Festo DDLI-25 User manual

Operating
instructions
8113360
2019-05b
[8113362]
Linear drive
DDLI25_63

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Translation of the original instructions
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
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

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Table of contents
1 Control sections and connections 4............................................
2 Function and application 5...................................................
3 Transport and storage 5.....................................................
4 Requirements for use 6......................................................
5 Installation 7..............................................................
5.1 Installation, mechanical 7....................................................
5.2 Installation, pneumatic 10.....................................................
5.3 Installation, electric 11.......................................................
6 Commissioning 12...........................................................
6.1 Commissioning the complete system 12..........................................
6.2 Commissioning DDLI 12.......................................................
7 Operation 14...............................................................
8 Maintenance and care 14.....................................................
9 Repair 14..................................................................
10 Accessories 14..............................................................
11 Trouble-shooting 15.........................................................
12 Technical data 16............................................................

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1 Control sections and connections
1 2 3 456 7 8
1Measuring system connection
2Compressed air connection with push-in
fitting (blue releasing ring)
3Earthing (e.g. via screws 4in the connection
cap)
4Screws with female thread for attachment of
the drive (4x per side)
5Slide
6Mounting thread for useful load
7Cylinder barrel with integrated displacement
encoder
8Compressed air connection with push-in
fitting (black releasing ring)
Fig. 1
For all available product documentation èwww.festo.com/pk

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2 Function and application
When compressed air is applied to the cylinder chambers in alternate sequence, the piston moves
backwards and forwards in the profiled tube. By means of a rigid connection to the piston, the slide
also moves. The slot in the cylinder barrel required for this is covered by a sealing band system. The
displacement encoder enables the position of the slide to be ascertained clearly at any time.
The displacement encoder with CAN axis interface is suitable for use with:
– end-position controllers SPC11-MTS-AIF-2
– axis controller SPC200 with axis interface SPC-AIF-MTS-2
– end-position controller CPX-CMPX
– position controller CPX-CMAX
– measuring module CPX-CMIX.
The linear drive DDLI in intended for the pneumatic positioning of
loads in slide operation.
The DDLI is intended for use in an industrial environment. Outside
of industrial environments, e.g. in commercial and mixed-residen
tial areas, actions to suppress interference may have to be taken.
Fig. 1 Slide mode
Note
Unpressurized movement of the slide is permitted only for fault correction and at low
speed. If excessive speed is used, the resulting low pressure can pull the sealing band
into the piston chamber. This leads to:
– high leakage and
– impermissible acceleration (e.g. in vertical mounting position).
3 Transport and storage
 Take into account the weight of the DDLI.
Depending on the design, the DDLI weighs over 40 kg.
 The following should be observed with regard to storage:
– short storage times
– cool, dry, UV and corrosion resistant.
– free from strong magnetic fields.

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4 Requirements for use
Note
Malfunctions will occur if the device is not used correctly.
 Make sure that the specifications contained in this chapter are adhered to at all
times.
 Take into consideration the legal regulations applicable for the destination, as well as:
– regulations and standards,
– regulations of the testing organizations and insurers,
– national specifications.
 Note the warnings and instructions on the product and in the relevant operating instructions.
 Remove all transport packaging, such as plastic sheets, caps and cartons (except for any covers in
the pneumatic ports).
The material used in the packaging has been specifically chosen for its recyclability (exception: oil
paper = residual waste).
 Observe the local regulations for environmentally friendly waste management of electronic compon
ents.
 Take into account the material specifications (èTechnical data).
 Use the product in its original status, without any unauthorised product modifications.
 Take into consideration the ambient conditions at the location of use.
Corrosive elements in the environment (e.g. ozone) will reduce the service life of the product.
 Compare the maximum values specified in these operating instructions with your actual application
(e.g. pressures, forces, torques, temperatures, masses, speeds).
Operation of the product in compliance with the relevant safety regulations is contingent on adher
ence to the load limits.
 Take the tolerance of the tightening torques into account. Unless otherwise specified, the tolerance
is ± 20 %.
For vertical installation:
 Make sure that the slide has reached a stable position when it comes to a stop (e.g. the lowest
point or secured with external stops).
 Make sure the compressed air is properly prepared (èTechnical data).
 Read also the documentation for your control system (e.g. CPX-CMAX).

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5 Installation
5.1 Installation, mechanical
Note
Incorrectly parameterised positioning drives can perform sudden unexpected move
ments.
 Use the DDLI only with the specified mounting positions and parameters
(èdrive-specific information on the controllers).
 Observe the mounting requirements and instructions specified, especially in the
descriptions for the controllers used.
 Leave all screws and threaded bolts in their original states, un
less you are requested to modify them in these instructions.
 Avoid the sealing band being pressed and/or sucked in.
Damage to the sealing band reduces its reliability in operation.
Jerky movement of the unpressurized slide can cause a partial
vacuum that sucks the sealing band into the piston chamber. Fig. 2
 Avoid the band system becoming damaged or excessively dirty.
Damage can cause leakage and reduce the performance of the DDLI.
 Make sure that the device is installed free of distortion and deflection.
For fastening the drive:
 Use:
– MUP central supports or
– foot mountings of type HP in combination with additional MUC central supports.
The following table shows the required minimum number of central supports and foot mountings.
Stroke range
[mm]
Number of mounting attachments
Central supports Foot mounting + Central supports
100 … 400 2 2 0
401 … 600 2 2 1
601 … 1200 3 2 1
1201 … 1400 3 2 2
1401 … 2000 4 2 2
Tab. 1

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Note
Excessive distances between the central supports can reduce the positioning accuracy.
 Use at least the specified number of fastening elements (èTab. 1).
 Make sure that the plates are equally distributed over the complete drive length.
For attachment of HP foot mountings and MUC central supports:
1. Place the foot mountings, as needed, on the threads 4on the
DDLI and at first screw the mounting screws in lightly.
2. Place the central supports over the slot nuts in the mounting
slot.
3. Screw in the mounting screws lightly at first so that the central
supports can still be moved.
4. Move the central supports so that the spaces between the
central supports and, if applicable, foot mounting are the same.
5. Tighten all mounting screws on the DDLI evenly with the
subsequent tightening torque (èTab. 2).
6. Fasten the DDLI via the foot mountings and central supports. Fig. 3
Tightening torques for fastening screws
Foot mounting HP
Size 25 32 40 63
[Nm] 3.0 4.0 5.0 14
Central support MUP
Size 18/25-P 32 40 63
[Nm] 2.9 4.5 5.5 18
Tab. 2

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7. Make sure that the central supports are outside the positioning
range of the movable load (especially with side mounting). To do
this, push the movable load one time over the complete
positioning path.
Fig. 4
To fasten the useful load:
 Place the useful load so that the break-down torque from force
F remains parallel to the axis of motion and the lever arm a
remains low (Mx, My, Mz è12 Technical data). Fig. 5
With hard and stiff useful loads:
Note
If the slide 5becomes bent against a buckled use
ful load the service life of the guide will be reduced.
 Make sure the mounting surface of the useful
load is even. Fig. 6
 Note the tightening torques when attaching the useful load on the slide:
Size 25 32 40 63
Screw M5 M6 M8
Tightening torque [Nm] 3.5 6.5 12
Tab. 3
Effective loads with own guide:
 Adjust the guide of the effective load and the DDLI so that they are exactly parallel.
Only in this way can you avoid overloading on the slide (permissible forces è12 Technical data).
 Make sure that the effective load is coupled free of play to the DDLI (0.1 mm).
The driver DARD-L1-...-M offers a torque-free and almost backlash-free power transmission.

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5.2 Installation, pneumatic
When using in a vertical or sloping position:
Warning
Uncontrolled moving masses can cause personal injury and material damage (risk of
crushing). If there is a pressure failure, the moveable load (slide mass + mass of the
effective load) will slide down.
 Read the documentation for your controller (e.g. CPX-CMAX). There you will find
information on pneumatic circuits with which the moveable mass can be prevented
from falling down.
 Check whether safety measures are required to prevent slow sinking as a result of
leakage (e.g. toothed latches or moveable bolts).
 Connect the tubing connections in the supply ports. The
threaded connectors are marked with different colours on the
releasing ring:
– blue releasing ring at connection 2:
movement to the right towards the measuring system end
– black releasing ring at connection 8:
movement to the left towards the measuring system
connection
The required tubing O.D. is summarised in the following table
(èTab. 4).
2 8
Fig. 7
Size Stroke [mm] Tubing outside diameter [mm]
25 100 … 160 6
225 … 2000 8
32 100 6
160 … 2000 8
40 100 … 750 8
850 … 2000 10
63 100 … 300 8
360 … 450 10
500 … 2000 12
Tab. 4

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For control of the DDLI:
 Use proportional directional control valve MPYE or VPWP for
speed control and positioning (example of circuit èFig. 8). This
circuit is not suitable for stopping the slide in the event of a
pressure failure.
If used as a measuring cylinder:
 Use the one-way flow control valves GRLA for setting the speed
and, in addition, external stops.
Fig. 8
5 ìm
5.3 Installation, electric
 Wire the DDLI to the earth potential.
The internal thread (A) of the cover screws can be used for this
purpose, for example (èTab. 5).
 Wire the measuring system connection 1to the control system.
Only the existing cable may be used for this purpose.
Fig. 9
(A)
1
Size 25 32 40 63
Female thread (A) of the cover screws M4 M5 M5 M8
Max. tightening torque [Nm] 3.0 4.0 5.0 14
Tab. 5
Pin allocation DDLI:
Pin Function Pin allocation
124 V DC
2n. c.
30 V
4 CAN_H
5 CAN_L
– Screening
Tab. 6

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6 Commissioning
6.1 Commissioning the complete system
 Slowly pressurise the system as a whole.
In this way you will prevent sudden uncontrolled movements.
For slow start-up pressurization, use safety start-up valve type HEL.
6.2 Commissioning DDLI
Before each commissioning and in operation:
Warning
Fast moving parts can cause injury to people in
the environment of the DDLI.
 Make sure that, in the travel range,
– nobody can place his/her hand in the path
of moving components (e.g. by providing a
protective guard).
– There are no foreign objects in the path of
the moving components.
It should not be possible to touch the DDLI
until the load has come to complete rest.
Warning
Without external cushioning, the DDLI may be damaged if the specified loads and
speeds are exceeded (èdrive-specific information on the controllers).
 If necessary, use external shock absorbers of sufficient size and stops. The permiss
ible forces and torques must not be exceeded.
Note
Special commissioning regulations apply to the electronic control of the DDLI.
 Complete the commissioning in accordance with the descriptions for your controller.
 Check that the tubing is connected correctly.
 Start a test run in accordance with the descriptions for your controller.
 Check that the settings on the DDLI and all configuration data in the controllers used
(e.g. CPX-CMAX) are correct:
– Fixed stops
– Max. positioning range
– Motion sequence
– No obstructions which limit movement.
Fig. 10

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When high demands are placed on the positioning behaviour at the CPX-CMAX:
 Take into account a stroke reduction rfor each end position.
Only limited positioning behaviour is available within the stroke
reduction.
You will achieve the best possible positioning behaviour with a
stroke reduction of 10 % per end position. However, the stroke
reduction must not drop below the following values. If used as a
measuring cylinder, no stroke reduction is required.
Fig. 11
Size 25 32 40 63
Stroke reduction r [mm] 25 25 35 35
Tab. 7
For use with SPC11/CPX-CMPX:
 Make sure that the external end stops are stable and cannot deform elastically.
When used as a measuring cylinder:
1. Close the one-way flow control valves
– for both sides at first completely
– then one rotation open again
2. Slowly pressurize the DDLI.
3. Start a test run.
Note
For setting the speed:
 Make sure that the slide reaches the end positions without striking hard against
them or bouncing back.
4. Unscrew the one-way flow control valves until the desired speed is reached.

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7 Operation
For changes of the effective stroke in combination with position controller CPX-CMAX:
 Check whether the effective stroke remains within the permissible limits (èFig. 11).
If the useful load or dynamics are modified:
 Check whether other cushioning elements are required on the SPC200/CPX-CMAX
(è6.2 Commissioning the DDLI and èmanuals for your controller).
8 Maintenance and care
To maintain the belt system:
 Clean the belt system as required with a soft cloth.
 Avoid cleaning agents which will damage the belt system (PU).
Excessive friction or grease-solvent cleaning agents (e.g. soap suds) will damage the grease layer.
9 Repair
 Recommendation: Send the product to our repair service.
This will ensure that special attention is given to the necessary fine tuning and testing.
To replace the displacement encoder, it is mandatory that the DDLI be sent to our repair service.
 Information about spare parts and accessories (èwww.festo.com/spareparts)
10 Accessories
Note
SPlease select the accessories you need from our catalogue
(èwww.festo.com/catalogue)

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11 Trouble-shooting
Malfunction Possible cause Remedy
Malfunctions in
position sensing
Strong external magnetic fields,
environmental influences outside the
specifications
Eliminate external magnetic fields
Observe the specifications
Hard impact at
the end positions
The mass of the effective load is too
great
Reduce the mass of the effective load
Excessive speed Reduce speed
Insufficient cushioning Use sufficient external cushioning
elements
èInstructions on fault correction in the documentation for your controller.
Heavy leakage Linear module integrated in a distorted
manner
Fasten the linear actuator to a flat
base.
Seal worn Return to Festo for repairs.
Sealing band pressed/sucked in For unpressurized linear drive:
Loosen the tubing connection and
move the slide twice by hand through
the entire stroke (if necessary, move
fixed stops into the end position)
Avoid low pressure in the piston
chamber (e.g. only move the
unpressurized slide slowly)
Linear drive does
not achieve the
desired speed
Air volume not sufficient Increase connection cross-section
Connect volumes in series
High friction or counteracting force Select larger drive
Tab. 8

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12 Technical data
Mechanical, pneumatic
Size 25 32 40 63
Pneumatic connection G1/8 G1/8 G1/4 G3/8
Mode of operation Double-acting
Position sensing with integrated displacement encoder
Mounting position Any
Operating medium Compressed air in accordance with ISO 8573-1:2010
[6:4:4]
Note on the operating medium Operation with lubricated medium not possible
Operating pressure [bar] 2 … 8
Ambient temperature [°C] –10 … +60
Theoretical force at 6 bar [N] 295 483 754 1870
Speed [m/s] 0.05 … 3 0.04 … 3 0.04 … 3 0.03 … 3
Cushioning Elastic cushioning rings/pads at both ends
Max. impact energy in the end
positions
[Nm] 0.05 0.12 0.25 0.5
Note on materials Free of copper and PTFE
Information on materials
Cylinder barrel, cover, slide Anodised aluminium
Belt reverser POM
Cover strip Steel
Seals NBR, TPE-U (PU)
Product weight
At 0 mm stroke [kg] 1.10 1.72 2.58 8.73
per 10 mm stroke [kg] 0.034 0.043 0.058 0.139
Tab. 9

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Permissible force and torque loading
Size 25 32 40 63
Fzmax [N] 330 480 800 1600
Mxmax [Nm] 1.2 1.9 3.8 5.7
Mymax [Nm] 20 40 60 150
Mzmax [Nm] 3 5 8 24
Formula for combined loads:
0, 4x |Fz|
Fzmax
)|Mx|
Mxmax
)
|My|
Mymax
)0, 2x |Mz|
Mzmax
v1
|Mz|
Mzmax
v1
|Fz|
Fzmax
v1
Tab. 10
Electrical data for all sizes
Displacement encoder Magnetostrictive, contactless, absolute measuring,
digital
Protection class (measuring
system incl. housing and
connection technology)
IP67 (with correctly mounted plug socket with cable)
Electrical connection Cable with 5-pin plug, round design M9
Cable length [m] 1.5
Interface CAN to ISO/DIS 11898
Transmission rate [Mbps] 1
Linearity error (with reference
to the maximum stroke)
[%] ± 0.02 F. S. (min. ± 50 ìm)
Repetition accuracy1) [mm] ± 0.01 (up to 1000 mm stroke)
± 0.02 (1001 … 2000 mm stroke)
Supply voltage [V DC] 24 (± 25 %)
Current consumption [mA] Typically 100
Temperature coefficient 15 ppm/°C
CE marking (declaration of
conformity èwww.festo.com)
to EU EMC Directive
1) In combination with CPX-CMIX. For specifications on repetition accuracy with end-position controllers or positioning controllers, see
respective description
Tab. 11

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tion of its contents to others without express authorization is
prohibited. Offenders will be liable for damages. All rights re
served in the event that a patent, utility model or design patent is
registered.
Copyright:
Festo SE & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Internet:
www.festo.com