Festo DGC-HD Series User manual

(en) Operating
instructions
8074748
2017-10a
[8074750]
Linear drive
DGC-HD

DGC-HD
2Festo – DGC-HD – 2017-10a
Original instructions
Symbols: Installation and commissioning may only be per
formed in accordance with these instructions by
technicians with appropriate qualifications.
Warning
Caution
Note
Environment
Accessories
English – Linear drive DGC-HD 3.......................................................

DGC-HD
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English – Linear drive DGC-HD
Table of contents
1 Control sections and connections 4............................................
2 Function and application 5...................................................
3 Transport and storage 5.....................................................
4 Requirements for product use 6...............................................
5 Installation 7..............................................................
5.1 Mechanical installation 7.....................................................
5.1.1 Carrying out the product installation 7..................................
5.1.2 Installation of the effective load 9.....................................
5.1.3 Installation of accessories 10..........................................
5.2 Pneumatic installation 11.....................................................
6 Commissioning 12...........................................................
7 Service and maintenance 14...................................................
8 Repair 15..................................................................
9 Accessories 15..............................................................
10 Troubleshooting 16..........................................................
11 Technical data 17............................................................
12 Characteristic curves 18......................................................

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Documentation on the product
For all available product documentation èwww.festo.com/pk
1 Control sections and connections
13 4256
7
89aJaA
1Shock absorbers (2x)
2Guide rail (2x)
3Lubrication hole for bearing guide (4x)
4Thread and centring hole for mounting the
effective load (12x)
5Slide
6Thread for optional switch lug (on both
sides, 2x)
7Supply ports
8Surface for profile mounting
9Slot for slot nut mounting and accessories
(on both sides)
aJ Groove for proximity switch (on both sides)
aA Supply ports with plug screws
Fig. 1

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2 Function and application
When the compressed air ports are pressurised alternately, the internal slide moves backwards and
forwards in the cylinder barrel. By means of a rigid connection, the slide 5also moves. The slot in the
cylinder barrel required for this is covered by a band system. The slide is bearing mounted. The refer
ence position of the slide can be detected using proximity sensors in the slots aJ.
The linear drive DGC-...-HD is intended for positioning effective
loads with large loads. It is approved for the slide and yoke
operating modes (èobserve load limits).
Pressureless movement of the slide is permitted only for fault cor
rection 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. with vertical mounting posi
tion).
Fig. 2 Slide operation
Fig. 3 Yoke operation
3 Transport and storage
Note
 Avoid touching the guide rail with your hands during transport und storage. Other
wise the layer of grease will be damaged.
 Take the product's weight into account. Depending on the version, the DGC-HD can weigh up to
100 kg.
For transport, the conveyors must be positioned at the permissible support spacing
(support spacing è12 characteristic curves).
 Make sure storage conditions are as follows:
– short storage times
– cool, dry, well-shaded, corrosion-resistant locations.

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4 Requirements for product 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 testing organisations and insurers
– national specifications.
 Note the warnings and instructions on the product and in the relevant operating instructions.
 Remove all transport packaging, such as foils, caps and cardboard.
The packaging is intended for recycling
(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 chapter).
 Use the product in its original status, without any unauthorised product modifications.
 Take into consideration the ambient conditions at the location of use.
Corrosive environments (e.g. ozone) reduce the service life of the product.
 Compare the limit values in these operating instructions with those of your application (e.g. forces,
torques, temperatures, loads, 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 %.
 Make sure there is a supply of correctly prepared compressed air (èTechnical data chapter).

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5 Installation
5.1 Mechanical installation
 Avoid the sealing band being pressed and/or sucked in.
Damage to the sealing band reduces its reliability in operation. Jerky movement of the unpressur
ised slide can cause a partial vacuum 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.
 Prevent the band system from becoming damaged or excessively dirty.
Damage to the DGC-HD will reduce its reliability and service life.
5.1.1 Carrying out the product installation
Note
Heavy tensile loads may cause the screws in the cover to be pulled out.
 Fasten the DGC-HD with profile mountings or slot nuts (èTab. 1). Mounting on the
connector/end cap is not possible.
 When installing, ensure that there is no tension or deflections
present (evenness of mounting surface ≤0.05 % of the stroke
length; max. 0.5 mm). For gantry applications, parallel align
ment of the axes is additionally required. For additional informa
tion, please contact your local Festo Service. Fig. 4
 Place the DGC-HD so that all the control sections are accessible.
 Observe the required support spacings. The diagrams (è12 Characteristic curves) show the sup
port spacing, which is dependent on the mounting position and effective load. If the specified min
imum distances are exceeded, it is imperative to carry out an individual functional test.
Note
Unsuitable mounting techniques can damage the DGC-HD.
 Make sure that the mounting components are outside the positioning range of the
slide.

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 Fasten the DGC-HD.
 Please select the corresponding accessories from our catalogue (èwww.festo.com/catalogue).
Profile mounting Slot nut mounting
MUE NST
aA
Profile mounting in the slot aA of the mounting
surface 8
Slot nut mounting in slot aA.
When tilted, the slot nuts slide into the slot at
each position of the profile
Tab. 1
 Tighten the mounting screws uniformly with the following tightening torque.
Size 18 25 40
Screw MUE M5 M5 M8
NST (lateral) M5 M5 M6
NST (underneath) M5 M6 M6
Tightening torque MUE [Nm] 5 5 20
NST (lateral) [Nm] 5.9 5.9 9.9
NST (underneath) [Nm] 5.9 9.9 9.9
Tab. 2

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5.1.2 Installation of the effective load
Hard and rigid effective loads (e.g. steel):
Note
If the aluminium slide is bent against a curved effect
ive load, the service life of the guide will be reduced.
 Make sure that the mounting surface of the effect
ive loads is even to within t ≤ 0.01 mm.
If additional slides are used, possible differences in
height must be compensated for.
Fig. 5
t
 Place the effective load in such a way that the break-down
torque resulting from force F (parallel to the axis of motion) and
lever arm “a” remains small.
Fig. 6
aF
 Fasten the effective load to the slide with the screws and cent
ring sleeves.
 Make sure that the tightening torques and maximum screw-in
depth D is adhered to.
Fig. 7
Size 18 25 40
Screw (lateral/top) M5 M6 M6
Max. screw-in depth D [mm] 8.4 9.5 10
Centring (H7) [mm] 9 9 9
Tightening torque [Nm] 5.9 9.9 9.9
Tab. 3
Effective loads with own guide:
 Adjust the guides of the effective load and of the DGC-HD so that they are exactly parallel.
This avoids overloading of the guide and increased wear.

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5.1.3 Installation of accessories
If proximity sensors are used:
 Use:
– inductive proximity sensors with switch lug aB (èAssembly instructions of the accessory used)
in the slot aJ or with mounting bracket aC
– magnetic proximity sensors in the slot aJ.
Mounting
in the grooves aJ (èFig. 1) with mounting bracket aC
aJ
aB aC
aB
Tab. 4
To protect the end positions:
 Use emergency buffer or shock absorber (èAssembly instructions of the accessory used).
To avoid contamination:
 Use slot covers in all unused grooves.

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5.2 Pneumatic installation
For installation in a vertical or inclined position:
Warning
Injury to people and material damage!
If there is a pressure failure, the work mass will
slide down.
 Check whether HGL non-return valves are
required. In this way, you can prevent the work
mass from sliding down suddenly.
 Check whether safety measures are required to
prevent slow sinking as a result of leakage
(e.g. toothed latches, moving bolts or
emergency buffers). Fig. 8
 Select the suitable compressed air 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.
W(1)
W(2)
A(2)
A(2)
A(2)
A(1)
21
1
2
W = Supply ports from the plant
1= End position cover side
1 = Movement to the cover side
A = Alternative ports
2= End position, connection side
2 = Movement to the connection side
Fig. 9
For setting the speed:
 Rotate the one-way flow control valves GRLA into the supply ports.

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6 Commissioning
Before each commissioning and in operation:
Warning
Moving masses can cause personal injury and
material damage (risk of crushing).
 Make sure that, in the path of the moving
components
– nobody can place his/her hand
(e.g. through a protective guard),
– there are no foreign objects.
It should not be possible to touch the DGC-HD
until the load has come to complete rest.
Fig. 10
At medium or large useful loads or high speeds:
 Use the sizing software “DGC-QuickCalc” for pneumatic drives in the support portal
(èwww.festo.com/sp).
 Make sure that cushioning devices are of sufficient size.
Without external cushioning devices the DGC-HD will withstand maximum speeds and useful loads
in accordance with catalogue specifications or table (è11 Technical data).
Even in the event of malfunctions, the limit values must not be exceeded.
Carrying out commissioning
 Slowly pressurise the system as a whole.
In this way you will prevent sudden uncontrolled movements.
For slow start-up pressurisation, use start-up valve type HEL.
1. Close the one-way flow control valves
– for both sides at first completely
– then one turn open again.
2. Pressurize the DGC-HD as follows:
– At first on both sides simultaneously. The slide will then
move slightly to a centre of equilibrium.
– Then exhaust the DGC-HD on one side. In this way you can
avoid peak loadings on the DGC-HD and in the compressed
air network.
Fig. 11
3. Start a test run.
4. Check whether the speed of the slide has to be modified.
5. Open up the one-way flow control valves slowly until the desired slide speed is reached.
As intended, the slide should reach the end position without striking hard against it or bouncing
back.

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For precision adjustment of the stroke:
Warning
The DGC-HD will be damaged if the DGC is operated without the stop sleeve (H) and the
lock nut (K).
 Assemble the cushioning components together only with the stop sleeve (H) and the
lock nut (K).
1. Loosen the lock nut (K).
2. Screw the cushioning element in or out.
For reasons of stability, distance d (èFig. 12) must not exceed
the values in the following table.
3. Tighten the lock nuts (K) with the following tightening torque.
Fig. 12
HK
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 effective load or dynamic response is modified:
 Check whether other cushioning components are required.

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7 Service and maintenance
For cleaning and maintenance:
 Clean the band system and guide rail as required with a soft cloth.
Any media which will not damage the material may be used as cleaning agents.
 Avoid cleaning agents which will damage the belt system, which is made of PU.
Excessive rubbing or the use of grease-solvent cleaning agents (e.g. soap suds) will damage the
grease layer.
Note
The lubrication interval Sint is dependent on the load acting on the product.
 Halve the lubrication interval Sint (èFig. 13) if any of the following situations apply:
– dusty and dirty environment
– nominal strokes 2000 mm
– speeds 2 m/s
– positioning profile: Zdelta operation (frequent acceleration and braking)
– ambient temperatures 40 °C
– product has been in operation for 3 years.
If more than one of the above criteria are simultaneously met, the normal lubrication
interval must be divided by four.
 Grease the following components:
Bearing guide Guide rail
Lubricating point (èFig. 1) Lubrication hole 3Surface 2
Lubrication interval (èFig. 13) As required 1)
Grease 2) Roller bearing grease
1) Or if there is no longer a layer of grease on the component
2) Grease gun, blast pipes and grease (è9 Accessories)
Tab. 6

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To grease the bearing guide:
1. Calculate the load comparison factor fv with
the aid of the formula for combined loads
(è11 Technical data) and determine the lub
ricating interval Sint from it (èFig. 13).
Fig. 13
fv
2. Grease the bearing guide on both sides at all
lubrication holes 3.
3. Move the slide the complete travel distance
during lubrication in order to distribute the
grease evenly inside.
Alternatively, Festo offers a service inspection
which includes lubrication.
Otherwise, the DGC-HD is maintenance-free.
Fig. 14 3
8 Repair
 Recommendation: Send the DGC-HD to our repair service.
This way the required fine tuning and tests will be taken into special consideration.
 Information about spare parts and accessories can be found at: (èwww.festo.com/spareparts).
To replace cushioning elements:
 Observe the section “For precision adjustment of the stroke” (è6 Commissioning).
9 Accessories
Note
 Please select the corresponding accessories from our catalogue
(èwww.festo.com/catalogue).
Designation Part number/type
Grease gun with needle-pointed nozzle
Nozzle pipe, axial outlet port
Nozzle pipe, radial outlet port
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) (èSpare parts catalogue at www.festo.com/spareparts)
Tab. 7

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10 Troubleshooting
Malfunction Possible cause Remedy
Uneven movement
of the slide
One-way flow control valve
not installed correctly
If possible reduce the exhaust (not the supply air)
Tension Install the DGC-HD free of tension (evenness of the
bearing surface: è5.1 Mechanical installation)
Align the DGC-HD so that it is exactly parallel to the
second axis
Grease the DGC-HD (è8 Service and maintenance)
Roller bearing/bearing
guide defective
Return DGC-HD to Festo for repairs
Slide does not
move
Loads too high Reduce mass of the effective load/travel speed
Mounting screws for
effective load too long
Observe max. screw-in depth
(è5.1.2 Installation of the effective load)
Heavy leakage Seal worn Replace worn parts:
– yourself with set of wearing parts
– send product to Festo for repairs
Sealing band pressed/
sucked in
When the linear drive is unpressurized, move the
slide twice manually 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)
Cylinder does not
reach the desired
speed
Air volume lacking – Increase connection cross-sections
– Connect volumes in series
High friction or
counteracting force
Observe limits
Tab. 8

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11 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
Cushioning YSR Shock absorber, hard characteristic curve
YSRW Shock absorber, soft characteristic curve
Mounting position Any
Operating medium Compressed air to ISO 8573-1:2010 [7:–:–]
Note on the operating medium Operation with lubricated medium possible (required during
subsequent operation)
Operating pressure [bar] 2.5 … 8 1.5 … 8
Ambient temperature [°C] –10 … +60
Theoretical force at 6 bar [N] 153 295 754
Max. speed [m/s] 3
Max. impact energy (èwww.festo.com/catalogue)
Permissible force 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:
fv+|Mx|
Mxmax
)
|My|
Mymax
)|Mz|
Mzmax
)
|Fy|
Fymax
)|Fz|
Fzmax
v1
Note on materials Contains paint-wetting impairment substances (PWIS)
Materials
Profile, cover, slide Aluminium
Ball bearing, guide, screws Steel
Wiper seal POM
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: sizing software “DGC-QuickCalc” (èwww.festo.com/sp)
Tab. 9

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12 Characteristic curves
Maximum permissible support span l as a function of the force F
DGC-18-HD
DGC-25-HD
DGC-40-HD
DGC-18-HD
DGC-25-HD
DGC-40-HD
Fig. 15

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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 AG & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Internet:
www.festo.com