Festo ELFA-KF Series User manual

Operating
instructions
8113434
2019-05d
[8113436]
Guide axis
ELFA-KF/-RF

ELFA-KF/-RF
2 Festo – ELFA-KF/-RF – 2019-05d
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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English – Guide axis ELFA-KF/-RF
Table of contents
1 Configuration 20............................................................
2 Safety 20..................................................................
2.1 Intended use 20.............................................................
2.2 General safety information 21..................................................
2.3 Mounting and connecting 21...................................................
2.4 Qualification of specialized personnel 21.........................................
3 Function 21................................................................
4 Transport 22...............................................................
5 Installation 22..............................................................
5.1 Mechanical installation 22.....................................................
5.1.1 Mounting the axis 23.................................................
5.1.2 Mounting attachment components 24...................................
5.1.3 Mounting accessories 25.............................................
6 Commissioning 26...........................................................
7 Maintenance and care 26.....................................................
8 Disassembly and repair 28....................................................
9 Disposal 28................................................................
10 Accessories 29..............................................................
11 Fault clearance 30...........................................................
12 Technical data 31............................................................
13 Characteristic curves 33......................................................

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1 Configuration
For all available product documentation èwww.festo.com/pk
8
aJ
aJ12 3
6
45
7
9
7
1Thread/centring holes for foot mounting
2Profile housing with
– Recirculating ball bearing guide (ELFA-KF)
– Roller bearing guide (ELFA-RF)
3Thread/centring holes for attachment com
ponents
4Slide
5Cover band
6Slots for mounting/accessories
7Relubrication opening
8Thread for switch lug
9Slots for proximity sensors
aJ Sealing air connection
Fig. 1
2 Safety
2.1 Intended use
The intended use of the ELFA guide axis is to form the basic struc
ture of cantilever or gantry systems using a drive axis and a passive
guide axis. The guide axis is permitted for slide operating mode.
Fig. 2

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2.2 General safety information
 Take into consideration the legal regulations for the respective destination.
 Only use the product if it is in its original status and in an excellent technical status.
 Use the product only within the defined values (è12 Technical data and 13 Characteristic curves).
 Take into account labelling on the product.
 Do not make any unauthorised modifications to the product.
 Observe other applicable documents.
 Take into consideration the ambient conditions at the location of use.
Protect the product from the following:
– Wetness or moisture
– Corrosive coolant or other materials (e.g. ozone)
– UV radiation
– Oils, greases and grease-solvent vapours
– Grinding dust
– Glowing chips or sparks
2.3 Mounting and connecting
 Observe tightening torques. Unless otherwise specified, the tolerance is ± 20 %.
 For ELFA-…-P0: Check the cavity in the area of the guide for foreign objects and remove these if
present.
2.4 Qualification of specialized personnel
Only qualified personnel may perform installation, commissioning, maintenance and disassembly of the axis.
The qualified personnel must be familiar with installation and operation of electrical and pneumatic control
systems.
3 Function
The slide of the ELFA guide axis supports a load so that it can move. Due to the coupling with a drive
axis (e.g. B.ELGA-TB-RF), the slide 4moves forwards and backwards. The slide is equipped with a ball
bearing guide (ELFA-KF) or roller bearing guide (ELFA-RF). An extended slide for version ELFA-RF (or an
additional slide to the left or right for version ELFA-KF) permits a higher load.
Determine the reference position of the slide as follows (è10 Accessories):
– Switch lug and proximity sensor in the slots 9
– Switch lug and proximity sensor in the sensor bracket.

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4 Transport
Note
Unexpected movement of components. The axis is non-braking and the slide can be
moved freely.
 Secure slide during transport.
 Take product weight into account (è12 Technical data).
 Comply with maximum permitted support spacing when attaching transportation aids
(è13 Characteristic curves).
5 Installation
5.1 Mechanical installation
Prerequisites
 Do not modify the screws and threaded pins.
Exception: Direct request to do so in these operating instructions.
 Position the product in such a way that its operating elements are accessible (e.g. relubrication
openings).
 Make sure that the mounting components are outside the travel range of the slide.
 Install product without tension or distortion.
 Fasten product to a mounting surface with flatness of 0.05 % of
the stoke length, but max. 0.5 mm.
 In the case of gantry structures, attention must also be paid to
parallel alignment or product height in the alignment of the
axes.
For additional information, please contact your local Festo Service.
 Take the required support clearances into consideration
(è13 Characteristic curves).
Fig. 3
When using the ELFA guide axis in combination with a drive axis, e.g. ELGA:
 Use mounting surfaces with identical evenness for both axes.
Use the same support clearances on the drive axis as on the guide axis.
In this way you will prevent tension due to uneven flexing.

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5.1.1 Mounting the axis
 Attach the ELFA (èFig. 4).
Interfaces for mounting components
On the cover On the profile On the profile
E.g. with foot mounting HPE1) E.g. with slot nuts NST1) E.g. with profile mounting MUE1)
1) èwww.festo.com/catalogue
Fig. 4
Note
Danger of screws being pulled out, if the axis is only mounted to the covers and
the torque load around the longitudinal axis is too great.
 If there is high loading, mount the axis on the profile with additional mounting com
ponents.
When using an ELFA guide axis in combination with an ELGA-TB/BS axis:
 Align and secure the drive axis.
Use the same support spacing/mounting points for the guide axis. The guide axis is aligned by moving
the slide to the mounting points. Mount the guide axis when the slide is located at each respective
mounting point.
If necessary, use a connection with tolerance compensation (fixed bearing/movable bearing).
In the case of gantry structures, attention must also be paid to parallel alignment or product height
in the alignment of the axes. Perform cushioning preferably on the axis with the larger payload.
 Tighten the screws on the cover:
– M5 with 5.9 Nm
– M6 with 9.9 Nm.
 In the case of mounting accessories, comply with the tightening torque specified in the associated
product information.

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5.1.2 Mounting attachment components
Prerequisites
Note
A warped attachment component bends the slide
and shortens the service life of the guide.
 Use an attachment component with an even
surface.
Evenness: t = 0.01 mm
Fig. 5
t
 Position the rated 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 as low as possible. Fig. 6
aF
Mounting
 Fasten the attachment to the slide with screws and centring
sleeves.
 Observe maximum screw-in depth D and tightening torque
(èTab. 1).
Fig. 7
Size 70 80 120
Screw M5 M5 M6 M5 M6
Tightening torque [Nm] 5.9 5.9 9.9 5.9 9.9
Max. screw-in depth D [mm] 7.5 9.5 12.5
Centring [H7] KF [mm] 5 9
KF, RF [mm] 9
Tab. 1

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5.1.3 Mounting accessories
To protect the end positions against uncontrolled excess travel:
 Check the necessity of proximity sensors (hardware limit switches).
If proximity sensors are used as limit switches:
 Preferably use proximity sensors with normally-closed function.
This protects against excess travel beyond the end position, if the proximity sensor cable is broken.
If proximity sensors are used as reference switches:
 Use proximity sensors that correspond to the input of the controller being used.
 Use proximity sensors with switch lug aA (èAssembly instructions for the accessory).
Mounting options for proximity sensors
in the slots 9(èFig. 1) with sensor bracket aB
9
aA aB
aA
Fig. 8
 Avoid external influences from magnetic or ferritic parts in the vicinity of the proximity sensors
(minimum distance of 10 mm from the slot nuts).
 Use slot covers in all unused slots to prevent contamination (èwww.festo.com/catalogue).
Connection option for sealing air
 Connect sealing air. To do this, remove the threaded pin
(aJ èFig. 9) on the cover and connect the compressed
air/vacuum suction supply. For additional protection, use
both sealing air connections.
Fig. 9
aJ

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6 Commissioning
Warning
Unexpected movement of components.
Injury due to impact or pinching.
 Protect the positioning range from manipulation
(e.g. with protective guards).
 Make sure that no foreign objects are present in
the positioning range.
 Carry out commissioning with low speeds and
torques.
Fig. 10
 Commission the unit following the operating instructions for the drive axis (e.g. ELGA-TB-RF).
7 Maintenance and care
WARNING
Unexpected movement of components.
Injury due to impacts or pinching.
 When working on the axis, switch off the controller and secure it to prevent it from
being switched back on unintentionally.
 For ELFA-…-P0: Check the cavity in the area of the guide for foreign objects and remove these if
present.
 Clean the axis as required with a soft cloth. Do not use aggressive cleaning agents.
Checking the cover band
 Check the cover band after every 2000 km of operating distance.
Waves on the cover band are a sign for wear of the band reverser.
 In case of wave formation, retension the cover band on both sides:
1. Loosen the threaded pins (èFig. 11).
2. Push the cover band into the cover. The cover band must not butt against the inner top side of
the slide.
3. Tension the cover band with a clamping element 5(èFig. 11).
4. Tighten the threaded pins (tightening torque: 2 Nm).
If the cover band can no longer be retensioned:
 Replace the band reversers and cover band (èwww.festo.com/spareparts).

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Lubricating the guide
1
2
3
4
5
1Cover band
2Relubrication openings
3Cover
4Threaded pin
5Clamping element (è10 Accessories)
Fig. 11
1. Calculate the load comparison factor fvwith
the aid of the formula for combined loads
(è12 Technical data).
2. Read lubrication interval Sint (èFig. 12).
Fig. 12
fv
Note
The lubrication interval Sint is dependent on the load acting on the product.
Load factors:
– dusty and dirty environment
– Nominal stroke ,2000 mm or 300 mm
– Speed ,2 m/s
– Travel profile Ztriangular operation (frequent acceleration and braking)
– Ambient temperature ,+40 °C
– Service life of the product ,3 years
 If one of these factors applies, halve the lubrication interval Sint.
 If several factors apply at the same time, reduce the lubrication interval by three-
quarters.
3. Oil or grease the guide at all relubrication openings (èFig. 11).
Accessories and permitted lubricant (è10 Accessories).

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Amount of lubricant at each relubrication opening:
Size 70 80 120
Amount of lubricant
Grease for ELFA-KF [g] 0.4 0.8 1.4
Oil for ELFA-RF [ml] 1.0 … 1.5 1.5 … 2.5 –
Tab. 2
8 Disassembly and repair
WARNING
Unexpected movement of components.
Injury due to impacts or pinching.
 When working on the axis, switch off the controller and secure it to prevent it from
being switched back on unintentionally.
 Observe notes on transport (è4 Transport).
If repairs are required:
 Send the axis to Festo or contact your local Festo Service (èwww.festo.com).
Festo carries out the required repairs, fine adjustments and checks.
 Information about spare parts and accessories (èwww.festo.com/spareparts).
9 Disposal
 Dispose of the packaging and the axis at the end of its useful life in an environmentally-friendly
manner and in accordance with the applicable provisions.

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10 Accessories
èwww.festo.com/catalogue
Maintenance accessories:
Designation Part number/type
ELFA-KF
Grease gun with needle-pointed nozzle 647958/LUB-11)
Nozzle pipe, axial outlet port 647959/LUB-1-TR-I1)
Nozzle pipe, radial outlet port 647960/LUB-1-TR-L1)
Roller bearing grease LUB-KC1 from Festo1)
ELFA-RF
Oil gun 8041022/AZTP-S-L1)
Oil cartridge 8041024/AZLO-H1-C-101)
Oil Elkalub VP 916, Chemie-Technik Co., Vöhringen
1) (èSpare parts catalogue at www.festo.com/spareparts)
Tab. 3

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11 Fault clearance
Malfunction Possible cause Remedy
Squeaking
noises, vibrations
or the axis is not
running smoothly.
Tensions Install axis without tension,
Observe evenness of the bearing surface:
(è5.1 Mechanical installation).
Change arrangement of the tool/payload.
Align axis so it is exactly parallel to the second
axis.
Alter the travel speed.
Insufficient lubrication at
guide
Lubricate the axis (è7 Maintenance and care).
Guide is defective. Send axis to Festo or contact the local Festo
service.
Wear on guide or band
reverser
Slide does not
move.
Loads are too high. Reduce load mass/torques.
Mounting screws for the
payload are too long
Comply with the max. screw-in depth
(è5.1.2 Mounting attachment components).
Slide travels over
end position.
Proximity sensor does not
switch.
Check proximity sensor, connections and
controller.
Cover band has
waves.
Wear on band reverser Retension the cover band
(è7 Maintenance and care).
Replace the band reverser and cover band
(èwww.festo.com/spareparts).
Oil leak between
profile housing
and cover.
Oil accumulator for ELFA-RF
is completely saturated.
Replace oil accumulator.
Tab. 4

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12 Technical data
Size 70 80 120
Design Mechanical axis
Guide KF Recirculating ball bearing guide
RF Roller bearing guide –
Mounting position any
Max. speed KF [m/s] 5
RF [m/s] 10 –
Max. acceleration [m/s2] 50
Ambient temperature [°C] –10 … +60
Degree of protection P0 IP00
– IP40
2nd moment of area KF RF
Iy KF [mm4]146 x 103257 x 1031240 x 103
Iz KF [mm4]459 x 103914 x 1034370 x 103
Iy RF [mm4]139 x 103270 x 103–
Iz RF [mm4]433 x 1031020 x 103–
Max. perm. forces
Fy KF [N] 1500 2500 5500
Fz KF [N] 1850 3050 6890
Fy = Fz RF [N] 500 800 –
Max. perm. torque
Mx KF [Nm] 16 36 104
My = Mz KF [Nm] 132 228 680
Mx1) RF(-L) [Nm] 11 (11) 30 (30) –
My = Mz1) RF(-L) [Nm] 20 (40) 90 (180) –
Determination of the load compensation factor for
combined loads:
fv +|Mx|
Mxmax
)
|My|
Mymax
)|Mz|
Mzmax
)
|Fy|
Fymax
)|Fz|
Fzmax
v1
1) Data for RF-...-S corresponds to data for RF

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Size 70 80 120
Note on materials Contains PWIS2)
Materials
Cover, profile, slide Anodised aluminum
Guide Steel
Screws, castors, cover band Steel
Covers PA, POM, PE, steel
Band reverser POM
Buffer NBR
Weight (standard slide, with cover band)
Zero stroke length KF [kg] 2.22 3.74 8.5
Per metre of stroke KF [kg] 3.84 4.89 10.32
Zero stroke length RF [kg] 1.92 4.28 –
Per metre of stroke RF [kg] 3.05 4.71 –
2) PWIS = paint-wetting impairment substances
Tab. 5

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13 Characteristic curves
ELFA-KF
Force Fy/Fz and support spacing L with a maximum deflection of 0.5 mm
LL
ELFA-KF-70
ELFA-KF-80
ELFA-KF-120
ELFA-KF-70
ELFA-KF-80
ELFA-KF-120
Fig. 13

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ELFA-RF
Force Fy/Fz and support spacing L with a maximum deflection of 0.5 mm
LL
ELFA-RF-70
ELFA-RF-80
ELFA-RF-70
ELFA-RF-80
Fig. 14

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tion of its contents to others without express authorization is
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registered.
Copyright:
Festo SE & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Internet:
www.festo.com