 7 2 DGE ZR RF Note It is imperative to attach an additional clamp piece to the toothed belt axes DGE 25 ZR RF and DGE 40 ZR RF so that the toothed belt can oscillate fr...

Page 65: ...ting kit for ELGA TB Type Frequency f Sleeve for plunger Slide position Stop bolt position ELGA TB G 70 146 2 Hz 25 mm S L or S R 11 mm E ELGA TB G 80 133 3 Hz 25 mm S L or S R 11 mm E ELGA TB G 120 1...

Page 66: ...lt tension meter frequency meter for measurement with and without test equipment Special bonding of the test probe for use with the test equipment Order alternatives Type Optibelt TT mini S plus Avail...

Page 67: ...repair instructions for the respective toothed belt axis for an overview of the tools and aids for setting the toothed belt pretension 12 Liability The General Terms and Conditions of Festo AG Co KG...

Page 68: ...nty 1 Festo products are being continuously developed with regard to hardware and soft ware The hardware status and where appli cable the software status of the product can be found on the name plate...