Festo DGE ZR-RF Series User manual

(en) Operating
instructions
Toothed belt axis
DGE-…-ZR-RF
8074332
2017-11e
[8074334]

DGE-…-ZR-RF
Festo DGE-…-ZR-RF 2017-11e
2
Translation of the 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 3.........................................................................

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Festo DGE-…-ZR-RF 2017-11e English 3
Documentation on the product
For all available product documentation èwww.festo.com/pk
Toothed belt axis DGE-...-ZR-RFEnglish
1 Operating elements and connections
aJ 2 3 4
5
9
7
8
6
9
1
1Toothed belt
2Greasing nipple
3Centring recesses with or without fastening thread
4Slide with grooves for fastening the work load
5Drive shaft
6Internal thread for fastening the switch lug
7Groove for fastening the sensor support
8Slot for inserting the sliding blocks (only size 25)
9Internal thread for fastening the motor mounting kit
aJ Internal thread for fastening the axis
Fig. 1

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2 Function and application
A toothed belt on a drive shaft converts the
rotary movement of a motor into a linear
movement. The slide then moves backwards
and forwards.
The slide is carried by rollers and guide rods
inside the cylinder barrel.
The DGE-...-ZR-RF is intended for the exact
and fast positioning of effective loads.
It is approved for operation in slide mode and
yoke mode (observe loading limits).
The DGE-...-ZR-RF is not permitted for use in
applications in which vegetable water-soluble
fats or oils could penetrate into the axis.
Note
The toothed belt axis DGE-...-ZR-RF is not self-locking: When input torque is not
applied, the slide can be moved freely.
Generally, a latching function of the complete system can be achieved with
motors with an integrated holding brake or other suitable means, such as
clamping systems, motors with high gear ratios or self-locking gears. The choice
of suitable means depends on the application and safety requirements.
SPlease select the appropriate motor from our catalogue
èwww.festo.com/catalogue
You will then be operating two devices which are especially matched to each
other.
STo design the DGE-...-ZR-RF, use the Festo design software “Positioning Drives”
(èwww.festo.com).
SAdhere to the maximum permitted values for forces, torque and speeds
èchapter 12 “Technical data”.
Fig. 2
Fig. 3: Slide operation
Fig. 4: Yoke operation

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3 Transport and storage
STake into consideration the weight of the DGE-...-ZR-RF.
The DGE-...-ZR-RF weighs up to 120 kg, depending on the design.
SEnsure the following storage conditions:
– short storage times
– cool, dry, shaded storage locations protected from corrosion
– no oils, greases or grease-dissolving fumes.
In this way you can ensure the capability of the toothed belt.

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4 Conditions for the safe use of the product
Warning
Unexpected fast-moving masses can cause injury to people or damage to
property (danger of fingers being crushed).
SApply power to the drive motor, at first limited to low speeds and torques.
Note
Malfunctions will occur if the device is not used correctly.
SMake sure that the specifications in this chapter are always observed.
In this way the product will perform as intended.
SCompare the maximum values specified in these operating instructions with
those of your actual application (e.g.forces, torques, temperatures, masses,
speeds).
Operation of the product in compliance with the relevant safety regulations is
contingent on adherence to the load limits.
STake 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.
SPlease comply with national and local safety laws and regulations.
SRemove transport packaging such as foils and cardboard.
It is intended that the packaging be recycled on the basis of its constituent
materials (exception: oiled paper = other waste).
SUnauthorised product modification is not permitted.
SNote the warnings and instructions on the product and in the relevant
operating instructions.
STake the tolerance of the tightening torques into account. Unless specified
otherwise, the tolerance is ±20 %.

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5 Installation
Mechanical installation
SDo not modify the settings of screws and
threaded pins if there is no direct
requirement to do so in these operating
instructions.
SFit the motor onto the axis in accordance
with the assembly instructions for the
motor mounting kit recommended in the
catalogue.
Preparing the product for fitting
Note
Please note that in the case of heavy loadings the axis must not be fastened
only by the front cover.
Excessive tensile loads will cause the cover screws to be pulled out.
With use of the upper threaded holes in the
endcaps:
SEnsure the maximum screw-in depth of
7mm (with use of HP-25: use screw
M4x10).
Fig. 5
Fig. 6

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Installing the product:
SSelect the necessary mounting position.
SCheck whether additional protection against entry of drops (grease, oil, water)
and particles is needed.
Protection against penetra
tion of drops and particles
Low Better
Installation
position
Vertical,
diagonal or
horizontal with
toothed belt
on top
Diagonal or
horizontal with
toothed belt at
bottom
Fig. 8
Fitting in a vertical or sloping position:
Warning
Masses falling suddenly can cause personal
injury and material damage (crushing).
If there is a power cut or if the toothed belt
breaks, the work load will slide down.
SMake sure that you only use motors with
an integrated spring-loaded holding brake.
SCheck whether additional external safety
measures are required to prevent the work
load from sliding down (e.g.toothed
latches, moving bolts or emergency
buffers).
Fig. 7: Low Better
Fig. 9

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With all mounting positions:
SPlace the DGE-...-ZR-RF so that all the
operating parts are accessible.
SMake sure that the device is fitted free
of mechanical stress and distortion
(evenness of mounting surface:
0.2 mm / 30 cm).
Fig. 10
Fig. 11

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Products with long stroke lengths:
SUse the centre support MUP-...
Fig. 12 shows the distances between supports required for the DGE-...-ZR-RF.
L [mm]
F [kg]
1200 1500 1800 2100 2400 2700
0
1
2
3
4
5
6
7
8
9
10
3000
DGE-25-ZR-RF...
1
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
DGE-40-ZR-RF...
L [mm]
F [kg]
1600 2800 3200 3600 40002000 2400
0
10
20
30
40
50
60
70
80
90
100
DGE-63-ZR-RF...
F
Installation
F
Installation
LL
1
2
2
1
2
position1 position 2
Fig. 12: Distances between supports L required for the DGE-...-ZR-RF as a factor of
mounting position, rated size and useful load F

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When fitting centre supports:
SPosition the centre supports at equal
distances over the complete axis length,
not only over the stroke path.
SFasten the centre supports on the
DGE-...-ZR-RF as shown in Fig. 13.
If the device is tilted, the sliding blocks of
the centre supports will slide into the
groove at any point on the profile.
SMake sure that the centre supports are
outside the positioning range of the slide
by pushing it once over the complete
positioning path.
STighten the fastening screws evenly.
Fig. 13
40
63
Dia. 25
Fig. 14

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To fasten the work load:
SUse the fastening thread or slot nuts (accessories).
SPlace the useful load so that the tilting
torque of the force parallel to the move
ment axis and lever arm “a” remains low.
Useful loads with their own guide:
SAdjust the guides of the useful load and
the DGE-...-ZR-RF so that they are exactly
parallel.
Only in this way can you avoid over
loading on the slide (permitted forces
èchapter “Technical data”).
The service life of the DGE-...-ZR-RF will
then remain as expected.
With hard and stiff work loads (steel):
Note
If the aluminium slide becomes bent against
a buckled useful load, the service life of the
guide will be reduced.
SMake sure that the mounting surface of
the useful loads is even to within
t ≤ 0.01 mm.
For useful load geometries with projection in
the longitudinal direction of the slide:
SMake sure that the useful load does not
strike against the motor.
Fig. 15
aF
Fig. 16
m
DGE
Fig. 17
t
Fig. 18

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Installing external accessories
Preparations for fitting the external accessories
SCheck to see which interrogation variant is required for your application.
Inter
rogation
variant
1. The controller requires a
separate reference point
2. The controller
does not require a
separate reference
point
Additional to
points 1 and
2. irrespective
of the type of
controller
Necessity
of scanning
elements
1 reference point switch
2 hardware limit switches
Only 2 hardware limit
switches
Always 2 safety
limit switches
Mounting
require
ments
Reference point switch
overlaps with a hardware limit
switch. The hardware limit
switch overlaps with the safety
limit switches.
Hardware limit
switches as
reference point
switches overlapping
a safety limit switch
With safety
distance from
mechanical end
position
Fig. 19
SUse scanning elements with the following features:
Scanning
element
Version Purpose Remark
Safety
limit
switch
Mechanical
roller switch
with switching
function:
N/C contact
Triggering the
EMERGENCY STOP
function
– In accordance with accident
prevention regulations
– Will only prevent conse
quent damage in the case
of programming errors
Hardware
limit
switch
Switching
function:
N/C contact
Triggering the maximum
braking
(emergency ramp)
– Still enables damage-free
braking in the case of
programming errors
Software
limit
switch
–Limits of the positioning
range through
programmed control
– Are not usually overrun
Reference
point
switch
Switching
function:
N/O contact
Definition of a basis
point for the
DGE-...-ZR-RF
Regular checks of the
position are recommended
Fig. 20

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Making sure there is a controlled braking path:
SMake sure that this condition is always observed: s > n.
Only in this way can you avoid states with undefined positions after incorrect
programming of the product.
–Braking distance n, which can be achieved at the maximum speed
(ascertain: empirically under load or calculated from the motor braking
torque)
–Switching path s of the SIE-...
DGE-...-ZR-RF Switching travel s
...-25-... 97 mm
...-40-... 159 mm
...-63-... 222 mm
Fig. 21
Deviations with s < n:
SUse the proximity sensors specified in our catalogue under “Accessories” as
reference and hardware limit switches (èwww.festo.com/catalogue).
If inductive or mechanical limit switches are used:
SUse switching lugs of length d (èFig. 25).

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If you are using inductive limit switches:
SAvoid external influence caused by magnetic or ferritic parts in the vicinity of
the reference point switches and limit switches.
With use of inductive proximity switches SIE-...:
aF = sensor lug
aG = sensor support
aH = proximity sensor
With small sizes, hammer head screws
(accessories) can be used for fastening
the sensor support in the groove.
These use the recess in the cover as a
guide channel.
A 90° turn will bring the hammer head
screw into its holding position.
Fig. 22 aFaGaH Fig. 23
Fig. 24

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Increased protection against subsequent damage:
SUse shock absorbers or fixed stops of sufficient size outside the safety limit
switches.
The effective stroke of the product may be shorter, depending on the
mounting situation.
Carrying out the fitting of external accessories
For placement of the proximity switches:
1. Place the safety limit switches in the mechanical end positions (W) as shown
in Fig. 25.
2. Place the hardware limit switches near the mechanical end positions.
At first the limit switches can still be shifted in the longitudinal direction
(cable reserve; for accurate positioning èchapter “Commissioning”).
3. If necessary, place a reference point switch between both hardware limit
switches (exact positioning: see chapter “Commissioning”).

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STake into account the following plan for positioning the proximity switches:
Fig. 25
WS
n
R
H
d > x
x
OO/2 O
(X)
(Z)
r
W
S
n
H
r
hh
M
d > h
h = n + r
d
(M) = Motor
(X) = Interface to emergency stop circuit
(Z) = Interface to controller
W = Mechanical end position
S = Safety limit or switching point of the safety limit switches
H = Switching point of the hardware limit switches
R = Reference point position
O = Positioning limits of the software controller
O/2 = Stroke centre
d = Switch lug length
h = Stroke reserve
n = Braking distance 1
r = Braking distance 2
x = Distance of the reference point switch from the hardware limit switch close to the motor
If proximity sensors are used as limit switches:
SUse proximity sensors with normally-
closed function. (N.C.= normally closed)
These will protect a DGE with a fractured
proximity-sensor cable against
overrunning the end position.
To prevent soiling:
SUse cover rails (accessories) in all unused grooves.
Fig. 26

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Fitting electric components
SConnect the electric control elements
(in accordance with the relevant operating
instructions).
– Connect the motor to the controller (Z)
and the main power supply via an inter
mediately switched power amplifier.
– Connect the reference point switch to
the controller power supply and the
controller (Z).
– Connect the safety limit switch to the controller power supply and the
separately switched EMERGENCY STOP device (X) (èchapter “Connecting
electric circuits”).
– Connect the hardware limit switch to the controller power supply and to the
controller (Z).
Installing circuitry
Note
If used in safety-relevant applications, additional measures are necessary.
In Europe, for example, the standards in the EC machinery directive must be
observed.
Without additional measures in accordance with statutory minimum
requirements, the product is not suitable for use in safety-related sections of
control systems.
Fig. 27
X
Z
M

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6 Commissioning
Preparing for commissioning
Warning
Moving masses can cause personal injury and
material damage (crushing).
SMake sure that, in the travel range,
– nobody can place his/her hand in the path
of the moving load (e.g.by use of a
protective crate),
– there are no foreing objects.
It should not be possible to touch the DGE
until the mass has come to a complete
standstill.
Fig. 28
Note
Incorrect specification values of the braking ramp in STOP situations
(e.g. EMERGENCY STOP, Quick Stop) result in an overloading of the toothed belt
axis and can destroy it or drastically reduce the service life.
SCheck the settings of all braking ramps in your controller or the higher-level
controller (deceleration values and jerk).
SMake sure that the deceleration values (braking deceleration, deceleration
times), taking into account the speed of travel, moving load and mounting
position, are set so that the maximum drive torque or maximum feed force of
the used toothed belt axis are not exceeded.
STo design the toothed belt axis, use the Festo design software
“PositioningDrives” èwww.festo.com.

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Note
Block-shaped acceleration profiles (without smoothing) cause high peaks in the
drive force, which can result in drive overload. In addition, through overswing
effects, positions outside the permissible range can occur. A smoothed acceler
ation specification reduces vibrations in the overall system and has a positive
effect on the mechanical equipment load.
SCheck which regulator settings can be adjusted (e.g. smoothing, flattening of
the acceleration profile).
Positioning the limit switches
1. First push the cantilever arm into a mechanical end position (W) èFig. 30.
2. Then position the slide at the distance h (safety distance) from the mechanical
end position (h = n + r) èFig. 25.
Type Distance h
DGE-25-ZR-RF 63 mm
DGE-40-ZR-RF 100 mm
DGE-63-ZR-RF 172 mm
Fig. 29
3. Push the hardware limit switch for the
relevant end position in the direction of
the switching lug up to its switching
point.
4. Fasten the hardware limit switch exactly
at this point.
5. Repeat the last four points in the other
end position.
6. Push the slide into the end positions.
You can thus check whether the hardware limit switches function correctly and
whether the switching lug is seated free of play.
7. Fasten the safety limit switches between the relevant mechanical end position
(W) and the nearby hardware limit switch (H).
Fig. 30
W
h
H