Festo DGC-HD Series Parts list manual

8100423
DGC-HD
Linear drive
8100423
2018-10b
[8100425]
Instructions | Operat-
ing

Translation of the original instructions
2 Festo — DGC-HD — 2018-10b

3Festo — DGC-HD — 2018-10b
1 Applicable documents................................................................................................. 4
2 Operating elements and connections.......................................................................... 4
3 Function and application............................................................................................. 4
4 Transport and storage................................................................................................. 5
5 Requirements for product use..................................................................................... 5
6 Installation.................................................................................................................. 6
6.1 Mechanical installation................................................................................................. 6
6.1.1 Installing the product..............................................................................................6
6.1.2 Installation of the payload...................................................................................... 8
6.1.3 Installation of accessories...................................................................................... 9
6.2 Pneumatic installation.................................................................................................. 9
7 Commissioning............................................................................................................ 11
8 Maintenance and care................................................................................................. 12
9 Repair........................................................................................................................... 14
10 Accessories.................................................................................................................. 14
11 Fault clearance............................................................................................................ 15
12 Technical data............................................................................................................. 16
13 Characteristic curves................................................................................................... 17
Table of contents

1 Applicable documents
All available documents for the product èwww.festo.com/pk.
2 Operating elements and connections
1Shock absorber (2x)
2Guide rail (2x)
3Lubrication hole for bearing guide (4x)
4Thread and centring hole for payload mount-
ing (12x)
5Slide
6Thread for optional switch lug (at both ends,
2x)
7Supply ports
8Surface for profile mounting
9Slot for accessories (at both ends)
10 Slot for nut mounting (at both ends)
11 Slot for proximity sensor (at both ends)
12 Supply ports with plug screws
Fig. 1
3 Function and application
When the compressed air supply ports are pressurised reciprocally, the internal slide in the cylinder
barrel moves back and forth. The rigid connection causes the slide 5 to move too. The slot in the cyl-
inder barrel required for this is covered by a belt system. The slide is mounted on a roller bearing. The
reference position of the slide can be queried with the help of proximity sensors in the slots aA.
Applicable documents
Festo — DGC-HD — 2018-10b4

The linear drive DGC-...-HD is intended for positioning payloads with large masses. It is approved for
the slide and yoke operating mode (èobserve load limits).
Fig. 2 Slide mode
Fig. 3 Yoke mode
Unpressurised movement of the slide is permitted only for fault clearance and at low speeds. If the
speed is too high, the negative pressure that occurs can pull the sealing band into the piston chamber.
This can lead to:
– High leakage and
– Impermissible acceleration (e.g. with a vertical mounting position).
4 Transport and storage
NOTICE!
• Avoid touching the guide rail with your hands during transport and storage, as this will damage
the grease film.
– Take the product's weight into account. The DGC-HD weighs up to 100kg depending on the
design. For transport, the conveyors must be spaced according to the permissible support spa-
cings (support spacings è 13 Characteristic curves).
– Ensure storage conditions as follows:
– Short storage times
– Cool, dry, well-shaded, corrosion-resistant locations.
5 Requirements for product use
NOTICE!
Malfunctions will occur if the device is incorrectly used.
• Make sure that the specifications contained in this chapter are adhered to at all times.
– Take into consideration the legal regulations applicable for the location as well as:
– Regulations and standards
– Regulations of the testing organisations and insurers
– National specifications
– Observe the warnings and notes on the product and in the relevant operating instructions.
– Remove transport packaging, such as films, caps and cardboard.
The material used in the packaging has been specifically chosen for its recyclability (exception:
oiled paper = residual waste).
Transport and storage
5Festo — DGC-HD — 2018-10b

– Observe the local regulations for the environmentally-friendly disposal of electronic components.
– Take into account the material specifications (è 12 Technical data).
– Use the product in its original status, without any unauthorised 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 limit 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 depends on adher-
ence to the load limits.
– Take the tolerance of the tightening torques into account. Unless otherwise specified, the toler-
ance is ±20%.
– Make sure there is a supply of correctly prepared compressed air (è 12 Technical data).
6 Installation
6.1 Mechanical installation
– Avoid pressing or suctioning the sealing band.
Damage to the sealing band reduces operating reliability. Jerky movement of the unpressurised
slide can cause negative pressure that sucks the sealing band into the piston chamber.
– Leave all screws and threaded bolts in their original states, unless you are requested to modify
them in these instructions.
– Avoid damaging or contaminating the belt system.
Damage reduces safety and the lifecycle of the DGC-HD.
6.1.1 Installing the product
NOTICE!
Tensile loads that are too heavy may cause the screws in the cover to be pulled out.
• Mount the DGC-HD with profile mountings or slot nuts (è Tab. 1 ). It is not possible to mount on
the connection cover/end cap.
– Ensure an installation without distortions and bends (evenness of the bearing surface ≤ 0.05%
of the stroke length; max. 0.5mm). For gantry applications, attention must also be paid to parallel
alignment when aligning the axes. For additional information, please contact your local Festo Ser-
vice.
– Position the DGC-HD in such a way that its operating elements are accessible.
– Observe the required support spacing. The diagrams (è 13 Characteristic curves) give the sup-
port spacing that results dependent on the mounting position and payload. Exceeding the spe-
cified minimum distance requires a functional test in each individual case.
NOTICE!
Unfavourable mounting variants can damage the DGC-HD.
• Ensure that the mounting components are outside the travel range of the slide.
1. Mount the DGC-HD.
Installation
6 Festo — DGC-HD — 2018-10b

2. Please select the corresponding accessories from our catalogue (èwww.festo.com/catalogue).
Profile mounting Slot nut mounting
MUE NST
Profile mounting in the slot for the mounting
surface 8èFig. 1.
Slot nut mounting in the slotaJ èFig. 1.
When tilting, the slot nuts glide into the slot at
each point.
Tab. 1
3. Tighten the retaining screws evenly with the following tightening torque.
Size 18 25 40
MUE M5 M5 M8
NST (at the side) M5 M5 M6
Screw
NST (underneath) M5 M6 M6
MUE [Nm] 5 5 20
NST (at the side) [Nm] 5.9 5.9 9.9
Tightening
torque
NST (underneath) [Nm] 5.9 9.9 9.9
Tab. 2
Installation
7Festo — DGC-HD — 2018-10b

6.1.2 Installation of the payload
For hard and stiff payloads (e.g. made from steel):
NOTICE!
If the aluminium slide is bent against a curved payload, the service life of the guide will be reduced.
• Make sure that the mounting surface of the payloads is even to within t ≤ 0.01 mm. When using
additional slides, any differences in height must be compensated.
Fig. 4
– Position the payload in such a way that the break-down torque resulting from the force F (parallel
to the axis of motion) and the lever arm "a" remains low.
Fig. 5
1. Mount the payload on the slide with the screws and centring sleeves.
2. Ensure that the tightening torques and the max. screw-in depth D are observed.
Fig. 6
Size 18 25 40
Screw (side/top) M5 M6 M6
Max. screw-in depth D [mm] 8.4 9.5 10
Centring hole (H7) [mm] Æ9Æ9Æ9
Tightening torque [Nm] 5.9 9.9 9.9
Tab. 3
For payloads with own guide:
Installation
8 Festo — DGC-HD — 2018-10b

– Adjust the guides of the payload and DGC-HD so that they are exactly parallel.
You will then avoid overloading the guide and increased wear.
6.1.3 Installation of accessories
If proximity sensors are used:
• Use:
• Inductive proximity sensor with switch lug aC (èassembly instructions for the accessories
used) in the slot aA or with a mounting bracket aD in the slot 9
• Magnetic proximity switches in the slot aA.
Mounting alternatives:
Fig. 7 Mounting in the slot
Fig. 8 Mounting via mounting bracket
To protect the end positions:
• Use an emergency buffer or shock absorber (èassembly instructions for the accessories used).
To avoid contamination:
• Use slot covers in all unused slots.
6.2 Pneumatic installation
For installation in a vertical or sloping position:
Installation
9Festo — DGC-HD — 2018-10b

WARNING!
Personal injury and material damage!
If there is a pressure failure, the working load will fall.
• Check whether HGL check valves are necessary. This prevents the moving load from suddenly slip-
ping.
• Check whether safety measures are required to prevent slow sinking as a result of leakage (e.g.
toothed latches, moveable bolts or emergency buffers).
• Select the appropriate supply ports.
In addition to the supply ports provided at the factory (W), there are also the alternative ports (A).
These are fitted with plug screws.
Fig. 9
Legend Description
W1 Supply port ex works (movement to shutoff side 1)
W2 Supply port ex works (movement to connection side 2)
A1 Alternative connection (movement to shutoff side 1)
A2 Alternative connection (movement to connection side 2)
1Shutoff side
2Connection side
Tab. 4
To set the speed:
• Screw the one-way flow control valves GRLA into the check valves.
Installation
10 Festo — DGC-HD — 2018-10b

7 Commissioning
Before each commissioning and in operation:
WARNING!
Payloads can cause personal injury and material damage (risk of crushing).
• Make sure that, in the travel range:
– Nobody can place his/her hand in the path of moving components (e.g. by providing a pro-
tective guard).
– There are no foreign objects in the path of the moving components.
It should not be possible to grasp the DGC-HD until the load has come to a complete rest.
With medium or large payloads and/or at high speeds:
– Use the engineering software "DGC-QuickCalc" for pneumatic drives in the support portal
(èwww.festo.com/sp).
– Use sufficiently large arrester fixtures.
Without external arrester fixtures, the DGC-HD will tolerate the maximum speeds and payloads set
out in the catalogue specifications or table (è 12 Technical data).
The limit values may not be exceeded, even during malfunctions.
Commissioning – processing
– Slowly pressurise the system as a whole.
In this way you will prevent sudden uncontrolled movements.
For slow start-up pressurisation, use on-off valve HEL.
1. Close the one-way flow control valves
– for both sides initially, and
– then open again one turn.
Fig. 10
2. Pressurise the DGC-HD as follows:
– Initially simultaneously at both sides. This causes the slide to move slightly to a point of bal-
ance.
– Then exhaust the DGC-HD on just one side. This prevents peak loads on the DGC-HD and in
the compressed air system.
3. Start a test run.
Commissioning
11Festo — DGC-HD — 2018-10b

4. Check whether the slide speed has to be modified.
5. Unscrew the one-way flow control valves slowly until the desired slide speed is reached.
The slide should reach the end positions without striking them harshly or recoiling.
For precision adjustment of the stroke:
NOTICE!
Operating the DGC without a stop sleeve (H) and lock nut (K) destroys the DGC-HD.
• Assemble the cushioning components only together with the stop sleeve (H) and the lock nut (K).
1. Loosen the lock nut (K).
2. Screw or unscrew the cushioning component. For stability reasons, the distance d may not exceed
the values from the following table (è Tab. 5).
3. Tighten the lock nuts (K) again with the following tightening torque.
Fig. 11
Size 18 25 40
Distance d [mm] 27.3 … 52.3 31 … 56 41 … 76
Tightening torque [Nm] 20 35 60
Tab. 5
If the useful load or dynamics are modified:
• Check whether other cushioning elements are required.
8 Maintenance and care
Cleaning and maintenance:
1. Clean the belt system and the guide rail with a soft cloth as required. Any agents that do not dam-
age the material may be used as cleaning agents.
2. 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.
Maintenance and care
12 Festo — DGC-HD — 2018-10b

NOTICE!
The lubrication interval Sint is dependent on the load acting on the product.
• Cut the lubrication interval Sint (è Fig.12) in half if any of the following situations apply:
– Dusty and dirty environment
–Nominal strokes > 2000 mm
–Speeds > 2 m/s
– Travel profile Z triangular operation (frequent acceleration and braking)
–Ambient temperatures > 40 °C
–Service age of product > 3 years
If several of these factors apply at the same time, the lubrication interval should be quartered.
• Grease the following components:
Bearing guide Guide rail
Lubricating point (è Fig.13) Lubrication hole 3Interface 2
Lubrication interval (è Fig.12) If required 1)
Grease 2) Roller bearing grease
1) or if the component no longer has a layer of grease
2) Pressure grease gun, blast pipes and grease (è10 accessories)
Tab. 6
To grease the bearing guide:
1. Calculate the load comparison factor fv with the help of the formula for combined loads
(è 12 Technical data) and determine the lubricating interval Sint (è Fig.12).
Fig. 12
2. Grease the bearing guide on both sides at all lubrication holes 3.
Maintenance and care
13Festo — DGC-HD — 2018-10b

Fig. 13
3. Move the slide along the complete positioning path during lubrication in order to distribute the
grease evenly.
Alternatively, Festo offers inspection services including re-lubrication. Otherwise, the DGC-HD is main-
tenance-free.
9 Repair
– Recommendation: Send the DGC-HD to our repair service.
As a result, the required fine tuning and tests will be taken into special consideration.
– Information about spare parts and aids can be found at: (èwww.festo.com/spareparts).
To replace the cushioning components:
– Observe the section "Precision adjustment of the stroke" (è 7 Commissioning).
10 Accessories
NOTICE!
• Please select the corresponding accessories from our catalogue
(èwww.festo.com/catalogue).
Designation Part number/type
Pressure grease gun with pinpoint nozzle
Blast pipe, axial outlet
Blast pipe, radial outlet
647958/LUB-1 1)
647959/LUB-1-TR-I 1)
647960/LUB-1-TR-L 1)
Roller bearing grease LUB-KC1 from Festo 1)
1) (èSpare parts catalogue under www.festo.com/spareparts)
Tab. 7
Repair
14 Festo — DGC-HD — 2018-10b

11 Fault clearance
Malfunction Possible cause Remedy
One-way flow control valve not
installed correctly
Control flow of exhaust air, if possible
(not supply air).
Install the DGC-HD in such a way, that
it is free of tension (evenness of the
bearing surface:
è 6.1 Mechanical installation)
Tensions
Align the DGC-HD so it is exactly paral-
lel to the second axis
Grease the DGC-HD
(è 8 Maintenance and care)
Irregular move-
ment of the slide
Roller bearing/bearing guide is defect-
ive
Send the DGC-HD to Festo for repair
Loads too high Reduce payload/travel speedSlide does not
move Retaining screws for the payload are
too long
Observe the maximum screw-in depth
(è 6.1.2 Installation of the payload)
Seal worn Replace wearing parts:
– Self-repair with a set of wearing
parts
– Return to Festo for repair
When the linear actuator is unpressur-
ised, move the slide by hand through
the entire stroke twice
(if necessary, move fixed stops into the
end position)
Heavy leakage
Sealing band pressed/sucked in
Avoid negative pressure in the piston
chamber (e.g. only move the unpres-
surised slide slowly when the valve is
disconnected).
Lack of volume air – Increase connection cross-section
– Connect volume upstream
Cylinder does not
reach the desired
speed High friction or counteracting force Observe limit values
Tab. 8
Fault clearance
15Festo — DGC-HD — 2018-10b

12 Technical data
Size 1) 18 25 40
Pneumatic connection M5 G1/8 G1/4
Design Pneumatic linear drive with heavy-duty guide
Guide Recirculating ball bearing guide
YSR Shock absorber, hard characteristicsCushioning
YSRW Shock absorber, soft characteristics
Mounting position Any
Operating medium Compressed air to ISO 8573-1:2010 [7:–:–]
Note on the operating medi-
um
Lubricated operation possible (in which case lubricated
operation will always be required)
Operating pressure [bar] 2.5 … 8 1.5 … 8
Ambient temperature [°C] –10 … +60
Theor. force at 6 bar [N] 153 295 754
Max. speed [m/s] 3
Max. impact energy (èwww.festo.com/catalogue)
Permissible forces on the slide
Fymax = Fzmax [N] 3650 5600 13000
Permissible torques on the slide
Mxmax [Nm] 140 300 900
Mymax = Mzmax [Nm] 275 500 1450
Condition for combined loads:
Note on materials Contains paint-wetting impairment substances
Materials
Profile, cover, slide Aluminium
Ball bearing, guide, screws Steel
Scraper POM
Technical data
16 Festo — DGC-HD — 2018-10b

Size 1) 18 25 40
Seals NBR, TPE-U
Weight
0 stroke [kg] 3.987 7.509 20.469
Per 10mm stroke [kg] 0.071 0.105 0.199
1) The following tool is available for sizing tasks: "DGC-QuickCalc" engineering software (èwww.festo.com/sp)
Tab. 9
13 Characteristic curves
Max. permissible support spacing l depending on the force F
Fig. 14
DGC-HD
l [mm]
F [N]
1500 2500 3500500
1
10
100
1000
10000
DGC-18-HD
DGC-25-HD
DGC-40-HD
Fig. 15
Characteristic curves
17Festo — DGC-HD — 2018-10b

Fig. 16
DGC-HD
l [mm]
F [N]
1000 2000 3000 4000 5000
1
10
100
1000
10000
DGC-18-HD
DGC-25-HD
DGC-40-HD
Fig. 17
Characteristic curves
18 Festo — DGC-HD — 2018-10b

Reproduction, distribution or sale of this document or communic-
ation of its contents to others without express authorization is
prohibited. Offenders will be liable for damages. All rights
reserved in the event that a patent, utility model or design patent
is registered.
Copyright:
Festo AG & Co. KG
73734 Esslingen
Ruiter Straße 82
Germany
[phone]
[phone]
Fax:
[email protected]
www.festo.com
Internet:
Phone:
e-mail: