Festo FDG-...-ZR-RF Series User manual

(en) Operating
instructions
Driveless guide axis
FDG-...-ZR-RF
8104202
2018-12a
[8104204]

FDG-...-ZR-RF
Festo FDG-...-ZR-RF 2018-12a
2
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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For all available product documentation èwww.festo.com/pk
Passive guide axis type FDG-...-ZR-RF English
1 Operating parts and connections
1234
5
6
7
1Internal thread for fastening the axis
2Lubrication nipple
3Centring recesses with or without fastening thread
4Groove for fastening the work load
5Slot for inserting the sliding blocks (only size 25)
6Internal thread for fastening a switching lug
7Groove for fastening the sensor supports
Fig. 1

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2 Function
The slides of the guide axis support a load whilst moving.
When the load is shifted along the direction of the axis, the slide follows very
smoothly.
An extended slide enables a loading with higher torques.
Fig. 2: Basic representation
8
8Bridge (transverse connection kit)
3 Application
The FDG-...-ZR-RF has been designed as a basic structure for boom or portal
systems consisting of a driving linear axis and a passive guide axis.

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4 Conditions of use
Please note
SMake sure that the specifications in this chapter are always observed.
The product will then function correctly and reliably.
SCompare the maximum values specified in these operating instructions with
your actual application (e.g. forces, masses, temperatures, torques).
Only if the loading limits are observed can the product be operated in
accordance with the relevant safety guidelines.
STake into account the ambient conditions
at the location.
Corrosive environments will impair the
service life of the product.
SRemove the packing from the product.
The packing is intended for recycling
(except for: oiled paper which must be
disposed of).
SObserve the specifications applicable to your location, as well as all local and
national laws and regulations.
SUse the product in its original state without undertaking any modifications.
SMake sure that safety measures cannot be ignored.
5 Transport and storage
SConsider the weight of the FDG-...-ZR-RF.
It weighs up to 100 kg.
SIf necessary fasten the slide, which runs
very smoothly, with adhesive tape.
Fig. 3
[°C] [%] [mbar]
Fig. 4

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6 Fitting
Mechanical components
SMake sure that this condition is observed:
Rated stroke FDG-...-ZR-RF ≥Rated stroke drive axis
Example (type plates): FDG-40-800-ZR-RF ≥DGE-40-800-ZR-RF
Only in this way will the multi-axis system function free of collision in the end
positions.
SPlease note that the rated stroke can be defined differently depending on the
axis and the manufacturer:
Definition of the rated stroke
with FDG-...-ZR-RF and DGE-...-ZR-RF: with other axes/manufacturers:
rr
h
h
h
h
h: Rated stroke r: Stroke reserve
SPosition the FDG-...-ZR-RF without tension
or bending (evenness of mounting surface:
0.2 mm/30 cm).
Axis fastening kits, centre supports and foot
fastenings will assist you here.
Please note
Take into account that, in the case of heavy loadings, the axis must not be
fastened only at the cover caps.
Excessive tensile loads will cause the cover screws to be pulled out.
Fig. 5

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In the case of articles with large stroke lengths:
SUse centre support type MUP-... .
Fig. 6 shows the necessary distances between supports.
L [mm]
F [kg]
1600 2800 3200 3600 40002000 2400
0
10
20
30
40
50
60
70
80
90
100
FDG-63-ZR-RF
L [mm]
F [kg]
1200 1500 1800 2100 2400 2700 3000
0
2,5
5
7,5
10
12,5
15
17,5
20
22,5
25
FDG-40-ZR-RF
L [mm]
F [kg]
1200 1500 1800 2100 2400 2700
0
1
2
3
4
5
6
7
8
9
10
3000
FDG-25-ZR-RF
F
Mounting position x
F
Mounting position y
x
Fig. 6:
Necessary distance between supports
L for FDG-...-ZR-RF as a factor of
mounting position, rated size and work
load F
y
x
y
x
y
LL

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SFasten the axis fastening kits or centre supports to the FDG-...-ZR-RF as shown
in the following diagram:
If necessary, sliding blocks in the profile grooves can serve as fastening devices.
If the FDG-...-ZR-RF is used in conjunction with a drive axis type DGE-... or
DGP(L)-...:
SUse the distances between supports of the drive axis also for the FDG-...-ZR-RF.
In this way you will avoid distortion due to uneven bending.
STighten the fastening screws for the transverse fastening at first only slightly
(see Fig. 7: Q).
The FDG-...-ZR-RF can then be further adjusted until it is mounted correctly.
Fitting the fastening elements
SMake sure that the axis fastening kit or
the centre supports are situated outside
the collision range of the slide, by pushing
the slide once over the complete position
ing path.
Fig. 7: Q = Play for transverse fastening
ÓÓÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ
Fig. 8

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If the FDG-...-ZR-RF is used in conjunction with a drive axis type DGE-... or
DGP(L)-...:
1. Make sure that the slide surfaces of both
axes lie at the same level within the com
plete positioning stroke.
2. Position the FDG-...-ZR-RF exactly parallel
to the drive axis.
3. Place the bridge (see Fig. 2) and the work
load onto the slides of the FDG-...-ZR-RF and
the drive axis as follows:
– The tilting torque of force F parallel to the
cylinder axis and distance d remains low.
Force F includes here the inertial force
F = m a, the force due to weight and
possible external forces.
– Only loadings within the framework of
the permitted values are effective
(see“Technicalspecifications”).
4. Push the bridge over the complete stroke path from one end position to the
other.
The guide axis will then position itself free of distortion to the drive axis.
5. Tighten the fastening screws (see Fig. 7: Q) of the guide axis.
Check whether shock absorbers or stops are also required externally.
Interrogating the slide positions
SUse sensors with inductive switching in conjunction with ferritic switching
lugs.
SComplete the fitting of the sensors in accordance with the operating instruc
tions for the sensors and for the drive axis.
You can protect unused sensor grooves against dirt deposits at best with cover
rails as described in the chapter “Accessories”.
Fig. 9
Fi
g
. 10
FF
d
d

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7 Commissioning and operation
Warning
SMake sure that:
– nobody can place his/her hand in the
path of the moving load (e.g. by
providing a protective screen)
– there are no objects within the
positioning path of the axis.
It must not be possible to touch the
FDG-...-ZR-RF until the mass has come to
a complete stand.
Please note
The slots in the cover caps enable objects (e.g. nuts or screws), which have
fallen unintentionally into the groove, to be extracted.
Warning
Objects ejected from the cover caps can
cause injury to human beings or damage
to property.
SMake sure that nobody can be hit by
these objects if he/she is in their path
(e.g.by providing a protective screen).
SApply current to the drive motor at first at
low speed and with low torques.
The slide will then move slowly over the
complete positioning path.
Fig. 11
Fig. 12
Fig. 13
0
1000
3000
2000
U
min

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8 Care and maintenance
SRecommendation:
Return the product to Festo for inspection after every 10,000 kilometres run.
SDo not adjust screws or threaded pins for which there are no direct demands
for modification in the operating instructions.
Lubricating the roller guide
SLubrication interval: as required, in principle at least after 10.000 km.
SNote that lubrication must be carried out more frequently:
– in dusty and dirty environments,
– with very short work strokes (running-in at a position).
SLubricate the FDG-...-ZR-RF at the lubrica
tion nipples on both sides of the slide.
Oil: e.g. Constant OY 390 from Klüber,
München
Grease gun: see Accessories.
Fitted into restricted spaces:
SUse blast pipe B (axial opening) or C
(radial opening) instead of the stan
dard blast pipe A.
SMove through the rated stroke once completely in order to distribute the oil
evenly in the interior of the FDG-...-ZR-RF.
At each maintenance procedure:
SCheck that the slide is set free of play and distortion.
If you find something unusual, see the chapter “Eliminating faults”.
9 Repairs
Faults during operation
SMake sure that the FDG-...-ZR-RF is overhauled only by our repair service
(e.g.if there is play between the slide and the guide).
In this way you will prevent damage to the axis at a later stage. The repair
procedures require settings with very accurate adjustments.
Fig. 14
A
B
C

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10 Accessories
Type Designation
MUP-... Centre supports
HP-... Foot fastening
HMAV-... Adapter kit HMP-...
HMSV-... Adapter kit SLT-...
HMVA-... Actuator adapter kit
HMVD-... Twin cantilever axis kit
HMVG-... Axis connecting kit (for distance between axes ≤ 200 mm)
HMVJ-... Adjusting kit
HMVK-... Cross connecting kit
HMVS-... Twin axis support kit
HMVT-... Twin axis connecting kit
HMVV-... Reinforcing kit
SIEN-... Sensor with normally-open / normally-closed function
HWS-... Sensor support
SF-... Switching lug
SIM-... Extension cable
ZBH-... Centring sleeves
NST/NSTL-... Sliding blocks
ABP-... Groove cover rail
647 958 Grease gun with pinpoint nozzle
647 959 Blast pipe, axial opening
647 960 Blast pipe, radial opening
Fig. 15

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11 Eliminating faults
Fault Cause Remedy
Loud running noises and
sluggish slide
Insufficient lubrication of
the slide bearing
Lubricate, if necessary
return to Festo
Red-brown colouring on
the guide rods
Rust due to insufficient
lubrication
Noticeable play on the
slide
Wear, damage Return product to Festo
Sluggishness of a twin
arrangement near the end
position
Insufficient parallelism
between drive and
FDG-...-ZR-RF
Readjust axes
“Engaging” at a position long downtime Disappears after a new
start-up phase
Vibration Axis overloaded Observe maximum loading
values
Dynamics too high Check modifications to
project planning
Incorrect arrangement of
the centre of gravity of the
work load
Shift centre of gravity
External interference on
base stand or in multi-axis
system
Eliminate interference
Missing or undefined
switching functions
Proximity switch or cable
defective
Replace defective part
Sensor support or
switching lug incorrectly
fitted
Correct fitting
Switching gap set
incorrectly
Readjust
Switch or connection
incorrect
Replace incorrect part

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12 Technical specifications
FDG-25-ZR-RF FDG-40-ZR-RF FDG-63-ZR-RF
Design Passive guide axis with roller guide
Temperature 0 ... + 60 °C (storage/operation)
Mounting position As desired
Slide speed max. 10 m/s
Permitted work load
horizontal
vertical
10 kg
5 kg
25 kg
12.5 kg
50 kg
25 kg
Permitted transverse load
FY, FZ150 N 300 N 600 N
Permitted torque loading: (values in brackets for variant GV)
Mx [Nm]
My [Nm]
Mz [Nm]
7
15 (30)
15 (30)
18
60 (120)
90 (180)
65
170 (340)
300 (600)
|Mx|
Mxmax
)|My|
Mymax
)|Mz|
Mzmax
)|Fy|
Fymax
)|Fz|
Fzmax
v1
Fy
My
Mx
Fx
Mz
Fz
Materials
Slide, cylinder barrel, cover: aluminium
Rollers, screws, sliding blocks: steel
Buffer, wiper strip: rubber, felt
Cover of slide in slot: IXEF
Guide rods: steel

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tion of its contents to others without express authorization is
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served in the event that a patent, utility model or design patent is
registered.
Copyright:
Festo AG & Co. KG
Ruiter Straße 82Postfach
73734 Esslingen
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Internet:
www.festo.com