Festo ELGA-BS-KF-70 Setup guide

Repair
instructions
(en)
Spindle axis
ELGA-BS-KF-...
7ELGA-BS-KFa_en

2 / 54 Festo 7ELGA-BS-KFa_en
Imprint
Version:
7ELGA-BS-KFa_en (12.2017)
Copyright:
©Festo AG & Co. KG
Postfach
73726 Esslingen
Germany
Editorial team:
Spare Part Documentation and
Support
Phone:
+49 / 711 / 347-0
Fax:
+49 / 711 / 347-2144
Email:
[email protected]
Internet:
http://www.festo.com
Reproduction, distribution or sale of
this document or communication of
its contents to others without express
authorisation is prohibited. Offenders
will be held liable for damages. All
rights reserved in the event that a
patent, utility model or design patent
is registered.
All product designations and brand
names used are the property of the
owners and not explicitly identied
as such.
All technical data are subject to
change according to technical
updates.

3 / 54Festo 7ELGA-BS-KFa_en
Foreword
These repair instructions are valid for the spindle axis listed on the title page to
the exclusion of any liability claims.
Differences compared to the descriptions in these repair instructions may arise
depending on the design and/or modication status of the spindle axis. The
user must check this prior to carrying out the repair and take the deviations into
consideration if necessary.
These repair instructions have been prepared with care.
Festo AG & Co. KG does not, however, accept liability for any errors in these
repair instructions or their consequences. Likewise, no liability is accepted for
direct or consequential damage resulting from incorrect use of the products.
Further information is given in Chapter 9 on page 53.
The relevant regulations on occupational safety, safety engineering, and
interference suppression as well as the stipulations contained in these repair
instructions must be observed when working on the products.

4 / 54 Festo 7ELGA-BS-KFa_en
Table of Contents
1 Important information 6
1.1 About these repair instructions 6
1.2 Symbols used in these repair instructions 6
1.3 Text designations used in these repair instructions 7
1.4 General safety instructions 7
1.5 Technical requirements 8
1.6 Standards and test values 8
2 General product description 9
2.1 Functional description 9
2.1.1 ELGA-BS-KF-…-ML 9
2.2 Sizes and part numbers 9
2.3 Slide variants and orientation denition 10
2.4 Type code 10
3 Component overviews and bill of materials 11
3.1 ELGA-BS-KF-70-…-ML components overview 12
3.1.1 ELGA-BS-KF-70-...-ML bill of materials 13
3.2 ELGA-BS-KF-80-…-ML components overview 14
3.2.1 ELGA-BS-KF-80-...-ML bill of materials 15
3.3 ELGA-BS-KF-120-…-ML components overview 16
3.3.1 ELGA-BS-KF-120-...-ML bill of materials 17
3.4 ELGA-BS-KF-150-…-ML components overview 18
3.4.1 ELGA-BS-KF-150-…-ML bill of materials 19
4 Repair steps 20
4.1 Preparatory steps 20
4.2 Visual inspection 21
4.3 Dismantling the spindle axis 21
4.3.1 Removing the cover band 21
4.3.2 Removing the bearing cap, bearing block and spindle assembly with slide module 22
4.3.3 Disconnecting the retainer or retainer module with spindle assembly from the slide module23
4.3.3.1 ELGA-BS-KF-70 / 80 23
4.3.3.2 ELGA-BS-KF-120 / 150 26
4.3.4 Replacing the retainer or retainer module 28
4.3.5 Checking and replacing the roller bearing and the spindle assembly 29
4.3.5.1 Checking and replacing the roller bearing with seat in the bearing block 29
4.3.5.2 Checking and replacing the deep-groove ball bearing with seat in the bear-
ing cap 30
4.3.5.3 Checking and replacing the spindle assembly 31
4.4 Mounting the spindle axis 32
4.4.1 Greasing during assembly 32
4.4.2 Mounting the retainer or retainer module with spindle assembly on the slide module 32
4.4.3 Mounting the roller carriages 34
4.4.3.1 ELGA-BS-KF-70 / 80 35
4.4.3.2 ELGA-BS-KF-120 / 150 37
4.4.4 Relubricating the recirculating ball bearing guide 41
4.4.5 Assembling the spindle axis 41
4.4.6 Mounting the cover band 43

5 / 54Festo 7ELGA-BS-KFa_en
Table of Contents
4.5 Replacing the buffers or buffer elements 44
4.5.1 Replacing the buffers or buffer elements in the bearing block and in the bearing cap 44
4.5.2 ELGA-BS-KF-150 only – Replacing the buffers in the slide module 45
4.5.2.1 Replacing the buffers which touch the bearing block 45
4.5.2.2 Replacing the buffers that touch the bearing cap 45
4.6 Replacing the measuring tape of the incremental displacement encoder 46
4.6.1 Remove the old measuring tape 46
4.6.2 Sticking on the new measuring tape 46
5 Assembly and functional test 49
5.1 No-load torque 49
5.2 Start-up 49
6 Cleaning 50
7 Maintenance 50
7.1 Check the reversing backlash 50
7.2 Checking the cover band 50
7.3 Relubricating the spindle axis 50
7.4 Relubricating the roller carriage and spindle assembly 51
8 Tools 52
8.1 Standard tools 52
8.2 Special tools 52
9 Liability 53

6 / 54 Festo 7ELGA-BS-KFa_en
1 Important information
1.1 About these repair instructions
This document contains important information about professional repair of the spindle axis type ELGA-BS-KF.
However, the costs of carrying out a repair must be considered in the case of larger defects.
Before carrying out a repair, the relevant chapter in these instructions must be read in full and followed consistently.
For reasons of clarity, these repair instructions do not contain all detailed information. The following documents should
therefore also be available when repairing the spindle axis:
– Operating instructions
Contains information about the installation and removal of the motor, motor ange, coupling and coupling housing of
the ELGA-BS-KF spindle axis and its function, structure, use, installation, commissioning, maintenance and care, etc.
It can be found on the Festo website (www.festo.com).
– Spare parts documentation
Contains an overview of the spare and wearing parts as well as information on their installation. This can be found in
the online spare parts catalogue on the Festo website (www.festo.com/spareparts).
– Information brochure – accessories, equipment and tools
Contains an overview of the available installation resources, e.g. lubricating greases, threadlocking agents,
maintenance tools, etc. (resources for installation and maintenance). The brochure can be found in the online spare
parts catalogue on the Festo website (http://spareparts.festo.com/xdki/data/SPC/0/PDF_SAFE/Fitting%20
aids.pdf).
1.2 Symbols used in these repair instructions
Danger categories
The following symbols identify text passages which draw attention to specic hazards.
Danger
Warning
Caution
Marking special information
The following symbols identify text passages which contain special information.
Note
Information
Environment

7 / 54Festo 7ELGA-BS-KFa_en
1.3 Text designations used in these repair instructions
• Activities that can be carried out in any order.
.1 Activities which should be carried out in the specied order.
– General lists.
Reference to further information.
Underlined, blue text indicates a cross-reference or hyperlink that you can click on in the PDF.
1.4 General safety instructions
Danger
Risk of fatal injury due to electric shock and uncontrolled movement of components.
– The spindle axis must be de-energised, depressurised and reliably secured against unauthorised switching back
on again before the maintenance and repair work begins.
Caution
The spindle axis may only be repaired by authorised and trained persons in accordance with the specications in the
technical documentation and using original spare parts.
Installation and repair by unauthorised and untrained persons, repairs using non-original spare parts or without the
technical documentation required for installation and/or repair are dangerous and therefore not permitted.
Repairs must only be carried out in conjunction with these repair instructions and the respective operating
instructions for the device, as well as the documents listed in Chapter 1.1 on page 6.
Caution
Lifting large loads can lead to permanent injury.
– The spindle axis must be lifted by several people or with suitable lifting gear, depending on its size and weight.
Caution
Unintended switching on can trigger unexpected movements and cause bruises.
– Ensure that the unit is protected against restarting before any modication or maintenance work or inspections
are carried out. Loosened parts can make unexpected movements or fall off.
– Secure parts against accidental movements or move them into a safe end position.
Note
Observe the given tightening torques. If no special information is given the tightening torques given in the relevant
standard apply to the screws, bolts and nuts used.
Note the strength class of the screws, bolts and nuts!
Festo recommends use of LOCTITE 243 thread locking agent.
In the event of damage caused by unauthorised manipulation, improper use or use of non-original spare parts, all
warranty and liability claims against the manufacturer expire.

8 / 54 Festo 7ELGA-BS-KFa_en
Instead of carrying out the repair yourself, your local Festo sales ofce offers the option of having the repair carried
out by Festo.
Components and equipment replaced during repair must be disposed of in accordance with the relevant local
environmental protection regulations.
1.5 Technical requirements
Note
The following instructions for safe and proper use must be observed:
– Observe the connection and ambient conditions specied in the technical data of the products and all the
connected components. The product can only be operated in compliance with the relevant safety guidelines if you
comply with the limit values and load limits (see enclosed documentation).
– The spindle axis gantries must be in faultless technical condition.
– The spindle axis may only be operated in its original condition and without unauthorised modications.
– The spindle axis is designed for industrial use.
1.6 Standards and test values
Standards and test values which products comply with and full can be found in the “Technical data” sections of the
enclosed documentation.

9 / 54Festo 7ELGA-BS-KFa_en
2 General product description
2.1 Functional description
The ELGA-BS-KF is a spindle axis, which is designed for movements with large forces and precise repetition accuracy.
A rotating ball screw converts the rotational movement of a motor into linear motion. This causes the piston to move
backwards and forwards. The mechanics of the spindle axis are not automatically locking. After the input torque is
removed the slide module can move freely. The ELGA-BS-KF is approved for slide and yoke operation.
2.1.1 ELGA-BS-KF-…-ML
145 6 972 38 aJ aA
aD
aC
aB
aE
1Bearing block
2Cover band
3Belt reversal, top
4Belt reversal, bottom
5Spindle nut
6Retainer or retainer module
7Slide module
8Lubrication nipple
9Displacement encoder
aJ Bearing cap
aA Sealing air connections,
not visible
aB Cylinder barrel
aC Spindle assembly
aD Roller carriage
aE Roller track
2.2 Sizes and part numbers
Size Part number
ELGA-BS-KF-70-…-ML 8024918
ELGA-BS-KF-80-…-ML 8024919
ELGA-BS-KF-100-…-ML 8024920
ELGA-BS-KF-150-…-ML 8024921
The complete overview of features, accessories, type
codes, technical data and dimensions of the ELGA-BS-KF
spindle axes can be found in the product catalogue or on
the Festo website (www.festo.com).

10 / 54 Festo 7ELGA-BS-KFa_en
2.3 Slide variants and orientation denition
This illustration gives you an overview of the mounting designations of the spindle axis.
Lubrication nipple = reference point
(The side with the lubrication nipples
on the slide module is dened as the
front).
O = top
U = bottom
R = right
L = left
V = front
H = rear
2.4 Type code
The precise features of a toothed belt axis can be determined with the help of the product labelling on the toothed belt
axis. The order code describes the features of the toothed belt axis, separated by a hyphen “-”.
Example:
ELGA-BS-KF-80-500-30H-20P-ML-M1-F
8024919 HD13
ABCDEFG12345
5
4
1
2
3
1Order code
2Part number
3Serial number
4Product Key
5Product Key Code
Data Matrix Barcode
(http://pk.festo.com/ + Product Key)
The order code on the product labelling provides the following information:
ELGA ELGA type spindle axis
BS Ball screw
KF Recirculating ball bearing guide
80 Size
500 Stroke [mm]
30H Stroke reserve [mm]
20P Spindle pitch, 20 mm / spindle rotation
ML Motor attachment position, left-hand side
M1 Incremental displacement encoder, resolution 2.5 μm
F Displacement encoder attachment position, front

11 / 54Festo 7ELGA-BS-KFa_en
3 Component overviews and bill of materials
The component overviews with corresponding bills of materials for the following spindle axes are listed on the following
pages:
Size Part number Components list Bill of materials
ELGA-BS-KF-70-…-ML 8024918 Chapter 3.1 on page 12 Chapter 3.1.1 on page 13
ELGA-BS-KF-80-…-ML 8024919 Chapter 3.2 on page 14 Chapter 3.2.1 on page 15
ELGA-BS-KF-100-…-ML 8024920 Chapter 3.3 on page 16 Chapter 3.3.1 on page 17
ELGA-BS-KF-150-…-ML 8024921 Chapter 3.4 on page 18 Chapter 3.4.1 on page 19
The following diagrams are intended only to provide an overview of the individual components. To order spare and
wearing parts, please use the online spare parts catalogue on the Festo website (www.festo.com/spareparts).

12 / 52 Festo 7ELGA-BS-KFa_en
3.1 ELGA-BS-KF-70-…-ML components overview

13 / 52Festo 7ELGA-BS-KFa_en
No. Designation, type
1 Socket head screw, DIN 912-M4×25-8.8
2 Hex nut, DIN 985-M8×1-8
3 Deep-grooved ball bearing, DIN 625-629-2RS
4 Bearing block
5 Grub screw, DIN 913-M5×6-45H
6 Buffer element
7 Cylinder barrel
8 Roller track
9 Socket head screw, F-M4×5.5-10.9
10 Adhesive tape
11 Magnetic strip
12 Cover band
13 Slot nut
14 Slot nut
15 Slot nut
16 Measuring tape
17 Slot nut
18 Measuring tape cap
19 Countersunk screw, DIN 965-M3×8-4.8-H
20 Cap
21 Socket head screw, DIN 912-M4×16-8.8
22 Spindle assembly
23 O-ring, 3×1-N-NBR70
24 Retainer
25 Socket head screw, DIN 912-M4×45-8.8
26 Roller carriage
27 O-ring, ISO 3601-B-1.5×1-N-NBR70
28 Lubricating channel
29 Lubricating channel
30 Socket head screw, DIN 912-M3×5-8.8
31 Lubricating head
32 O-ring, 3×1-N-NBR70
33 Lubricating head module
34 Clip
35 Socket head screw, DIN 6912-M4×6-A2-70
36 End cap
37 Belt reversal
No. Designation, type
38 Socket head screw, DIN 912-M3×20-10.9
39 Centring pin, ZBS-5
40 Slide module
41 Lubrication nipple, D1 M3
42 Socket head screw, DIN 912-M4×14-10.9
43 Washer, DIN 7349-4.3
44 Sensor bracket
45 Sensor mounting
46 Retaining washer, S-4
47 Socket head screw, DIN 912-M4×8-8.8
48 Sensor bracket
49 Measuring unit
50 Measuring unit
51 Bearing cap
52 Sealing plug, G1/8-AL-SA
53 Deep-groove ball bearing, F-698-2RS
54 Retaining ring, DIN 471-8×0.8
55 Lubricating grease LUB-KC1, silicone free
56 Screw locking agent, LOCTITE-243
3.1.1 ELGA-BS-KF-70-...-ML bill of materials

14 / 52 Festo 7ELGA-BS-KFa_en
3.2 ELGA-BS-KF-80-…-ML components overview

15 / 52Festo 7ELGA-BS-KFa_en
3.2.1 ELGA-BS-KF-80-...-ML bill of materials
No. Designation, type
1 Socket head screw, DIN 912-M5×30-8.8
2 Slotted nut, GUK 10×0.75
3 Angular ball bearing, DIN 628-7200-B-2RS
4 Bearing block
5 Grub screw, DIN 915-M6×8-45H
6 Buffer element
7 Cylinder barrel
8 Roller track
9 Socket head screw, DIN 912-M4×7-12.9
10 Adhesive tape
11 Magnetic strip
12 Cover band
13 Slot nut
14 Slot nut
15 Slot nut
16 Measuring tape
17 Slot nut
18 Measuring tape cap
19 Countersunk screw, DIN 965-M3×8-4.8-H
20 Cap
21 Socket head screw, DIN 912-M5×22-10.9
22 Spindle assembly
23 O-ring, 3×1-N-NBR70
24 Retainer module
25 Socket head screw, DIN 912-M5×45-10.9
26 Roller carriage
27 O-ring, ISO 3601-B-1.5×1-N-NBR70
28 Lubricating channel
29 Lubricating channel
30 Socket head screw, DIN 912-M3×5-8.8
31 Lubricating head
32 O-ring, 3×1-N-NBR70
33 Lubricating head module
34 Clip
35 Socket head screw, DIN 6912-M4×6-A2-70
36 End cap
37 Belt reversal
No. Designation, type
38 Socket head screw, DIN 912-M3×25-12.9
39 Centring pin, ZBH-9
40 Slide module
41 Lubrication nipple, D1 M3
42 Socket head screw, DIN 912-M4×14-10.9
43 Washer, DIN 7349-4.3
44 Sensor bracket
45 Sensor mounting
46 Retaining washer, S-4
47 Socket head screw, DIN 912-M4×8-8.8
48 Sensor bracket
49 Measuring unit
50 Measuring unit
51 Bearing cap
52 Sealing plug, G1/8-AL-SA
53 Deep-groove ball bearing, F-698-2RS
54 Retaining ring, DIN 471-8×0.8
55 Lubricating grease LUB-KC1, silicone free
56 LOCTITE 243 screw locking agent

16 / 52 Festo 7ELGA-BS-KFa_en
3.3 ELGA-BS-KF-120-…-ML components overview

17 / 52Festo 7ELGA-BS-KFa_en
3.3.1 ELGA-BS-KF-120-...-ML bill of materials
No. Designation, type
1 Socket head screw, DIN 912-M6×40-10.9
2 Slotted nut, GUK 16×1
3 Angular ball bearing, DIN 628-7203-B-2RS
4 Bearing block
5 Grub screw, DIN 915-M6×12-45H
6 Buffer
7 Cylinder barrel
8 Roller track
9 Socket head screw, DIN 912-M5×14-12.9
10 Adhesive tape
11 Magnetic strip
12 Cover band
13 Slot nut
14 Slot nut
15 Slot nut
16 Measuring tape
17 Slot nut
18 Measuring tape cap
19 Countersunk screw, DIN 965-M3×8-4.8-H
20 Cap
21 Socket head screw, DIN 912-M6×20-10.9
22 Spindle assembly ML
23 O-ring, 3×1-N-NBR70
24 Retainer
25 Socket head screw, DIN 912-M6×60-10.9
26 Roller carriage
27 Socket head screw, DIN 912-M5×20-10.9
28 Barbed L-tting, LCN-M5-PK-2
29 Flange screw, F-M4×10-A-70
30 Fittings kit
31 Clip
32 Socket head screw, DIN 6912-M5×6-A2-70
33 End cap
34 Belt reversal
35 Slide module
36 Centring sleeve, ZBH-9
37 Lubrication nipple, DIN 3405-AM 6
No. Designation, type
38 Socket head screw, DIN 912-M4×14-10.9
39 Washer, DIN 7349-4.3
40 Sensor bracket
41 Sensor mounting
42 Retaining washer, Böllhoff-53070-S5-A1
43 Socket head screw, DIN 912-M5×10-10.9
44 Sensor bracket
45 Measuring unit
46 Measuring unit
47 Bearing cap
48 Sealing plug, G1/8-AL-SA
49 Deep-groove ball bearing, XF+DIN 625-6200-2RS
50 Retaining ring, DIN 471-10×1
51 Lubricating grease LUB-KC1, silicone free
52 LOCTITE 243 screw locking agent

18 / 52 Festo 7ELGA-BS-KFa_en
3.4 ELGA-BS-KF-150-…-ML components overview

19 / 52Festo 7ELGA-BS-KFa_en
3.4.1 ELGA-BS-KF-150-…-ML bill of materials
No. Designation, type
1 Socket head screw, DIN 912-M8×60-10.9
2 Slotted nut, GUK 30×1.5
3 Angular ball bearing, DIN 628-7206-B-2RS
4 Bearing block
5 Grub screw, DIN 915-M6×12-45H
6 Buffer
7 Cylinder barrel
8 Roller track
9 Socket head screw, DIN 912-M6×20-12.9
10 Adhesive tape
11 Magnetic strip
12 Cover band
13 Slot nut
14 Slot nut
15 Slot nut
16 Measuring tape
17 Slot nut
18 Measuring tape cap
19 Countersunk screw, DIN 965-M3×8-4.8-H
20 Cap
21 Socket head screw, DIN 912-M8×30-10.9
22 Spindle assembly ML
23 O-ring, ISO 3601-B-5×1,5-N-NBR75
24 Retainer module
25 Socket head screw, DIN 912-M8×70-10.9
26 Socket head screw, DIN 912-M8×118-10.9
27 Socket head screw, DIN 912-M6×20-10.9
28 Roller carriage
29 Reducer, M6-M3-SW8
30 Barbed L-tting, LCN-M3-PK-2-B
31 Flange screw, F-M4×10-A-70
32 Fittings kit
33 Clip
34 Socket head screw, DIN 6912-M5×6-A2-70
35 End cap
36 Belt reversal
37 Centring sleeve, ZBH-9
No. Designation, type
38 Slide module
39 Lubrication nipple, DIN 3405-AM 6
40 Socket head screw, DIN 912-M4×14-10.9
41 Washer, DIN 7349-4.3
42 Sensor bracket
43 Sensor mounting
44 Retaining washer, Böllhoff-53070-S5-A1
45 Socket head screw, DIN 912-M5×10-10.9
46 Sensor bracket
47 Measuring unit
48 Measuring unit
49 Bearing cap
50 Sealing plug, G1/8-AL-SA
51 Deep-groove ball bearing, XF+DIN 625-6005-2RS
52 Retaining ring, DIN 471-25×1.2
53 Socket head screw, DIN 912-M8×50-8.8
54 Lubricating grease LUB-KC1, silicone free
55 LOCTITE 243 screw locking agent

20 / 54 Festo 7ELGA-BS-KFa_en
4 Repair steps
Where possible, it is advisable to dismantle the spindle axis from the system entirely before carrying out the repair.
Before starting the repair, dismantle any attachment components in accordance with the instructions in the
corresponding operating instructions.
Keep your working environment clean and tidy.
Before dismantling the spindle axis the cause of the failure must be investigated to prevent repeated and premature
failure. A spindle axis that has been used as intended will not normally show any signs of premature failure.
This investigation is not necessary in the case of non-premature failure (fatigue time). However, the condition of the
spindle axis (general condition, etc.) must always be checked.
In case of uncertainty, we recommend replacing all the components mentioned to rule out reciprocal effects during later
operation.
In the event of premature failure of the spindle axis the operating conditions should be examined more closely.
The following possibilities should be considered, among other things:
– Overloading
• In case of overloading, the application parameters (load, speed) should be adjusted accordingly.
– Ambient conditions/material resistance
• Check whether the ambient temperature is within the permissible range.
• Check the chemical and physical ambient conditions for harmful substances, such as dust, abrasive particles,
cooling lubricants, solvents, ozone, radiation, water-soluble substances, greases and oils, etc.
Note
The repair should preferably be carried out on a stable and at work surface with storage for small parts.
To prevent damage to the roller track and other components, do not use pointed or sharp-edged assembly tools.
Depending on the model, the attachment position of the motor for the ELGA-BS-KF spindle axis can either be on the
left or the right-hand side.
The repair steps in these repair instructions only consider the left-hand motor attachment position.
The ELGA-BS-KF-…-MR spindle axis (right-hand motor mounting) differs from the ELGA-BS-KF-…-ML spindle axis (left-
hand motor mounting) only in that, for the right-hand motor attachment position, the bearing block is on the right and
the bearing cap is on the left and the corresponding spindle assembly MR (right-hand motor mounting) is installed.
4.1 Preparatory steps
Danger
Risk of fatal injury from electric shock.
The control of the drive motors is still charged after the voltage has been switched off (capacitor voltage). As such, you
must wait approx. 3 minutes after switching off the voltage before the motor cables can be removed. The capacitors
discharge their voltage during this time.
1. Disconnect the spindle axis from the power supply and secure it from being switched on again accidentally.
2. Remove the motor and encoder cables.
3. Dismantle the motor, axial kit or parallel kit.