Festo DFPD-Series Setup guide

Repair

instructions (en)

Quarter-turn actuator

DFPD

DFPDb_en

Imprint

Version:

DFPDb_en (09.2018)

©Festo AG & Co. KG

Postfach

D-73726 Esslingen

Editorial team:

Spare Part Documentation and

Support

Phone:

+49 / 711 / 347-0

Fax:

+49 / 711 / 347-2144

E-Mail:

[email protected]

Internet:

http://www.festo.com

Foreword

These repair instructions are valid for the quarter-turn actuator listed on the

title page to the exclusion of any liability claims.

The general terms and conditions of business (Allgemeinen Geschäftsbedingun-

gen - AGB) of Festo AG & Co. KG apply; these can be read on the Festo website

(www.festo.com).

Differences compared to the descriptions in these repair instructions may

arise depending on the design and/or modication status of the quarter-turn

actuator. 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.

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.

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 up-

dates.

2 / 74 DFPDb_en

Table of Contents

1 Important information 5

1.1 About these repair instructions 5

1.2 Symbols used 5

1.2.1 Danger categories 5

1.2.2 Repair steps 5

1.2.3 Cleaning and greasing 6

1.3 Text designations used in these repair instructions 6

1.4 Tools 6

2 General safety instructions and information 6

2.1 General safety instructions 6

2.2 General information 7

3 Sizes, part numbers and component lists with bills of material 8

3.1 DFPD-10 components overview 10

3.1.1 DFPD-10 bill of materials 11

3.2 DFPD-20-…-D components list 12

3.2.1 DFPD-20-…-D bill of materials 13

3.3 DFPD-20-…-S components list 14

3.3.1 DFPD-20-…-S bill of materials 15

3.4 DFPD-40 / 80 / 120 / 160-…-D components list 16

3.4.1 DFPD-40-…-D bill of materials 17

3.4.2 DFPD-80-…-D bill of materials 18

3.4.3 DFPD-120-…-D bill of materials 19

3.4.4 DFPD-160-…-D bill of materials 20

3.5 DFPD-40 / 80 / 120 / 160-…-S components list 21

3.5.1 DFPD-40-…-S bill of materials 22

3.5.2 DFPD-80-…-S bill of materials 23

3.5.3 DFPD-120-…-S bill of materials 24

3.5.4 DFPD-160 -…-S bill of materials 25

3.6 DFPD-240 / 300 / 480-…-D components list 26

3.6.1 DFPD-240-…-D bill of materials 27

3.6.2 DFPD-300-…-D bill of materials 28

3.6.3 DFPD-480-…-D bill of materials 29

3.7 DFPD-240 / 300 / 480-…-S components list 30

3.7.1 DFPD-240-…-S bill of materials 31

3.7.2 DFPD-300-…-S bill of materials 32

3.7.3 DFPD-480-…-S bill of materials 33

3.8 DFPD-700 / 900 / 2300-…-D components list 34

3.8.1 DFPD-700-…-D bill of materials 35

3.8.2 DFPD-900-…-D bill of materials 36

3.8.3 DFPD-2300-…-D bill of materials 37

3.9 DFPD-1200-…-D components list 38

3.9.1 DFPD-1200-…-D bill of materials 39

3 / 74DFPDb_en

3.10 DFPD-700 / 900 / 2300-…-S components list 40

3.10.1 DFPD-700-…-S bill of materials 41

3.10.2 DFPD-900-…-S bill of materials 42

3.10.3 DFPD-2300-…-S bill of materials 43

3.11 DFPD-1200-…-S components list 44

3.11.1 DFPD-1200-…-S bill of materials 45

4 Repair steps 46

4.1 Dismantling 46

4.2 Assembly 58

5 Start-up 72

Table of Contents

4 / 74 DFPDb_en

1 Important information

1.1 About these repair instructions

This document contains important information about proper repair of the quarter-turn actuator type DFPD.

Before carrying out a repair, these repair instructions must be read in full and followed.

Other documentation for this product:

– Operating instructions (www.festo.com/sp)

– Spare parts documentation (www.festo.com/spareparts)

1.2 Symbols used

1.2.1 Danger categories

The following symbol identies text passages which draw attention to specic hazards.

Warning

Marking of special information

The following symbols identify text passages which contain special information.

Note

1.2.2 Repair steps

Familiarise yourself with the meaning of the symbols before starting the repair work.

Warning

There is a risk of injury due to uncontrolled movements of components.

Reference arrow

Symbol indicating the individual components to be noted.

Linear movement arrow

Carry out a linear movement

Slow movement

Carry out the dismantling / assembly step slowly and carefully.

Reference to repair steps

Follow the given repair steps.

Attention

Pay particular attention to notes and information.

Visual inspection

Perform a visual inspection.

5 / 74DFPDb_en

Tools

Use suitable tools.

Functional test /start-up

Follow the functional test /start-up information in the brief instructions (www.festo.com).

1.2.3 Cleaning and greasing

Cleaning

The components must be thoroughly cleaned to remove all foreign particles, machining residues and

old lubricants before they are greased.

Clean with a soft, lint-free cloth and non-abrasive cleaning agents. Check the compatibility of the clean-

ing agent with the materials to be cleaned.

Thin grease lm outside

A lm of grease covers the external surface so that the grease colour tarnishes the surface slightly.

Recommendation:

Apply the grease with a soft brush or similar.

1.3 Text designations used in these repair instructions

– 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 Tools

Among other things, the following standard tools are required to repair the quarter-turn actuator:

– Spanner

– Retaining ring pliers for external retaining rings

– Torque wrench

2 General safety instructions and information

2.1 General safety instructions

Warning

Read and follow all safety instructions and information. Failure to comply with these safety instructions and informa-

tion can result in serious injuries.

Note

To achieve ATEX conformity, the toothed discs must be replaced each time the corresponding screws or bolts are loos-

ened. When screwing back in, observe the tightening torques given for the screws.

– The control block may only be repaired by authorised and trained personnel acting in accordance with the require-

ments in these repair instructions and the brief instructions for the device.

6 / 74 DFPDb_en

– Pay attention to cleanliness while repairing the quarter-turn actuator. Do not allow dirt particles to get into the quar-

ter-turn actuator.

– A shutdown must be performed before any repair work is carried out.

– Before repairing the quarter-turn actuator, any attachments on it must be dismantled.

– The control block must be completely depressurised and de-energised, and reliably secured against unauthorised

restarting before starting any repair work is started.

– Accidental switching on or concealed pressure can trigger unexpected movements during dismantling of the quar-

ter-turn actuator. Therefore, completely vent the quarter-turn actuator before each repair.

– Use original spare parts only to repair the quarter-turn actuator.

– Wear the necessary personal protective equipment.

– In the event of damage to the quarter-turn actuator caused by

– unauthorised manipulation,

– non-intended use (misuse),

– use of non-original spare parts

all warranty and liability claims against the manufacturer expire.

– The technical documentation required for installation and start-up (functional test) of the quarter-turn actuator must

be available.

2.2 General information

– Standard tools are needed to repair the quarter-turn actuator, which must be available in a service workshop

(Chapter 1.4 on page 6).

– Components and equipment replaced during repair must be disposed of in accordance with the relevant local

environmental protection regulations.

– Where possible the repair should be carried out on a stable and at work surface with space for small parts.

– The gures of the repair steps show size DFPD-300-…-D / S-…-60 (12 installed springs) by way of example. Individual

minor differences between the quarter-turn actuator in hand and the illustrated example are possible.

– Depending on the temperature range (standard / T4 /T6), Festo recommends the following lubricants:

– SYNTHY POLYMER 402/2 (standard variant)

– HEVOLIT PE 280-1 FG (high-temperature variant T4)

– RENOLIT SI 300 M (low-temperature variant T6)

– Individual components must be greased when installing the quarter-turn activator. The following table shows the

recommended quantity of grease during the entire installation.

Size Recommended quantity of grease for installation

DFPD-10 2 g

DFPD-20 3 g

DFPD-40 5 g

DFPD-80 7 g

DFPD-120 11 g

DFPD-160 15 g

DFPD-240 20 g

DFPD-300 30 g

DFPD-480 45 g

DFPD-700 55 g

DFPD-900 65 g

DFPD-1200 85 g

DFPD-2300 110 g

7 / 74DFPDb_en

3 Sizes, part numbers and component lists with bills of material

The component lists with corresponding bills of materials for the following quarter-turn actuators are listed on the follow-

ing pages:

Size Part number Components list Bill of materials

DFPD-10 8042184 Chapter 3.1 on page 10 Chapter 3.1.1 on page 11

DFPD-20-…-D 8042185 Chapter 3.2 on page 12 Chapter 3.2.1 on page 13

DFPD-20-…-S Chapter 3.3 on page 14 Chapter 3.3.1 on page 15

DFPD-40-…-D 8042186 Chapter 3.4 on page 16 Chapter 3.4.1 on page 17

DFPD-40-…-S Chapter 3.5 on page 21 Chapter 3.5.1 on page 22

DFPD-80-…-D 8042187 Chapter 3.4 on page 16 Chapter 3.4.2 on page 18

DFPD-80-…-S Chapter 3.5 on page 21 Chapter 3.5.2 on page 23

DFPD-120-…-D 8042188 Chapter 3.4 on page 16 Chapter 3.4.3 on page 19

DFPD-120-…-S Chapter 3.5 on page 21 Chapter 3.5.3 on page 24

DFPD-160-…-D 8042189 Chapter 3.4 on page 16 Chapter 3.4.4 on page 20

DFPD-160-…-S Chapter 3.5 on page 21 Chapter 3.5.4 on page 25

DFPD-240-…-D 8042190 Chapter 3.6 on page 26 Chapter 3.6.1 on page 27

DFPD-240-…-S Chapter 3.7 on page 30 Chapter 3.7.1 on page 31

DFPD-300-…-D 8042191 Chapter 3.6 on page 26 Chapter 3.6.2 on page 28

DFPD-300-…-S Chapter 3.7 on page 30 Chapter 3.7.2 on page 32

DFPD-480-…-D 8042192 Chapter 3.6 on page 26 Chapter 3.6.3 on page 29

DFPD-480-…-S Chapter 3.7 on page 30 Chapter 3.7.3 on page 33

DFPD-700-…-D 8042193 Chapter 3.8 on page 34 Chapter 3.8.1 on page 35

DFPD-700-…-S Chapter 3.10.1 on page 41 Chapter 3.10.1 on page 41

DFPD-900-…-D 8042194 Chapter 3.8 on page 34 Chapter 3.8.2 on page 36

DFPD-900-…-S Chapter 3.10 on page 40 Chapter 3.10.2 on page 42

DFPD-1200-…-D 8042195 Chapter 3.9 on page 38 Chapter 3.9.1 on page 39

DFPD-1200-…-S Chapter 3.11 on page 44 Chapter 3.11.1 on page 45

DFPD-2300-…-D 8042196 Chapter 3.8 on page 34 Chapter 3.8.3 on page 37

DFPD-2300-…-S Chapter 3.10 on page 40 Chapter 3.10.3 on page 43

The following diagrams are intended only to provide an overview of the individual components. To order spare and

wearing parts, and sets of wearing parts please use the online spare parts catalogue on the Festo website

(www.festo.com/spareparts).

8 / 74 DFPDb_en

9 / 74DFPDb_en

3.1 DFPD-10 components overview

10 / 74 DFPDb_en

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