Festo DFPD-x-RS Series User manual

Quarter turn actuator
DFPD 10...500
Festo AG & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany
[phone]
www.festo.com
Operating instructions
(Original instructions)
8074849
2017-07b
[8074851]
Quarter turn actuator DFPD English.....................................
1 About this document
This document describes the use of the above-mentioned product. It contains
additional information for the use of the product in safety-oriented systems (safety
handbook in accordance with IEC 61508).
1.1 Further applicable documents
– Certification documents
– Operating conditions for explosion protection
For all available product documentation èwww.festo.com/pk
1.2 Target group
The document is targeted towards persons who mount and operate the product. It
is additionally targeted towards individuals who are entrusted with the planning
and application of the product in a safety-related system.
1.3 Specified standards
Version status
IEC 61508-1:2010 IEC 61508-4:2010
IEC 61508-2:2010 IEC 61511:2016
Fig. 1
2 Safety
General safety information
– The product may only be used in its original status without unauthorized modi
fications.
– Only use the product if it is in perfect technical condition.
– Take the ambient conditions into consideration at the location of use. Corrosive
environments reduce the service life of the product.
– Observe product labelling.
– Prior to all work, switch off compressed air supply and secure it against acci
dental restarting.
– Exhaust drive prior to mounting, installation and dismantling.
– Product must be regularly tested by a qualified person, and the test must be
documented èChapter 13.
Operating medium
– Only use compressed air in accordance with the specifications
èTechnical data.
– Use only unlubricated compressed air under normal conditions. Once the
product has been used with lubricated compressed air, it must continue to be
operated with compressed air only.
– Protect the device from pressure fluctuations. Use overpressure valves and
pressure regulators.
Return to Festo
Hazardous substances can endanger the health and safety of personnel and cause
damage to the environment. To prevent hazards, the product should only be re
turned upon explicit request by Festo.
– Consult your regional Festo contact.
– Complete the declaration of contamination and attach it to the outside of the
packaging.
– Comply with all legal requirements for handling hazardous substances and
transporting dangerous goods.
3 Intended use
The DFPD quarter turn actuator is intended to actuate process valves, such as ball
valves and butterfly valves with a rotation angle from 0° (valve closed) to 180°
(depending on design).
Note
The operating torque of the drive must not be higher than the maximum per
missible torque listed in ISO 5211, with reference to the size of the mounting
flange and of the coupling.
4 Additional information
– Accessories èwww.festo.com/catalogue
– Spare parts èwww.festo.com/spareparts
– Documents and literature èwww.festo.com/sp
5 Service
 Consult your regional Festo contact if you have technical questions
èwww.festo.com.
6 Information on functional safety
6.1 Attainable safety rating
The product is suitable for use as an element in a safety-related system in accord
ance with IEC 61511.
– In low-demand mode up to SIL 2
– In high-demand mode up to SIL 2.
Taking into account the necessary minimum hardware fault tolerance of HFT = 1,
the product can also be used up to SIL 3 with a redundant design of the entire
system.
Note
The suitability for certain applications can only be determined in connection with
the assessment of further components of the subsystem. These must achieve
the same safety level.
6.2 Safety function
Single-acting quarter turn actuators DFPD-...-RS / DFPD-...-LS
The element safety function consists of the control valve taking the switching posi
tion if compressed air is switched off. Return is achieved through spring force.
Double-acting quarter turn actuators DFPD-...-RD / DFPD-...-LD
The element safety function consists in the execution of a complete working stroke
(opening or closing of the process valve) within a defined time.
6.3 Operating conditions
– General instructions on safe operation èChapter 2.
– Periodic tests (performance test) èChapter 13.
– Ambient conditions and additional technical specifications èChapter 16.
6.4 Limitations of use
If used in a safety-related system, the service life is limited to 8 years if the operat
ing conditions are complied with.
– Recommended interval for a complete performance test: 1 year.
– Maximum admissible interval for a complete performance test: 3 years.
If performance tests are negative, maintenance work must be performed immedi
ately.

6.5 Characteristic values
Safety standards (in accordance with IEC 61508) Value
Probability of Dangerous Failure on Demand
(Probability of Dangerous Failure on Demand)
PFDspec 8.89 · 10-4
Assumed Test Interval (Assumed Test Interval) Ti1 a
Confidence Level (Confidence Level) 1-á95 %
Hardware Fault Tolerance(Hardware Fault Tolerance) HFT 0
Diagnostic Coverage (Diagnostic Coverage) DC 0
Type of Sub System (Type of Sub System) Type A
Mode of Operation (Mode of Operation) Low demand and
high demand
Degree of coverage of dangerous errors through the proof
test (Proof Test Coverage)
PTC 88 %
Assumed Demands per Year(Low Demand Mode)
(Assumed Demands per Year)
nop 1 / a
Failure rate for dangerous errors not detected
(Lambda Dangerous Undetected)
ëDU 1.01 · 10-7 / h
Mean time to failure (dangerous)
(Mean Time to Failure dangerous)
MTTFD1,126 a
Average probability of a dangerous failure on demand
(Low Demand Mode)
(Average Probability of Failure on Demand)
PFDavg (TI= 1 a) 4.44 · 10-4
Assumed Demands per Year(High Demand Mode)
(Assumed Demands per Year)
nop 8760 / a
Average frequency of a dangerous failure per hour
(High Demand Mode)
(Probability of dangerous failure per hour)
PFH 1.01 · 10-7 / h
Fig. 2
7 Product overview
7.1 Design
1234
5
6
aB
9
aA
8
aJ
7
1Mounting thread for limit switch or
position sensor
2Transmission shaft (shaft groove
shows the process valve position –
here closed)
3Mounting thread for pneumatic
NAMUR switching valve
4Mounting thread for coding pin
5Compressed air connection (4)
6Mounting thread for pneumatic
NAMUR switching valve
7Mounting thread for coding pin
8Compressed air connection (2)
9End-position adjustment on both
sides
aJ Mounting thread for process valve
to ISO 5211
aA Coupling for process valve
aB Leakage slot
Fig. 3
Through the housing, a shaft is guided outward on both sides. Through this, the
reaction torque is transmitted to a process valve (èFig. 3, aA) and, if applicable, a
limit switch or position sensor (èFig. 3, 2).
The end stops can be adjusted in the range ± 5° through the end-position adjust
ment on both sides (èFig. 3, 9).
7.2 Product variants and type code
Fig. 4 explains selected product characteristics that are necessary to un
derstand the instructions.
Description of the complete type code:
èwww.festo.com/catalogue.
Characteristic Value Description
Type DFPD Quarter turn actuator
System of units –
N
Metric
Imperial
Size 10, 20, 40, 60, 80,
120, 160, 240, 300,
480
Swivel angle 90, 120, 135, 180 Swivel angle specification in [°]
Closing direction L
R
Closes to the left
Closes to the right
Mode of operation D
S
Double-acting
Single-acting
Spring configuration –, 20, 25, 30, 35, 40,
45, 50, 55, 60
Not for double-acting drive,
for connection pressure with single-acting drive
Flange hole pattern 1 F03 , F04, F05, F07,
F10, F12
Flange hole pattern according to ISO 5211
Flange hole pattern 2 –, 07, 10, 12 Flange hole pattern according to ISO 5211
Temperature range –, T4, T6 èTechnical data
Fig. 4
8 Function
The piston movement of the DPFD is converted through a rack & pinion kinematics
(rack and pinion principle) into a swivel motion of the transmission shaft.
– Single-acting quarter turn actuators: Return is
through spring force.
Fig. 5
– Double-acting quarter turn actuators: Through
pressurising and venting of the cylinder chambers,
the shaft turns back and forth.
Fig. 6
Symbol on the rating plate
Type Mode of operation Symbol
DFPD-...-RD-...
DFPD-...-LD-...
Double-acting
Closes to the right / left
DFPD-...-RS-... Single-acting (spring return)
Closes to the right
DFPD-...-LS-... Single-acting (spring return)
Closes to the left
Fig. 7
9 Transport and storage
Warning
Danger of crushing! Danger of shearing!
The product without accessories weighs up to 20.9 kg, depending on the
product version.
Body parts can be crushed or severed if the product falls.
 Use appropriate load handling equipment.
 When shipping used products: comply with all legal requirements for handling
hazardous substances and transporting dangerous goods.
For return to Festo èChapter 2.
 Remove all attachments.
 Store the product in a cool, dry, UV-protected and corrosion-protected environ
ment. Ensure that storage times are kept to a minimum.

10 Mounting and installation
Note
Mounting and installation should only be carried out by qualified personnel.
10.1 Mounting without adapter bridge
1. Prepare process valve.
– Adjust the switching shaft of the process valve
so that the desired operating method for open
ing and closing is implemented.
2. Place the quarter turn actuator on the switching
shaft of the process valve. The square of the pro
cess valve must sit in the coupling of the quarter
turn actuator (èFig. 3, aA ) without jamming.
3. Fasten the quarter turn actuator to the connection
flange of the process valve with 4 corrosion-resist
ant screws and retaining rings (material: VA).
4. Tighten the screws crosswise.
– Tightening torque èFig. 10
Fig. 8
10.2 Mounting with adapter bridge
1. Have suitable adapter bridge and shaft extension
ready.
– Accessories èwww.festo.com/catalogue
2. Fasten the adapter bridge (èFig. 9, 1) to the
quarter turn actuator.
– Align studs of the adapter bridge lengthwise to
the drive.
– Align open side of the adapter bridge on the
process valve.
– Tighten screws, but not yet fully tight.
3. Prepare process valve.
– Adjust the switching shaft of the process valve
so that the desired operating method for open
ing and closing is implemented.
4. Insert shaft extension (èFig. 9, 2). The square
of the shaft extension must sit in the coupling of
the quarter turn actuator (èFig. 3, aA ) without
tilting.
5. Place the quarter turn actuator with adapter
bridge and shaft extension onto the switching
shaft of the process valve. The square of the pro
cess valve must sit in the coupling of the shaft ex
tension without jamming.
6. Fasten the adapter bridge to the connection flange
of the process valve with 4 corrosion-resistant
screws and retaining rings (material: VA).
7. Tighten the screws at both the drive and process
valve crosswise.
– Tightening torque èFig. 10
Fig. 9
1
2
Flange type F03 F04 F05 F07 F10 F12
Tightening torque [Nm] 5 … 6 9 … 10 22 … 24 46 … 50 80 … 84
Fig. 10
10.3 Pneumatic port
Single-acting quarter turn actuators
Prevent corrosive atmosphere in spring space. In a corrosive atmosphere, use a
rebreather block.
 Fasten a filter element to the exhaust port 4 (A) to prevent ingress of dirt.
Type Compres
sed air con
nection
Effect
DFPD-...-RS-...,
DFPD-...-LS-...
2Air supply; always connected
4Pressurisation of spring space
Fig. 11
Double-acting quarter turn actuators
Type Compres
sed air con
nection
Effect
DFPD-...-RD-... 2 Direction of rotation of air supply anti-clockwise1)
4Direction of rotation of air supply clockwise1)
DFPD-...-LD-... 2 Direction of rotation of air supply clockwise1)
4Direction of rotation of air supply anti-clockwise1)
1) Viewed from the connection point of the accessory
Fig. 12
11 Commissioning
Note
Commissioning should only be carried out by qualified personnel.
Prerequisites
– The drive is fully mounted and connected.
Commissioning the drive
1. Pressurise drive slowly.
2. Check correct function at low travel speed.
– Direction of rotation of drive
– Process valve position
12 Malfunctions
Note
Repairs to the product are not permissible. In the event of malfunctions or fail
ure, replace the product and let Festo know about the failure. Return defective
products to Festo.
Malfunction Possible cause Remedy
Drive does not move in the
desired direction
Compressed air supply ports
connected incorrectly
 Correct the tubing
connection
Fig. 13
13 Maintenance
13.1 General
– Low demand mode: When used as intended, the product is maintenance-free.
– High demand mode DFPD-...-T6: For safety-related applications, replace con
summable parts after max. 20,000 switching cycles.
13.2 Proof Test (Proof Test)
The proof test consists of a full stroke test of the drive. Here, the complete rotation
of the shaft is checked at the connection to the process valve dependent on the
switching position of the control valve.
The switching position of the shaft can be determined visually (position of the
shaft groove), through a position sensor or through another suitable auxiliary
means.
 Conduct the proof test at least 1x every 3 years.
During the proof test, the safety of the application must be ensured.
1. Trigger rotation of the shaft at the control valve.
2. Measure the time until the quarter turn actuator completely performs the rota
tion of the shaft.
èThe test is successful if the quarter turn actuator completely performs the
movement within the switching time intended for control by the control
valve.
3. Check the drive externally (visual inspection).
èThe test is successful if no defect, leakage, or contamination is detected.
4. Document test results.

14 Dismantling
Note
Disassembly only by qualified personnel.
1. Switch off the energy supply (compressed air, electricity)
2. Loosen the pneumatic connections.
3. Remove external attachments.
4. Loosen the mounting screws of the drive at the process valve and remove the
drive.
15 Disposal
 Observe the local regulations for environmentally friendly disposal.
 Dispose of the product in an environmentally friendly manner. When doing this,
also take residual media into account
(potential recycling of hazardous waste).
16 Technical data
General DFPD DFPD-...-T4 DFPD-...-T6
Standard connection to the process valve ISO 5211
Cushioning None
Mounting position Any
Design Rack and pinion principle
Valve connection conforms to standard VDI/VDE 3845 (NAMUR)
Swivel angle
DFPD-...-90 [°] 0…90
DFPD-...-120 [°] 0…120
DFPD-...-135 [°] 0…135
DFPD-...-180 [°] 0…180
End position adjustment range 0° [°] ± 5
End position adjustment range 90° /
180°
[°] ± 5
Operating pressure [bar] 2…8 3…8 3…8
Nominal operating pressure
DFPD-...-RD, DFPD-...-LD
DFPD-...-...S-20
DFPD-...-...S-25
DFPD-...-...S-30
DFPD-...-...S-35
DFPD-...-...S-40
DFPD-...-...S-45
DFPD-...-...S-50
DFPD-...-...S-55
DFPD-...-...S-60
[bar]
[bar]
[bar]
[bar]
[bar]
[bar]
[bar]
[bar]
[bar]
[bar]
5.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
Operating medium Compressed air according to ISO8573-1:2010 [7:4:4]
Note on the operating medium Pressure dew point at least 10 °C below outside
temperature, lubricated operation possible (re
quired in further operation)
Ambient temperature [°C] 20…+80 0…+150 50…+60
CE marking (declaration of conformity
èwww.festo.com/sp)
To EU Explosion Protection Directive (ATEX)1)
Material
Housing Anodised wrought aluminium alloy
Cap Coated die-cast aluminium
Shaft Steel, nickel-plated
Stainless steel (only R3 variant)
Screws Stainless steel
Seal NBR FPM FVMQ
1) Take into account certification-specific documentation èwww.festo.com/sp
Fig. 14
Type Air consumption per cycle at an operating pressure of
6bar1)
DFPD-10-RP-90-D [l] 0,54
DFPD-20-RP-90-D [l] 1,21
DFPD-20-RP-90-S [l] 0,60
DFPD-40-RP-90-D [l] 2,47
DFPD-40-RP-90-S [l] 1,80
DFPD-40-RP-180-D [l] 4,80
DFPD-80-RP-90-D [l] 5,30
DFPD-80-RP-90-S [l] 3,60
DFPD-120-RP-90-D [l] 7,80
DFPD-120-RP-90-S [l] 5,40
DFPD-120-RP-180-D [l] 14,40
DFPD-160-RP-90-D [l] 10,80
DFPD-160-RP-90-S [l] 7,20
DFPD-250-RP-90-D [l] 15,60
DFPD-240-RP-90-S [l] 10,20
DFPD-240-RP-180-D [l] 28,20
DFPD-300-RP-90-D [l] 26,40
DFPD-300-RP-90-S [l] 13,20
DFPD-480-RP-90-D [l] 40,20
DFPD-480-RP-90-S [l] 21,00
DFPD-480-RP-180-D [l] 66,60
1) Theoretical value for a complete swivel motion (0° - max. swivel angle - 0°)
Fig. 15