Festo DFPI-ND2P Series Setup guide

Repair
instructions
(en)
Linear actuator
DFPI-…-ND2P
7DFPIb_en

2 / 55 Festo 7DFPIb_en
Editorial information
Version:
7DFPIb_en (06.2015)
Copyright:
©Festo AG & Co. KG
Postfach
73726 Esslingen
Germany
Editorial team:
PM-SD
Tel.:
+49 (0) 711 / 347-0
Fax:
+49 (0) 711 / 347-2144
E-mail:
[email protected]
Internet:
http://www.festo.com
The reproduction, distribution or sale
of this document or communication of
its contents to others without express
authorisation is prohibited. Offenders
will be held liable for damages. All
rights reserved in the event that a
patent, utility model or design patent
is registered.
All product designations and brand
names used are the property of the
owners and not explicitly identied
as such.
All technical data is subject to change
according to technical updates.

3 / 55Festo 7DFPIb_en
Foreword
These repair instructions are valid for the linear actuator listed on the title page
to the exclusion of any liability claims.
Deviations compared to the descriptions in these repair instructions may arise
depending on the design and/or modication status of the specic linear
actuator. The user must check this prior to carrying out the repair and take the
deviations 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 consequences. Likewise, no liability is accepted for
direct or consequential damage resulting from incorrect use of the products.
More detailed information on this can be found in section 9 „Liability“.
The relevant regulations on occupational safety, safety engineering and
interference suppression as well as the stipulations contained in these repair
instructions must be observed when working on the products.

4 / 55 Festo 7DFPIb_en
Table of contents
1 Important information 6
1.1 About these repair instructions 6
1.2 Pictograms used in these repair instructions 6
1.3 Text markings used in these repair instructions 7
1.4 Safety instructions 7
1.4.1 General safety information 7
1.4.2 Intended use 7
1.4.3 Technical prerequisites 7
1.4.4 Qualication of specialised personnel 8
1.4.5 Standards and test values 8
2 General product description 8
2.1 Functional description 8
2.2 Types and part numbers 9
2.3 Orientation designation 9
2.4 Type code 9
2.5 Production series 10
3 Components list 11
3.1 DFPI-100 / 125 / 160-…-ND2P-C1V-A 11
3.2 DFPI-100 / 125 / 160-…-ND2P-C1V-A-P 13
3.3 DFPI-100 / 125 / 160-…-ND2P-G2 15
3.4 DFPI-200 / 250 / 320-…-ND2P-C1V-A 17
3.5 DFPI-200 / 250 / 320-…-ND2P-C1V-P-A 19
3.6 DFPI-200 / 250 / 320-…-ND2P-G2 21
4 Repair steps 23
4.1 Preparation for dismantling 23
4.1.1 Disconnecting supply lines from the linear actuator 24
4.2 Visual inspection 24
4.3 Repair steps for the bearing cap 24
4.3.1 Replacing bearing cap components 25
4.4 Repair steps for the piston 27
4.4.1 Replacing the piston components 27
4.4.2 Replacing the magnet holder 28
4.5 Repair steps for the end cap module 30
4.5.1 Replacing the displacement encoder 31
4.5.2 Replacing the controller with electronic function module 32
4.5.3 Replacing the electronic function module 33
4.5.4 Replacing the valve block 35
4.6 Fitting the end cap module 38
4.7 Repair steps for the end cap module 39
4.7.1 Replacing the displacement encoder 40
4.7.2 Replacing the driver board with the input board 40
4.7.3 Replacing the valve block 42
4.8 Fitting the end cap module 45
4.9 Assembling the linear actuator 46
4.9.1 Connecting supply lines to the linear actuator 48

5 / 55Festo 7DFPIb_en
Table of contents
5 Troubleshooting 49
5.1 DFPI-ND2P-C1V-…-A 49
5.2 DFPI-ND2P-G2 52
6 Cleaning and greasing 53
6.1 Cleaning 53
6.2 Greasing 53
6.2.1 Denition of terms 53
7 Maintenance and care 54
8 Tools 54
8.1 Standard tools 54
8.2 Equipment and measuring devices 54
9 Liability 54

6 / 55 Festo 7DFPIb_en
1 Important information
1.1 About these repair instructions
This document contains important information about the professional repair of the linear actuator type DFPI-…-ND2P.
Before carrying out a repair, the relevant section in these instructions must be read in full and followed consistently.
For reasons of clarity, these repair instructions do not contain complete detailed information. The following documents
should therefore also be available while performing repair work on the linear actuator:
– Operating instructions
Contain information about the function, structure, application, installation, commissioning, maintenance and care,
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 information on their installation. This can be found in
the online spare parts catalogue on the Festo website (http://spareparts.festo.com).
– Assembly aids
Contains an overview of available assembly aids such as lubricating greases, thread locking agents, maintenance
tools, etc. (information brochure "Accessories, equipment and tools" (7Accessories_a_en)). This can be found in
the online spare parts catalogue on the Festo website (http://spareparts.festo.com/xdki/data/SPC/0/PDF_SAFE/
Fitting%20aids.pdf).
1.2 Pictograms used in these repair instructions
Warning
... means that non-observance may result in serious personal injury or damage to property.
Caution
... means that non-observance may result in personal injury or damage to property.
Note
... means that non-observance may result in damage to property.
Marking special information
The following pictograms mark passages in the text which contain special information.
Information:
Recommendations, tips and references to other sources of information.
Environment:
Information on the environmentally-friendly use of Festo products.

7 / 55Festo 7DFPIb_en
1.3 Text markings used in these repair instructions
• •Indicates activities that can be carried out in any order.
.1 Indicates activities that should be carried out in the order specied.
– Indicates general lists.
Underlined, blue text indicates a cross-reference or hyperlink that you can click on in the PDF. The section marked in the
text will then be displayed in the document.
1.4 Safety instructions
1.4.1 General safety information
Warning
Risk of injury from electric shock.
• The linear actuator DFPI must be de-energised and depressurised and reliably secured against unauthorised
restart before starting any maintenance and repair work.
Caution
The linear actuator DFPI must only be repaired by authorised and trained persons in accordance with the
specications in the technical documentation and using original spare parts.
Installation and repair by unauthorised and untrained persons, repairs using non-original spare parts or without the
technical documentation required for installation and/or repair are dangerous and therefore not permitted.
Repairs must only be carried out in conjunction with these repair instructions as well as the respective operating
instructions for the device.
Instead of carrying out the repair yourself, your local Festo sales ofce offers the option of having the repair carried
out by Festo.
Components and equipment replaced as part of a repair must be disposed of in accordance with the locally valid
environmental protection regulations.
1.4.2 Intended use
The DFPI is intended to actuate linear process valves in systems, such as gate valves and shut-off valves.
1.4.3 Technical requirements
Note
The following instructions for correct and safe use must be observed:
– Observe the connection and ambient conditions specied in the technical data of the products and all the
connected components. The product can only be operated in compliance with the relevant safety regulations if you
comply with the limit values and load limits (see enclosed documentation).
– The linear actuator must be in faultless technical condition.
– The linear actuator must be operated in its original status, without unauthorised modications.
– The linear actuator is designed for industrial use.
– Observe all further warnings and instructions in this documentation.

8 / 55 Festo 7DFPIb_en
1.4.4 Qualication of specialised personnel
Caution
The linear actuator must only be repaired by authorised or trained persons in accordance with the specications in the
technical documentation and using original spare parts. Installation and repair work carried out by unauthorised and
untrained persons is dangerous, and therefore not permissible.
Furthermore, repair and installation staff must be knowledgeable about the following areas:
– Installation and operation of electrical control systems
– The applicable regulations for operating safety-engineered systems
– The applicable regulations for accident prevention and occupational safety
1.4.5 Standards and test values
Standards and test values that the products must comply with and full can be found in the “Technical data” sections
of the accompanying documentation.
2 General product description
2.1 Functional description
The DFPI-…-ND2P is a linear actuator with the functional principle of a double-acting piston for power transmission and a
built-in displacement encoder. The piston moves in the cylinder barrel when a cylinder chamber is pressurised. The piston
rod transmits the movements to the outside. The advanced piston rod is retracted again when the other cylinder chamber
is pressurised. The linear actuator is only available in versions with a built-in displacement encoder (DFPI-…-E-P) and with
an additional, built-in controller and valve block
(DFPI-…-C1V-… ). On the -P connection type, the electrical and pneumatic connections are well protected from external
mechanical inuences by a sturdy housing.
1 4 5 6 82 3
aJ
9
71Bearing cap
2Piston rod seal
3Cylinder barrel
4Piston rod
5Piston
6Magnet holder
7Intermediate cap
8End cap
9Housing (-P variants only)
aJ Valve block

9 / 55Festo 7DFPIb_en
2.2 Types and part numbers
Type Part number
DFPI-100-…-ND2P-E-P-G2 1808236
DFPI-100-…-ND2P-C1V-A / DFPI-100-…-ND2P-C1V-P-A 1548004 / 1548005
DFPI-125-…-ND2P-E-P-G2 1808239
DFPI-125-…-ND2P-C1V-A / DFPI-125-…-ND2P-C1V-P-A 1548020 / 1548021
DFPI-160-…-ND2P-E-P-G2 1808242
DFPI-160-…-ND2P-C1V-A / DFPI-160-…-ND2P-C1V-P-A 1548026 / 1548028
DFPI-200-…-ND2P-E-P-G2 1804245
DFPI-200-…-ND2P-C1V-A / DFPI-200-…-ND2P-C1V-P-A 1548030 / 1548032
DFPI-250-…-ND2P-E-P-G2 1808253
DFPI-250-…-ND2P-C1V-A / DFPI-250-…-ND2P-C1V-P-A 1548037 / 1548039
DFPI-320-…-ND2P-E-P-G2 1808263
DFPI-320-…-ND2P-C1V-A / DFPI-320-…-ND2P-C1V-P-A 1548041 / 1548044
A complete overview of features, accessories, type codes, technical data and dimensions for the linear actuator DFPI-…-
ND2P can be found in the product catalogue or on the Festo website (www.festo.com).
2.3 Orientation designation
This diagram provides an overview of the orientation designations for the linear actuator.
Orientation:
Festo = Reference point
(rating plate)
O = Top
U = Underneath
R = Right
L = Left
V = Front
H = Rear
2.4 Type code
The precise features of a linear actuator can be determined with the help of the rating plate. The type code is located
directly beneath the Festo logo and provides the linear actuator's features, separated by hyphens (-).
Example 1:
DFPI-100-125-ND2P-C1V-P-A-E
551380 A308 Rev 02
1
42
3
1Type code
2Test number
3Serial number
4Part number

10 / 55 Festo 7DFPIb_en
Example 2:
DFPI-100-125-ND2P-E-P-G2
551380 A308 Rev 02
1
42
3
1Type code
2Test number
3Serial number
4Part number
The type code on these rating plates provides the following information:
DFPI Linear actuator of the type DFPI
100 Diameter of the installed piston
125 Stroke 125 mm
NNo cushioning
D2 Analogue displacement encoder
P- Displacement measurement via potentiometer
C1 Control via controller 1
V Integrated directional control valve
-P- Protected connection type
A Analogue feedback signal
-E- External controller attachment position (no specication indicates internal attachment position)
G2 Second generation
-E Retracted piston safety position (no specication indicates advanced safety position)
A list and description of all the equipment features available for the linear actuator can be found in the data sheet,
which is available on the Festo website (www.festo.com).
2.5 Production series
The linear actuator type DFPI-…-ND2P is built with 2 different controllers. The repair steps differ depending on the
controller, and are described separately for each controller in these repair instructions.
See section 4.5 „Repair steps for the end cap module“. See section 4.7 „Repair steps for the end cap module“.