Festo DNCKE S Series User manual

8145483
DNCKE-...-S / KEC-...-S
Cylinder with clamping unit / Clamping unit
8145483
2020-10e
[8145485]
Operating instructions

Translation of the original instructions
2 Festo — DNCKE-...-S / KEC-...-S — 2020-10e

3Festo — DNCKE-...-S / KEC-...-S — 2020-10e
1 About this document................................................................................................... 4
1.1 Applicable Documents.................................................................................................. 4
1.2 Specified standards...................................................................................................... 4
2 Safety........................................................................................................................... 4
2.1 Safety instructions........................................................................................................ 4
2.2 Intended use................................................................................................................ 5
2.3 Foreseeable misuse...................................................................................................... 5
3 Further information..................................................................................................... 5
4 Service..........................................................................................................................5
5 Product design............................................................................................................ 5
6 Function........................................................................................................................7
7 Assembly..................................................................................................................... 7
7.1 Mounting the clamping unit.......................................................................................... 8
7.2 Mounting attachments................................................................................................. 10
7.3 Mounting the accessories............................................................................................. 10
8 Installation.................................................................................................................. 10
8.1 Pneumatic installation.................................................................................................. 10
8.1.1 Functional tests...................................................................................................... 11
8.1.2 Connecting tubing to the clamping unit.................................................................. 12
9 Commissioning............................................................................................................ 13
9.1 Dismantling the round material (only required for KEC).................................................13
9.2 Adjustment of the clamping unit................................................................................... 15
9.3 Test run......................................................................................................................... 16
9.4 Checking clamping force/overtravel............................................................................. 18
10 Operation..................................................................................................................... 23
10.1 Regular adjustment of the clamping unit...................................................................... 24
10.2 Characteristic curves.................................................................................................... 25
11 Cleaning...................................................................................................................... 26
12 Malfunctions............................................................................................................... 26
12.1 Fault clearance............................................................................................................. 26
12.2 Repair............................................................................................................................27
13 Disposal........................................................................................................................28
14 Technical data............................................................................................................. 28
Table of contents

1 About this document
1.1 Applicable Documents
All available documents for the product èwww.festo.com/sp.
1.2 Specified standards
Version
DINENISO12100:2011-03
DINENISO4414:2011-04
DINENISO13849-1:2016-06
DINENISO13849-2:2013-02
Tab. 1
2 Safety
2.1 Safety instructions
– Only use the product in original status without unauthorised modifications.
– Only use the product if it is in perfect technical condition.
– Observe labelling on the product.
– Take into consideration the ambient conditions at the location of use.
– Prior to mounting, installation and maintenance work: Switch off power supply and secure it from
being switched back on.
– Observe tightening torques. Unless otherwise specified, the tolerance is ±20%.
The operating modes must guarantee that the residual risk is less than or equal to the accepted risk
èDINENISO12100. The measures for risk reduction must be implemented in accordance with
DINENISO4414, DINENISO12100 and DINENISO13849-1.
Monitor/check the function of the entire system during use in accordance with the measures defined
in the validation report èDINENISO13849-2.
About this document
Festo — DNCKE-...-S / KEC-...-S — 2020-10e4

2.2 Intended use
The clamping unit KEC is intended to serve both as an individual product and integrated into a cylinder
DNC (for cylinder with clamping unit DNCKE) for the following usage:
– As a safety device for holding and clamping round material.
– As a well-tried component for braking a linear movement (stopping a movement) for processing or
handling procedures in a normal industry environment without substances and ambient condi-
tions that influence the function or materials used.
If used as a braking device, e.g.for interrupting potentially dangerous movements in a danger zone, a
regular check of the overtravel as a factor of the travel speed and the frequency of the braking proced-
ures (increased wear) as well as of the ambient operating conditions (min./max. temperature) is
necessary.
2.3 Foreseeable misuse
The product is not suitable for positioning tasks or for transmitting torques and lateral forces. A self-
aligning rod coupler (è 3 Further information) can prevent the transmission of lateral forces and
bending moments.
3 Further information
– Accessories èwww.festo.com/catalogue.
– Spare parts èwww.festo.com/spareparts.
4 Service
Contact your regional Festo contact person if you have technical questions èwww.festo.com.
5 Product design
All available documents for the product èwww.festo.com/sp.
Further information
5Festo — DNCKE-...-S / KEC-...-S — 2020-10e

1Supply port for cylinder next to the adjusting
screws for the pneumatic cushioning (only
for DNCKE)
2Supply port for releasing the clamp
3Locking screw with internal hexagon socket
(for adjusting sleeve)
4Piston rod (DNCKE only)
5Adjusting sleeve with spanner flat
6Hollow bolts with thread for mounting
7Hole with filter element for exhausting the
clamping chamber
8Slots for proximity switches (DNCKE only)
9Round material for transportation lock (KEC
only)
Fig. 1
Definition
In these operating instructions, the designation clamping unit is used for:
• the individual product KEC
• the design type DNCKE integrated in the cylinder
In these operating instructions, the designation round material is used for:
• The transportation lock for KEC
• The piston rod for DNCKE
Product design
6 Festo — DNCKE-...-S / KEC-...-S — 2020-10e

1DNCKE-...-S 2KEC-...-S
Fig. 2
6 Function
Pressurising with compressed air on the supply port 2 (è Fig.1) opens the internal clamping com-
ponent through a pneumatically driven release mechanism. The round material can then move freely.
Fig. 3
If the supply port is exhausted, a spring-loaded mechanism generates the clamping force of the clamp-
ing component. The round material is then clamped.
Fig. 4
7 Assembly
Requirements
NOTICE!
Lateral loads and bending moments exerted on the round material damage its function and destroy
the internal clamping component.
• Load the round material only in the direction of movement. The use of a self-aligning rod coupler
(è 3 Further information) prevents lateral forces.
Function
7Festo — DNCKE-...-S / KEC-...-S — 2020-10e

Movement of the round material against the clamping forces leads to heavy wear on the internal
clamping component and the round material.
• Do not exceed the holding force at any time. Unexpected movements may occur.
When installing the clamping unit, observe the following points:
– Operating elements always accessible
– Product secured free from distortion and deflection
– Direct reaction forces via the mounting components as compressive force. Observe braking direc-
tion r è Tab. 2.
– Check whether safety measures (e.g.toothed latches or moving bolts) are also required externally
èDINENISO12100 and DINENISO13849-1.
– Select the installation type for the desired application. Additional assembly alternatives è Tab. 2.
7.1 Mounting the clamping unit
Interfaces for mounting components on the cover
e.g.with foot mounting HNC (only permissible
for use as a holding device)
e.g.with flange mounting FNC (approved for use
as a holding and braking device – observe brak-
ing direction r)
Tab. 2
Assembly
8 Festo — DNCKE-...-S / KEC-...-S — 2020-10e

Dimensions (see catalogue specifications)
Clamping unit KEC
Tab. 3
Dimensions (see catalogue specifications)
Clamping unit (with cylinder) DNCKE
Tab. 4
DNCKE 40 63 100Size
KEC 16 20 25
L11) [mm] 178 208.5 287
ZJ+ (plus stroke length) [mm] 277 315 408
TG [mm] 38 56.5 89
E [mm] 54 80 126
Screw-in depth [mm] 9.5…15 12.5…14 14…17
Screw M6 (4x) M8 (4x) M10 (4x)
Assembly
9Festo — DNCKE-...-S / KEC-...-S — 2020-10e

DNCKE 40 63 100Size
KEC 16 20 25
Tightening torque [Nm] 5 13 30
1) Dimension varies depending on setting of the adjusting screw.
Tab. 5
1. Place the clamping unit in the intended position.
2. Tighten screws evenly. Tightening torques è Tab. 5.
7.2 Mounting attachments
Mounting on the DNCKE
• Mount the attachment component on the piston rod. The spanner flat aJ on the piston rod serves
as a counter holder for the lock nut. If necessary, secure the lock nut with screw locking agent.
Fig. 5
7.3 Mounting the accessories
If proximity switches are used in the cylinder with clamping unit DNCKE:
– Use Festo accessory proximity switches èwww.festo.com/catalogue.
1. Place the proximity switches in the grooves 8 of the cylinder.
2. Mount the proximity switches in the desired switching positions.
Fig. 6
8 Installation
8.1 Pneumatic installation
Requirements
• Check the following accessories for use:
Installation
10 Festo — DNCKE-...-S / KEC-...-S — 2020-10e

Designation Type Function
Slow pressure reduction with loss of compressed airCheck valve HGL
Redundancy with stop function
Compensation reservoir VZS Reduction of pressure fluctuations in the downstream com-
pressed air line
Tab. 6
• Use a one-way flow control valve, e.g.GRLZ or GRLA, directly in the relevant supply port.
For control of the cylinder with clamping unit:
• Select a suitable control for the specific application.
Example for clamping unit control
2 functions are possible:
– Protection against unexpected start-up of the piston rod (holding function)
– Stopping a dangerous movement of the piston rod (emergency brake function)
Before the clamping unit is released, measures must be taken to prevent the piston rod from advan-
cing suddenly.
Fig. 7
8.1.1 Functional tests
Functional test when used as a holding device (clamping function)
The frequency or test interval of a static functional test is to be determined based on the applica-
tion/risk assessment and the category selected in accordance with DINENISO13849. In addition, the
static functional test, if not required by C-type standards or other regulations, must be performed at
least once per month and every 100000 switching cycles.
Functional test when used as an emergency braking device (emergency brake/emergency stop func-
tion)
In principle, a static functional test and a dynamic braking test are required after every emergency
brake (emergency stop).
The frequency or test interval of a dynamic braking test is to be determined based on the applica-
tion/risk assessment and the category selected in accordance with DINENISO13849. In addition, the
Installation
11Festo — DNCKE-...-S / KEC-...-S — 2020-10e

dynamic braking test, if not required by C-type standards or other regulations, must be performed at
least once per year. After the dynamic braking test, a static functional test must be performed. Instruc-
tions for conducting the static functional test and the dynamic braking test
è 9.4 Checking clamping force/overtravel.
8.1.2 Connecting tubing to the clamping unit
When operated in normal ambient air (without particles):
1. Remove covers (if present) from the supply ports.
2. Remove dirt particles and foreign matter from the ports and tubing lines.
3. Use short tubing lines where possible. This will reduce switching times.
4. Connect the tubing to the supply ports of the clamping unit 2 and to the supply ports of the cylin-
der 1 in accordance with DINENISO4414.
2Supply port for clamping unit 1Supply port for cylinder
Fig. 8
DNCKE 40 60 100Size
KEC 16 20 25
Supply port for clamp-
ing unit
2G1/8 G1/4 G3/8
Supply port for cylinder
(DNCKE only)
1G1/4 G3/8 G1/2
Tab. 7
Installation
12 Festo — DNCKE-...-S / KEC-...-S — 2020-10e

When operated in ambient air containing fine dust and mist to prevent dirt particles from entering the
pneumatic system:
1. Use a barbed fitting, e.g.QS-CM-M5, instead of the filter nipple in the exhaust channel 7 of the
spring interior.
2. Route the hose in an area with clean ambient air.
Fig. 9
9 Commissioning
WARNING!
Unexpected movement of components. Injury due to electric shock, impact or crushing.
• Protect positioning range from access, e.g.using protective guards.
• Foreign objects must not be present in the travel range.
• The holding force must correspond to the intended values
è 9.4 Checking clamping force/overtravel.
• The limit values must not be exceeded è 14 Technical data.
NOTICE!
Clamping without round material will destroy the internal clamping component.
• The clamping unit KEC must be pressurised at all times when the round material is not inserted. If
the clamping unit KEC is exhausted when the round material is not inserted, the high spring force
will deform the internal clamping component until it cannot function.
9.1 Dismantling the round material (only required for KEC)
1. Pressurise the supply port 2 to at least 3.8bar.
Commissioning
13Festo — DNCKE-...-S / KEC-...-S — 2020-10e

Fig. 10
2. Loosen the locking screw 3 using an Allen key.
DNCKE 40 63 100Size
KEC 16 20 25
Spanner size for intern-
al hexagon socket 3 ß
[mm] 6 8
Tab. 8
Fig. 11
3. Unscrew the adjusting sleeve 5 half a turn anticlockwise.
4. Pull supplied round material 9 out completely.
NOTICE!
If the round material is inserted at an angle, the scraper and seals might be damaged.
• A 15° chamfer at least 3mm wide at the end of the round material ensures it can be slid on
easily. Rod quality è 14 Technical data.
Commissioning
14 Festo — DNCKE-...-S / KEC-...-S — 2020-10e

Fig. 12
5. Carefully slide the clamping unit onto the rod of the attachment product.
6. Adjust the KEC to the new round material è 9.2 Adjustment of the clamping unit.
9.2 Adjustment of the clamping unit
Adjustment is not required for initial start-up of DNCKE.
1. Exhaust the cylinder in a stable position, e.g.Example, with vertical installation at the lowest
point.
Fig. 13
2. Pressurise the supply port 2 to at least 3.8bar.
3. Loosen the locking screw 3 using an Allen key.
DNCKE 40 63 100Size
KEC 16 20 25
Spanner size for intern-
al hexagon socket 1 ß
[mm] 6 8
Tab. 9
Commissioning
15Festo — DNCKE-...-S / KEC-...-S — 2020-10e

Fig. 14
4. Unscrew the adjusting sleeve 5 half a turn anticlockwise.
Fig. 15
5. Turn the adjusting sleeve 5 clockwise until the round material can no longer move.
6. Turn the adjusting sleeve 5 anticlockwise until the round material is just free to move, approx.
10…30°.
Fig. 16
7. Re-tighten the locking screw 3.
– Tightening torque: 7Nm.
8. Exhaust the clamping unit. The round material is then clamped.
9.3 Test run
• Comply with critical limits for all loads.
Commissioning
16 Festo — DNCKE-...-S / KEC-...-S — 2020-10e

For setting the speed and pneumatic cushioning:
Fig. 17
1. First, fully screw in the screws of the upstream one-way flow control valves aA and the pneumatic
cushioning aB on the DNCKE, then loosen by about one revolution.
2. Pressurise the complete system slowly, e.g.with the soft start valve HEL.
3. Pressurise the cylinder at the same time at both supply ports 1 (è Fig.1) (DNCKE only). This pre-
vents movement in the direction of the unpressurised cylinder chamber.
4. Pressurise the clamping unit at the supply port 2 (è Fig.1) to a minimum of 3.8bar. In some cir-
cumstances, this will be enough for the piston rod to move slowly into the advanced end position.
5. Start a test run at a low switching frequency and low impact speed.
6. Repeat the test run, increasing the speed incrementally until the operating speed is reached. If set
correctly, the payload, e.g.the moved machine part, should reach the end position without a hard
stop.
7. Check during the test run whether the following equipment settings need to be modified:
– Speed of the payload
– Pneumatic cushioning
– Clamping force
8. After completing the required adjustments:
– End the test run.
Commissioning
17Festo — DNCKE-...-S / KEC-...-S — 2020-10e

9.4 Checking clamping force/overtravel
WARNING!
Unexpected movement of components
Injury due to electric shock, impact or crushing.
If the clamping force of the clamping unit is no longer sufficient, the movable parts of the pneumatic
components can cause uncontrolled movements. Uncontrolled movements of the connected actuator
technology can cause personal injury or material damage. Frequent checking of the overtravel will
increase wear, depending on how often it is used.
• Perform a check of the overtravel only if the product is used as a brake.
The overtravel is dependent on the load and the ambient conditions: temperature, oil on the pis-
ton rod, number of switching cycles, speed, mass, operating pressure and control diagrams
è 10.2 Characteristic curves.
• The overtravel check in a dynamic braking test must be performed beginning with the maximum
possible speed in the application (the maximum permissible travel speed must not be exceeded).
• The clamping force is checked in the resting position.
The specified test examples correspond to cases of application with the maximum amount of stress.
Deviating applications (slanted mounting position) cannot be represented. It may be necessary to
make calculations for a specific application and carry out a specific test for that.
WARNING!
Unexpected movement of components
Injury due to electric shock, impact or crushing
• Make sure that there is a balance of forces acting on the operating cylinder’s piston. There is a
danger of the piston rod advancing suddenly when it is released due to the axial force (weight
force) applied, especially with vertical installation.
Observe the following points:
– The test force (test pressure) must be at least equal to the force (pressure) in the application or be
specified in the risk assessment for the application.
– The test force must not be greater than the maximum static holding force è 14 Technical data.
– The overtravel in the dynamic braking test must be less than the tolerable overtravel from the
application/risk analysis.
– The piston rod must not slip during a testing period of 60s. Remedy in case of slipping: readjust
the clamping unit è 9.2 Adjustment of the clamping unit.
Commissioning
18 Festo — DNCKE-...-S / KEC-...-S — 2020-10e

Horizontal mounting position
Case 1: without additional weight force:
Fig. 18
Size KEC 16 20 25
Test force FP[N] 1300 3200 8000
Tab. 10
Static functional test Dynamic braking test
Place the piston rod in the returned end position
Exhaust supply port 2 (è Fig.1).
The clamping is active.
Pressurise the cylinder chamber of the DNCKE in the advancing
direction at P=10bar while simultaneously exhausting the cyl-
inder chamber in the return direction.
That corresponds to the following test force (for testing with KEC
è Tab. 10).
– The movement begins (danger of crushing).
– The max. permissible travel speed must not be exceeded.
Exhaust supply port 2 (è Fig.1).
– Braking begins.
– The cylinder stops.
Pressurise the cylinder chamber
of the DNCKE in the advancing
direction at P=10bar while sim-
ultaneously exhausting the cylin-
der chamber in the return direc-
tion.
Test force for testing with KEC
è Tab. 10.
Determine the path from the exhaust start signal until the cylin-
der is at rest.
– This path equals the overtravel.
The test force (test pressure) should act for 60s. During this time, the piston must not move any fur-
ther.
Tab. 11
Commissioning
19Festo — DNCKE-...-S / KEC-...-S — 2020-10e

Vertical mounting position
Case 2: Test with additional weight force, suspended orientation:
Fig. 19
• Calculate the required test pressure PA using the following formula:
Symbol Description Unit
PATest pressure [MPa, psi, bar]
FPTest force [N]
m Payload [kg]
g Acceleration due to gravity [9.81]m/s2
A Piston surface [mm2]
Tab. 12
Size DNCKE 40 63 100
Test force FP[N] 1300 3200 8000
Piston surface A
advancing direction
[mm2] 1257 3117 7854
Tab. 13
Commissioning
20 Festo — DNCKE-...-S / KEC-...-S — 2020-10e