Festo DDPC User manual

Operating
instructions
8113368
201905b
[8113370]
Standard cylinder
DDPC

DDPC
2Festo – DDPC – 201905b
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 – Standard cylinder DDPC
Table of contents
1 Control sections and connections 4............................................
2 Function and application 4...................................................
3 Transport and storage 5.....................................................
4 Requirements for product use 5...............................................
5 Installation 6..............................................................
5.1 Mechanical installation 6.....................................................
5.2 Pneumatic installation 8.....................................................
5.3 Electrical installation 9.......................................................
6 Commissioning 10...........................................................
7 Operation 11...............................................................
8 Maintenance and care 11.....................................................
9 Disassembly and repair 11....................................................
10 Accessories 12..............................................................
11 Troubleshooting 12..........................................................
12 Technical data 13............................................................

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1 Control sections and connections
For all available product documentation èwww.festo.com/pk
1
2
3
45
6
7
1Supply ports
2Electrical connection of the measuring head
3Measuring head
4Flange screws with threaded holes for
mounting
5Square piston rod with integrated magnetic
measuring tape
6Centring collar
7Earth terminal
Fig. 1
2 Function and application
When the supply ports are pressurised alternately, the piston rod of the DDPC standard cylinder moves
in and out. The standard cylinder features an integrated, incremental displacement encoder. There is a
magnetic tape in the piston rod. A sensor in the bearing cap converts the magnetic pulses of the mag
netic tape into electric signals.
The DDPC has been designed for transporting work masses. The integrated measuring system has been
designed for monitoring the piston position in combination with a positioning controller from Festo
(e. g.B. CPX-CMPX, CPX-CMAX, SPC200, SPC11 “Soft Stop”) or for use as a measuring cylinder with
CPX-CMIX or DADE.
The DDPC is not intended for manufacturing processes which are sensitive to copper or PTFE.

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3 Transport and storage
 Take into account the weight of the DDPC.
Depending on the design, the DDPC weighs over 10 kg.
 The following should be observed with regard to storage:
– short storage times
– cool, dry, UV and corrosion resistant
– no influence from magnetic fields
4 Requirements for product use
Note
Special conditions apply to the electronic regulation of the DDPC:
 Note the warnings and instructions in the descriptions of the positioning controller.
Note
Improper handling can result in malfunctions.
 Make sure that the specifications contained in this chapter are adhered to at all
times.
This is the only way to ensure correct and safe product behaviour.
 Take into consideration the legal regulations applicable for the destination, as well as:
– regulations and standards,
– regulations of the testing organizations and insurers,
– national specifications.
 Note the warnings and instructions on the product and in the relevant operating instructions.
 Remove all of the transport packaging such as transparencies, caps and cartons
(with the exception of any covers in the pneumatic ports).
The material used in the packaging is intended for recycling
(exception: oil paper = residual waste).
 Observe the local regulations for environmentally friendly waste management of electronic compon
ents.
 Take into account the material specifications (èTechnical data).
 Use the product in its original status, without any unauthorised product modifications.
 Take 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.
 Compare the limit values specified in these operating instructions with your actual application
(e. g. pressures, forces, torques, temperatures, masses, speeds, etc.).
Operation of the product in compliance with the relevant safety regulations is contingent on adher
ence to the load limits.
 Take the tolerance of the tightening torques into account. Unless otherwise specified, the tolerance
is ±20 %.

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 Make sure the compressed air is properly prepared (èTechnical data).
 Maintain the selected medium for the total service life of the product.
Example: Always use non-lubricated compressed air.
 Pressurize your entire system slowly. There will then be no uncontrolled movements.
For slow start-up pressurisation, use start-up valve type HEL (èAccessories).
5 Installation
5.1 Mechanical installation
 Check the application of the DDPC:
– as a measuring cylinder
– with electronic control
Note
If the DDPC is used with electronic control:
 Use the DDPC only in the approved mounting positions
(èdrive-specific information on the positioning controllers).
 To install the mechanical system, please observe the instructions in the descriptions
of the positioning controller.
 Make sure that tubing and connection accessories have sufficient space for movement.
If the cylinders are arranged parallel:
 Take the following minimum space requirements into account. Otherwise the magnetic fields of the
two cylinders will influence each other and lead to evaluation faults in the measuring system.
Parallel assembly Offset assembly
Bearing cap flush (Y = 0) Bearing cap offset (Y >0)
Cable outlet between the
cylinders
Cable outlet not between the
cylinders
No minimum distance Minimum distance X 70 mm Minimum distance X 60 mm
Tab. 1

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In the case of direct fastening or use of mounting accessories in each case with cylinder collar hole
milling:
 Select a mounting option (e.g. from the following table).
Double screw connection with HNC foot
mounting in the threaded holes of the cover
screws
Quadruple screw connection with FNC flange
mounting in the threaded holes of the cover
screws
Tab. 2
 Tighten the mounting screws evenly.
The different product sizes have the following connecting threads and tightening torques:
Size 80 100
Connecting thread M10 M10
Tightening torque [Nm] 10 + 2 10 + 2
Tab. 3
If accessories are mounted on the piston rod:
 Use the following elements:
– only the thread of the piston rod.
– the square piston rod 5for counter pressure
(only in the retracted end position).
The maximum torque on the bearing must not exceed 5 Nm.
Fig. 2
5
– an external guide for the work load.
This will prevent lateral loads on the piston rod.
Lateral loads produce false measurement results and may
damage the measuring system.
Fig. 3

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When using additional proximity sensors:
 Place the proximity switches in the fastening grooves.
 Use slot covers over the grooves to fasten the cables and pro
tect them against dirt (èAccessories).
Fig. 4
5.2 Pneumatic installation
 Remove the covers from the compressed air supply ports.
 Connect the tubing of the DDPC to the supply ports 1
(èAccessories).
If the DDPC is used as a measuring cylinder:
 Screw the one-way flow control valves GRLZ or GRLA directly
into the relevant supply ports (èAccessories).
One-way flow control valves enable the speed to be set.
Fig. 5
If the DDPC is used with electronic control:
Note
 Observe the installation instructions and information specified especially for the
DDPC in the descriptions for the positioning controller.
 Use a proportional directional control valve for controlling the
DDPC (èAccessories).
The proportional directional control valve in conjunction with
the controller electronics creates the desired movement by
means of the differential pressure on the two piston surfaces.
Fig. 6

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5.3 Electrical installation
 Avoid external influences by magnetic or ferritic parts in the
vicinity of the measuring head (approx. 100 mm).
 Insert the screw with cutting thread supplied into the hole for
the earth terminal 7.
This ensures electrical contact is established in spite of the
anodising layer.
 Connect the earth cable with low impedance (short cable with
large cross-sectional area) to the earth potential.
Fig. 7
7
If the DDPC is used with electronic control:
 Connect the measuring system to the connecting cable as described in the descriptions for the posi
tioning controller.
If the DDPC is used as a measuring cylinder:
 Connect the measuring system as follows:
Pin Function Cable colour Pin allocation (M12-plug,
A-coding, plug view)
15 V black
2GND brown
3 sin+ red
4 sin– orange
5 cos– green
6 cos+ yellow
7 Screening Screening
8n. c. –
Tab. 4

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6 Commissioning
Warning
Injury to people and damage to property.
Fast moving parts can cause injury to people in the
vicinity of the DDPC.
 Make sure that nobody can place his/her hand
in the positioning range of the effective load
(e. g. by means of a protective guard). If the
DDPC is protected correctly, it should not be
possible to gain access to it until it has come to
a complete stand.
 Make sure no objects project into the position
ing range of the effective load.
Fig. 8
If the DDPC is used as a measuring cylinder:
 Observe the commissioning instructions for the measuring signal amplifier used.
1. Push the piston rod at first into a mechanical end position.
2. Screw the one-way flow control valves into both supply ports
– at first completely (delivery status)
– then one rotation open again.
3. Slowly pressurise the supply port of the mechanical end position.
4. Start a test run.
5. Unscrew the one-way flow control valves until the desired speed is reached.
6. End the test run.
If the DDPC is used with electronic control:
Note
Special commissioning regulations apply to the electronic control of the DDPC.
 Complete the commissioning procedure in accordance with the descriptions for the
positioning controller.
 Start a test run (at permiss. minimum pressure).
 Check to see if the settings on the DDPC or on the controller need to be modified:
– Reference stop
– Speed
– Switching points
– Motion sequence.
 End the test run.

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7 Operation
Warning
Injury to people and damage to property.
Fast moving parts can cause injury to people in the
vicinity of the DDPC.
 Make sure that nobody can place his/her hand
in the positioning range of the effective load
(e. g. by means of a protective guard). If the
DDPC is protected correctly, it should not be
possible to gain access to it until it has come to
a complete stand.
 Make sure no objects project into the
positioning range of the effective load.
Fig. 9
8 Maintenance and care
 Do not modify the settings of screws and threaded pins if there is no request to do so in these
instructions.
In this way you will prevent damage to the cylinder at a later stage.
Cleaning:
 Clean the outside of the DDPC with a soft cloth.
The following cleaning agents are permitted:
– Soap suds (max. +60 °C)
– Petroleum ether
– Any gentle detergent.
9 Disassembly and repair
On disassembly:
Warning
Injury to people and damage to property.
There is a danger of injury caused by pressure
forces which can eject the sensor if the connecting
screws are loosened under pressure.
 Make sure that the following energy sources
are switched off:
– Operating voltage
– Compressed air (drive exhausted on both
sides).
The sensor projects into the pressure
chamber of the DDPC. Fig. 10

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Replacing the sensor:
1. Unscrew the fastening screws.
2. Replace the sensor.
Note here the mechanical coding on the sensor housing and make sure that the seal is seated cor
rectly.
3. Screw the fastening screws in again.
The tightening torque is 0.6 Nm.
Recommendation:
 Return the product to our repair service for overhaul.
This way the required fine tuning and tests will be taken into special consideration.
 Information about spare parts and aids can be found at: www.festo.com/spareparts
10 Accessories
Note
 Please select the accessories you need from our catalogue
(èwww.festo.com/catalogue).
11 Troubleshooting
Malfunction Possible cause Remedy
Malfunction in
position sensing
Strong external magnetic fields Eliminate external magnetic fields
(e. g. by means of screening plates)
Environmental influences outside the
specifications
Observe the specifications
Magnetic strip in the piston rod
polarized due to strong magnetic fields
Send to Festo with a description of the
fault
Mounting fault when sensor is replaced Check the correct position of the
sensor coding nose in the cylinder
In combination
with positioning
controllers
See detailed description of the relevant positioning controller
Hard impact at
the end positions
Mass too large Reduce accelerated work mass
Excessive speed Reduce speed. Brake additionally with
work valves
Insufficient cushioning Use external cushioning elements
Tab. 5

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12 Technical data
Size 80 100
Design Double-acting standard cylinder with integrated
displacement encoder
Mounting position as desired (as measuring cylinder and for
positioning)
vertical (with Soft Stop)
Operating medium Compressed air to ISO 8573-1:2010 [6:4:4]
Note on operating/pilot medium The pressure dew point must be at least 10 degrees
below the ambient and media temperature.
Operating pressure [bar] 12 (as measuring cylinder)
[bar] 4 … 8 (for positioning / with Soft Stop)
Pneumatic connection G3/8 G1/2
Ambient temperature [°C] –20 … +80
Theoretical force at 6 bar
Return [N] 2721 4418
Advance [N] 3016 4712
Max. torque for protection against rotation
dynamic [Nm] 3
static [Nm] 5
Impact energy at
the end positions
[Nm] 1.8 2.5
Travel speeds as measuring cylinder1)
minimum [m/s] 0.05
maximum [m/s] 1
Stroke reduction at the end positions [mm] 25
Repetition accuracy with Soft Stop
end position [mm] 0.5
intermediate position module [mm] ± 2
Displacement resolution
With CASM or DADE [mm] 0,005
With SPC11 or SPC200 [mm] 0,02
Accuracy of measurement [mm] ± (0,07 mm ± 0,02*L/m)2)
Electrical connection Cable with plug, round form, M12, 8-pin, A-coding
Cable length [m] 1.5 (max. 30 m)
Output signal analogue
Protection class to IEC 60529 IP65
1) Higher speeds can be reached in combination with positioning controllers (see descriptions for the positioning controllers)
2) L = Length of measuring system in meters

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Size 10080
Vibration resistance in accordance
with IEC 68, Part 2-6
0.35 mm travel at 10 … 60 Hz,
5 g acceleration at 60 … 150 Hz
Continuous shock resistance in
accordance with IEC 68 Part 2-82
± 30 g at 11 ms duration;
5 shocks per direction
CE marking (see declaration of conformity)3)
èwww.festo.com/sp
In accordance with EU EMC Directive
Information on materials
Cover Wrought aluminium alloy
Seals Nitrile rubber, polyurethane
Cable sheath Polyurethane
Piston rod High-alloy steel
Screws Steel
Sensor cover Aluminium
Sensor head Polyacetal
Plug housing Polyester
Cylinder barrel Wrought aluminium alloy
Basic weight with 0 mm stroke [g] 3053 4330
Additional weight per 10 mm stroke [g] 87 95
3) The device is intended for use in an industrial environment. Outside of industrial environments, e.g. in commercial and mixed-res
idential areas, actions to suppress interference may have to be taken.
Tab. 6

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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
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Copyright:
Festo SE & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Internet:
www.festo.com