Festo DFPI-ND2P Series Repair Instructions
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Festo DFPI-ND2P Series Repair Instructions

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Linear actuator
DFPI-...-ND2P
Repair
instructions
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7DFPIb_en

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Summary of Contents for Festo DFPI-ND2P Series

  • Page 1 Linear actuator DFPI-…-ND2P Repair instructions (en) 7DFPIb_en...
  • Page 2 Editorial information Version: 7DFPIb_en (06.2015) Copyright: ©Festo AG & Co. KG Postfach 73726 Esslingen Germany Editorial team: PM-SD Tel.: +49 (0) 711 / 347-0 Fax: +49 (0) 711 / 347-2144 E-mail: service_international@festo.com Internet: http://www.festo.com The reproduction, distribution or sale of this document or communication of its contents to others without express authorisation is prohibited.
  • Page 3 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.

  • Page 4: Table Of Contents

    4.7.1 Replacing the displacement encoder 4.7.2 Replacing the driver board with the input board 4.7.3 Replacing the valve block Fitting the end cap module Assembling the linear actuator 4.9.1 Connecting supply lines to the linear actuator 4 / 55 Festo 7DFPIb_en...
  • Page 5 Table of contents Troubleshooting DFPI-ND2P-C1V-…-A DFPI-ND2P-G2 Cleaning and greasing Cleaning Greasing 6.2.1 Definition of terms Maintenance and care Tools Standard tools Equipment and measuring devices Liability Festo 7DFPIb_en 5 / 55...

  • Page 6: Important Information

    – 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 (http://spareparts.festo.com). – Assembly aids Contains an overview of available assembly aids such as lubricating greases, thread locking agents, maintenance tools, etc.

  • Page 7: Text Markings Used In These Repair Instructions

    Repairs must only be carried out in conjunction with these repair instructions as well as the respective operating instructions for the device. Instead of carrying out the repair yourself, your local Festo sales office offers the option of having the repair carried out by Festo.

  • Page 8: Qualification Of Specialised Personnel

    1 Bearing cap 2 Piston rod seal 3 Cylinder barrel 4 Piston rod 5 Piston 6 Magnet holder 7 Intermediate cap 8 End cap 9 Housing (-P variants only) aJ Valve block 8 / 55 Festo 7DFPIb_en...

  • Page 9: Types And Part Numbers

    Type code The precise features of a linear actuator can be determined with the help of the rating plate. The type code is located directly beneath the Festo logo and provides the linear actuator's features, separated by hyphens (-). Example 1:...

  • Page 10: Production Series

    Retracted piston safety position (no specification indicates advanced safety position) A list and description of all the equipment features available for the linear actuator can be found in the data sheet, which is available on the Festo website (www.festo.com). Production series The linear actuator type DFPI-…-ND2P is built with 2 different controllers.

  • Page 11: Components List

    Components list DFPI-100/125/160-…-ND2P-C1V-A This diagram is 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 (http://spareparts.festo.com). Festo 7DFPIb_en 11 / 55...
  • Page 12 End cap module Plug Flange receptacle Cable connector Socket head screw DIN 912-M4×14-A2-70 DIN 912-M4×14-A2-70 DIN 912-M4×14-A2-70 Flange receptacle module Lubricating grease LUB-KC1, silicone-free LUB-KC1, silicone-free LUB-KC1, silicone-free Thread locking agent LOCTITE 243 LOCTITE 243 LOCTITE 243 12 / 55 Festo 7DFPIb_en...

  • Page 13: Dfpi-100/125/160

    DFPI-100/125/160-…-ND2P-C1V-A-P This diagram is 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 (http://spareparts.festo.com). Festo 7DFPIb_en 13 / 55...
  • Page 14 DIN 908-G1/ 4A-A2-70 Sealing ring Housing Blanking plug Socket head screw DIN 912-M5×55-A2-70 DIN 912-M5×55-A2-70 DIN 912-M5×55-A2-70 Flange receptacle module Lubricating grease LUB-KC1, silicone-free LUB-KC1, silicone-free LUB-KC1, silicone-free Thread locking agent LOCTITE 243 LOCTITE 243 LOCTITE 243 14 / 55 Festo 7DFPIb_en...
  • Page 15 DFPI-100/125/160-…-ND2P-G2 This diagram is 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 (http://spareparts.festo.com). Festo 7DFPIb_en 15 / 55...
  • Page 16 I 3601 B-55×1.5-N-NBR70 I 3601 B-55×1.5-N-NBR70 I 3601 B-65×1.5-N-NBR70 O-ring Blanking plug Flange receptacle Socket head screws Flange receptacle module Lubricating grease LUB-KC1, silicone-free LUB-KC1, silicone-free LUB-KC1, silicone-free Thread locking agent LOCTITE 243 LOCTITE 243 LOCTITE 243 16 / 55 Festo 7DFPIb_en...
  • Page 17 DFPI-200/250/320-…-ND2P-C1V-A This diagram is 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 (http://spareparts.festo.com). Festo 7DFPIb_en 17 / 55...
  • Page 18 End cap Plug Flange receptacle Cable connector Socket head screw DIN 912-M4×14-A2-70 DIN 912-M4×14-A2-70 DIN 912-M4×14-A2-70 Flange receptacle module Lubricating grease LUB-KC1, silicone-free LUB-KC1, silicone-free LUB-KC1, silicone-free Thread locking agent LOCTITE 243 LOCTITE 243 LOCTITE 243 18 / 55 Festo 7DFPIb_en...

  • Page 19: Dfpi-200/250/320

    DFPI-200/250/320-…-ND2P-C1V-P-A This diagram is 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 (http://spareparts.festo.com). Festo 7DFPIb_en 19 / 55...
  • Page 20 DIN 908-G1/ 4A-A2-70 Sealing ring Housing Blanking plug Socket head screw DIN 912-M5×55-A2-70 DIN 912-M5×55-A2-70 DIN 912-M5×55-A2-70 Flange receptacle module Lubricating grease LUB-KC1, silicone-free LUB-KC1, silicone-free LUB-KC1, silicone-free Thread locking agent LOCTITE 243 LOCTITE 243 LOCTITE 243 20 / 55 Festo 7DFPIb_en...
  • Page 21 DFPI-200/250/320-…-ND2P-G2 This diagram is 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 (http://spareparts.festo.com). Festo 7DFPIb_en 21 / 55...
  • Page 22 I 3601 B-14×2-N-NBR70 Blanking plug Flange receptacle Socket head screw DIN 912-M6×60-A2-70 DIN 912-M6×60-A2-70 DIN 912-M6×60-A2-70 Valve block module Lubricating grease LUB-KC1, silicone-free LUB-KC1, silicone-free LUB-KC1, silicone-free Thread locking agent LOCTITE 243 LOCTITE 243 LOCTITE 243 22 / 55 Festo 7DFPIb_en...

  • Page 23: Repair Steps

    Remove any attachments (e.g. end-position lock adapter on the piston rod, etc.) in accordance with the accompanying operating instructions before starting any repair work. Only use the spare parts and assembly aids (grease, thread locking agent, etc.) provided in the set of wearing parts. Festo 7DFPIb_en 23 / 55...

  • Page 24: Disconnecting Supply Lines From The Linear Actuator

    O-ring or cylinder barrel. Sizes DFPI 100/125/160: 1. Unscrew the self-tapping screws in the bearing cap. 2. Pull the bearing cap forwards, away from the cylinder barrel. 24 / 55 Festo 7DFPIb_en...

  • Page 25: Replacing Bearing Cap Components

    4 Bearing cap 4.3.1 Replacing bearing cap components 1. Remove the small O-ring from the seat in the mounting flange in the bearing cap. 2. Carefully remove the O-ring from the groove in the bearing cap. Festo 7DFPIb_en 25 / 55...
  • Page 26 7. Insert the rod seal into the bearing cap. 8. Apply a light coating of grease to the O-rings. 9. Insert the O-rings into their respective seats. 26 / 55 Festo 7DFPIb_en...

  • Page 27: Repair Steps For The Piston

    (linear potentiometer) that is still in the cylinder barrel, these can only be replaced using a spare parts kit. Further information can be found on the Festo website (http://spareparts.festo.com). In this case, the magnet holder must be removed from the piston rod.

  • Page 28: Replacing The Magnet Holder

    5. Place the magnet holder on the piston rod and tighten to the appropriate torque. Type Tightening torque DFPI-100-…-ND2P- 108 Nm ±10% DFPI-125-…-ND2P- 108 Nm ±10% DFPI-160-…-ND2P- 108 Nm ±10% DFPI-200-…-ND2P- 310 Nm ±10% DFPI-250-…-ND2P- 310 Nm ±10% DFPI-320-…-ND2P- 345 Nm ±10% 28 / 55 Festo 7DFPIb_en...

  • Page 29: Repair Steps For The End Cap Module

    The linear actuator type DFPI-…-ND2P is built with 2 different controllers. The repair steps differ depending on the controller, and are described separately for each controller in these repair instructions; see section 2.5 „Production series“. Festo 7DFPIb_en 29 / 55...
  • Page 30 6. Apply a light coating of grease to the two O-rings of the end cap module. 7. Place the two O-rings in the seats of the end cap module. 8. Unscrew the retaining screws on the sensor plug and separate the plug halves. 30 / 55 Festo 7DFPIb_en...

  • Page 31: Replacing The Displacement Encoder

    2. Loosen the retaining nut on the cable connector and unscrew from the intermediate plate. 3. Remove the displacement encoder from the intermediate plate. The front union nut must also be loosened in order to remove the cable connector from the displacement encoder (linear potentiometer). Festo 7DFPIb_en 31 / 55...

  • Page 32: Replacing The Controller With Electronic Function Module

    If the numbers are no longer legible, mark the pilot lines before detaching them from the valve block. When connecting, make sure that the numbers on the pilot lines match the numbers of the connections on the valve block. 32 / 55 Festo 7DFPIb_en...

  • Page 33: Replacing The Electronic Function Module

    When removing the two plugs from the printed circuit board, make sure that the lines do not kink and the pins on the printed circuit board are not bent or torn off. 1. Disconnect the top and bottom plugs. 2. Unscrew the internal mounting screw. Festo 7DFPIb_en 33 / 55...
  • Page 34 Note When installing the controller, make sure that there are no kinks or tension in the tubing or cables. Kinked lines are susceptible to premature faults and will result in failure of the linear actuator. 34 / 55 Festo 7DFPIb_en...

  • Page 35: Replacing The Valve Block

    If the numbers are no longer legible, mark the pilot lines before detaching them from the valve block. When connecting, make sure that the numbers on the pilot lines match the numbers of the connections on the valve block. Festo 7DFPIb_en 35 / 55...
  • Page 36 250 mm ±3 mm DFPI-250-…-ND2P-…- 6 mm 250 mm ±3 mm 250 mm ±3 mm DFPI-320-…-ND2P-…- 6 mm 300 mm ±3 mm 300 mm ±3 mm Pneumatic tubing can be cut using sturdy scissors or a sharp knife. 36 / 55 Festo 7DFPIb_en...
  • Page 37 Plug the pneumatic tubing from pilot port 4 on the valve block into the push-in connector on the end cap. When doing so, thread the pneumatic tubing through the electronic function module in an arc. Festo 7DFPIb_en 37 / 55...

  • Page 38: Fitting The End Cap Module

    2. Screw the hexagon head screw on the earth terminal into the end cap and tighten to a torque of 2.7 Nm ±10%. 5. Push the two halves of the sensor plug together. 6. Tighten the retaining screws to a torque of 0.5 Nm ±10%. 38 / 55 Festo 7DFPIb_en...

  • Page 39: Repair Steps For The End Cap Module

    5. Clean the two O-rings and seats; see section „Cleaning“. 6. Disconnect the sensor plug from the hexagonal column. 7. Unscrew the hexagon head screw from the earth terminal. 8. Unscrew the retaining screws on the sensor plug. 9. Separate the plug halves. Festo 7DFPIb_en 39 / 55...

  • Page 40: Replacing The Displacement Encoder

    If the numbers are no longer legible, mark the pilot lines before detaching them from the valve block. When connecting, make sure that the numbers on the pilot lines match the numbers of the connections on the valve block. 40 / 55 Festo 7DFPIb_en...
  • Page 41 1. Plug the customer plug assembly into the input board. The colours of the individual wires in the customer plug assembly are as follows from top to bottom (end cap facing downwards): Blue White Black Grey Festo 7DFPIb_en 41 / 55...

  • Page 42: Replacing The Valve Block

    If the numbers are no longer legible, mark the pilot lines before detaching them from the valve block. When connecting, make sure that the numbers on the pilot lines match the numbers of the connections on the valve block. 1. Detach the valve cable assembly from the valve block. Y3 Y2 42 / 55 Festo 7DFPIb_en...
  • Page 43 Pneumatic tubing can be cut using sturdy scissors or a sharp knife. 4. Pull the pneumatic tubing out of the push-in connectors in the valve block by pushing the blue ring on the push-in fitting down, then pulling out the pneumatic tubing. Festo 7DFPIb_en 43 / 55...
  • Page 44 When installing the end cap module, make sure that there are no kinks or tension in the tubing and cables. Kinked tubing and cables are susceptible to premature faults and will result in failure of the linear actuator. 44 / 55 Festo 7DFPIb_en...

  • Page 45: Fitting The End Cap Module

    7. Tighten the retaining screws on the sensor plug to a torque of 2.7 Nm ±10%. 8. Apply a light coating of grease to the two O-rings of the end cap module; see section „Greasing“. 9. Place the two O-rings in the seats of the end cap module. Festo 7DFPIb_en 45 / 55...

  • Page 46: Assembling The Linear Actuator

    2. Insert the piston into the cylinder barrel so that the thread of the piston rod is opposite the Festo logo and facing away from it. A flat, blunt object can be used as an assembly aid so that the first lip seal does not fold back when inserting the piston.
  • Page 47 This work step can be skipped if the two push-in L-fittings have not been removed. 4. Screw the two push-in L-fittings into the bearing and end caps and tighten to a torque of 22.5 Nm ±10%. Festo 7DFPIb_en 47 / 55...

  • Page 48: Connecting Supply Lines To The Linear Actuator

    2. Tighten the retaining screws on the two plug halves to a torque of 0.5 Nm ±10%. 3. Apply a thin film of LOCTITE 243 to the mounting screws in the housing. 4. Tighten the mounting screws to a torque of 2.7 ±10% Nm. 48 / 55 Festo 7DFPIb_en...

  • Page 49: Troubleshooting

    Adjust speed of actuator using flow control valves D2 slowly closed and D4. Piston rod does not Initialisation/ Seal not seated correctly/faulty reach end position normal Check that seal is seated correctly/replace faulty seal. seal on piston Initialisation stops operation Festo 7DFPIb_en 49 / 55...
  • Page 50 D4. advances/retracts normal more slowly operation Replace valve block; see section 4.5.2 „Replacing the controller with electronic function module“. Dirt in valve block/ valve faulty Replace valve block; see section 4.7.3 „Replacing the valve block“. 50 / 55 Festo 7DFPIb_en...
  • Page 51 Normal block switching operation Replace valve block; see section 4.5.4 „Replacing the continuously at valve block“. Valve faulty unchanged setpoint. Replace valve block; see section 4.7.3 „Replacing the valve block“. Festo 7DFPIb_en 51 / 55...

  • Page 52: Dfpi-Nd2P-G2

    Piston rod moving too Compressed air supply too Increase/reduce compressed air supply. slow/fast high/low Piston rod suddenly Pneumatic components of advances/retracts intermediate cap/bearing cap Fix leaks in pneumatic components of bearing cap/end cap. more slowly leaking 52 / 55 Festo 7DFPIb_en...

  • Page 53: Cleaning And Greasing

    Festo recommends LOCTITE 7063 and LOCTITE 7070 for cleaning. When using other cleaning agents, make sure that they do not corrode the seals of the linear actuator. If in doubt, check the resistance of the seals using the data on the Festo website (www.festo.com). Greasing 6.2.1...

  • Page 54: Maintenance And Care

    (7Accessories_a_en). This can be found in the online spare parts catalogue on the Festo website (http://spareparts.festo.com/xdki/data/SPC/0/PDF_SAFE/Fitting%20aids.pdf Liability The General Terms and Conditions of Festo AG & Co. KG, which can be viewed on the Festo website (www.festo.com), apply. 54 / 55 Festo 7DFPIb_en...
  • Page 55 III. and IV) may be raised only if the user c) With the exception of the Festo logo, Festo cannot guarantee that the Electronic has observed the safety guidelines of the...

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