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Repair instructions (en)

Toothed belt axis

DGE-…-ZR-RF

7DGE_ZR_RFb_en

2 / 44 Festo 7DGE_ZR_RFb_en

Imprint

Version: 7DGE_ZR_RFb_en (11.2011)

Copyright: ©Festo AG & Co. KG P.O. Box D-73726 Esslingen

Editorial team: SC-S

Tel.: +49 (0) 711/347-0

E-mail: [email protected]

Internet: http://www.festo.com

The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without explicit authorisation is prohibited. Offenders will be liable for damages. All rights reserved, in particular the right to file patent, utility model or registered design ap-plications.

All product designations and brand names used are the property of the owners and not explicitly identified as such.

All technical data subject to change according to technical updates.

3 / 44Festo 7DGE_ZR_RFb_en

ForewordThese repair instructions are valid for the toothed belt axes listed on the title page to the exclusion of any liability claims.

Deviations compared to the descriptions in these repair instructions may arise depending on the design and/or modification status of the specific toothed belt 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 improper use of the products.

More detailed information on this can be found in chapter 7 “Liability”.

The relevant regulations on occupational safety, safety engineering and interfer-ence suppression as well as the stipulations contained in these repair instruc-tions must be observed when working on the products.


Table of contents

1 Important information 5

1.1 About these repair instructions 5

1.2 Pictograms used in these repair instructions 5

1.3 General safety information 6

2 General product description 6

2.1 Functional description 6

2.2 Types and part numbers 7

2.3 Overview of variants and mounting directions 7

3 Component overview 8

3.1 DGE-25-…-ZR-RF 8

3.2 DGE-40-…-ZR-RF 10

3.3 DGE-63-…-ZR-RF 12

4 Repair steps 14

4.1 Renewing the toothed belt 144.1.1 Replacing the toothed belt 154.1.2 Checking and setting the toothed belt pretension 194.1.3 Additional information on checking the toothed belt pretension 214.1.4 Cutting the toothed belt to length 22

4.2 Dismantling the toothed belt axis 234.2.1 Removing the drive covers 234.2.2 Dismantling the drive covers 25

4.3 Profiletrackrollerguide 274.3.1 Dismantling the slides 284.3.2 Setting the track roller pretension 324.3.3 Measuring the displacement force of the slide 34

4.4 Assembling the toothed belt axis 344.4.1 Preparing the cylinder barrel 344.4.2 Installing the drive covers 34

4.5 Assemblyandfunctioncheck 374.5.1 No-load torque 37

5 Maintenance 38

5.1 Cleaning and lubricating the toothed belt axis 38

5.2 Checkingandlubricatingtherollerbearingguide 38

5.3 Toothed belt pretension 38

6 Tools 39

6.1 Standard tools 39

6.2 Special tools 39

6.3 Devices and meters 40

6.4 Devices for in-house assembly 41

7 Liability 41


1 Important information

1.1 About these repair instructions

This document contains important information about the professional repair of the toothed belt axis of the type DGE-…-ZR-RF in the sizes 25, 40 and 63.

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

For reasons of clarity, these repair instructions do not contain complete, detailed information. The following documents should therefore also be available when repairing a toothed belt axis:

• Operating instructions

Contain information about the installation and removal of the motor, motor flange, coupling and coupling housing of the toothed belt axis DGE-…-ZR-RF as well as the function, structure, applica-tion, installation, commissioning, care and maintenance, etc. 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 infor-mation on their installation.

Can be found in the online spare parts catalogue on the Festo web-site (spareparts.Festo.com).

• Assembly aids

Contain an overview of available assembly aids such as lubricating greases, locking agents, main-tenance tools, etc. (aids for assembly and maintenance). Can be found in the online spare parts catalogue on the Festo website (www.Festo.com).

1.2 Pictograms used in these repair instructions

WarningThis sign indicates a dangerous situation for persons and/or the product. Failure to observe this warning can result in injury to persons and/or damage to the device.

NoteThis sign provides important tips and information that can make your work easier.

EnvironmentThis sign provides information on the steps required for environmentally friendly use of materials and equipment, as well as the guidelines and regulations that may need to be observed.

DocumentsThis sign contains references to other sections or documents containing additional information.

www.Festo.com

http://spareparts.festo.com


1.3 General safety information

WarningThe toothed belt axis must only be repaired by authorised and trained persons in accordance with the specifications in the technical documentation and using genuine spare parts.

Installation and repair by unauthorised and untrained persons, repairs using non-genuine spare parts as well as with-out 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 as well as the respective operating instructions for the device.

NoteInstead of carrying out the repair yourself, your local Festo sales office offers the option of having the repair carried out by Festo.

EnvironmentComponents and equipment replaced as part of a repair must be disposed of in accordance with the locally valid envi-ronmental protection regulations.

2 General product description

2.1 Functional description

The DGE-…-ZR-RF is a toothed belt axis based on the operational principle of a circulating toothed belt for power trans-mission. The rotary motion of a servo or stepper motor produces a linear motion in a toothed belt with a pulley at both ends of the axis that is then transmitted to the slide with roller bearings attached to the toothed belt using clamping components.

The slot in the cylinder barrel required for this is covered by the toothed belt that protects the roller bearing guide inside the axis against the entry of dirt.

By minimising the moving dead weight, a high dynamic response and shorter cycle times can be achieved. The DGE-…-ZR-RF is approved for slide operation and yoke operation (cantilever operation).

3

7

aJ

aA

9

642

8

1 5 1 Drive cover with corner pulley

2 Cylinder barrel

3 Clamping body for tensioning the toothed belt

4 Eccentric screw for setting the roller bearing pretension

5 Slide

6 Track rollers

7 Toothed belt pulley with drive trunnion

8 Guide rods

9 Wiper seal for lubricating the guide rods

aJ Toothed belt

aA Deep-groove ball bearing


2.2 Types and part numbers

Type Part number

DGE-25-…-ZR-RF 534391DGE-40-…-ZR-RF 534392DGE-63-…-ZR-RF 534393

The complete overview of features, accessories, type codes, technical data and dimensions for the toothed belt axes DGE-… -ZR-RF can be found in the product catalogue or on the Festo website (www.Festo.com).

2.3 Overview of variants and mounting directions

This diagram provides an overview of the mounting directions and variants for the toothed belt axis.

Drive shaft on left

Drive shaft on right

Versions:

GK = Standard slide

GV = Extended slide

Orientation:

O = Top

U = Underneath

R = Right

L = Left

V = Front

H = Rear

-H- = Position of the insertion points for slot nuts (DGE-25 only)

Drive shaft:

LK = No drive shaft on left

LV = Drive shaft on left, front

LH = Drive shaft on left, rear

LB = Drive shaft on left, front and rear

RK = No drive shaft on right

RV = Drive shaft on right, front

RH = Drive shaft on right, rear

RB = Drive shaft on right, front and rear


3 Component overview

3.1 DGE-25-…-ZR-RF

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 (spareparts.Festo.com).

10 - GK11 - GV

18

39

http://spareparts.Festo.com


Item Designation Type Note

1 Flange screw M5×58 Tightening torque 5.9 Nm, use LOCTITE 2432 Sealing cap3 Sealing disc4 Retaining ring DIN 472-37×1.55 Drive cover6 - 8 Toothed drive shafts With pressed-on deep-groove ball bearings9 Spring pin DIN 7346-4.5×1410 - 11 Toothed belt12 Threaded pin DIN 913-M5×6-45H Tightening torque 0.5 Nm13 Clamping plate14 Socket head screw DIN 912-M5×25-10.915 Lubrication nipple16 Clamping body17 Retaining ring DIN 471-25×1.2 Only installed with size 6318 Centring screw Tightening torque 9.9 Nm, use LOCTITE 24319 Eccentric screw Adjustment torque 0.5 Nm, use LOCTITE 24320 Set of wiper seals Impregnated with oil21 Track roller22 Fitting washer23 Buffer24 Slide module25 Slide26 Washer DIN 125-A-6.4-A227 Hex nut DIN 439 B-M6 Tightening torque 2.9 Nm, use LOCTITE 24328 Cover cap29 Cylinder barrel Aluminium profile with roller-swaged guide rods

(surface-hardened)30 Cover cap31 Cover cap32 Socket head screw DIN 912-M4×40-8.8 Tightening torque 2.9 Nm33 Sealing cap34 Coupling housing35 Centring ring36 Coupling housing module See operating instructions for assembly37 Coupling module See operating instructions for assembly38 Socket head screw DIN 912-M4×12-8.8 Tightening torque 2.9 Nm39 Coupling


3.2 DGE-40-…-ZR-RF

10 - GK11 - GV

18

39





1 Flange screw M6×80 Tightening torque 11 Nm, use LOCTITE 2432 Sealing cap3 Sealing disc4 Retaining ring DIN 472-47×1.755 Drive cover6 - 8 Toothed drive shafts With pressed-on deep-groove ball bearings9 Spring pin DIN 7346-5×2010 - 11 Toothed belt12 Threaded pin DIN 913-M8×8-45H Tightening torque 4 Nm13 Clamping plate14 Socket head screw DIN 912-M6×35-10.915 Lubrication nipple16 Clamping body17 Retaining ring DIN 471-25×1.2 Only installed with size 6318 Centring screw Tightening torque 24 Nm, use LOCTITE 24319 Eccentric screw Adjustment torque 2 Nm, use LOCTITE 24320 Set of wiper seals Impregnated with oil21 Track roller22 Fitting washer23 Buffer24 Slide module25 Slide26 Washer DIN 125-A-8.4-A227 Hex nut DIN 934-M8 Tightening torque 20 Nm, use LOCTITE 24328 Cover cap29 Cylinder barrel Aluminium profile with roller-swaged guide rods

(surface-hardened), size 25 shown30 Cover cap31 Cover cap32 Socket head screw DIN 912-M5×65-10.9 Tightening torque 5.9 Nm33 Sealing cap34 Coupling housing35 Centring ring36 Coupling housing module See operating instructions for assembly37 Coupling module See operating instructions for assembly38 Socket head screw DIN 912-M5×6-8.8 Tightening torque 10.5 Nm39 Coupling


3.3 DGE-63-…-ZR-RF

10 - GK11 - GV

18

39





1 Flange screw M8×125 Tightening torque 15 Nm, use LOCTITE 2432 Sealing cap3 Sealing disc4 Retaining ring DIN 472-80×2.55 Drive cover6 - 8 Toothed drive shafts With pressed-on deep-groove ball bearings9 Spring pin DIN 7346-7×2810 - 11 Toothed belt12 Threaded pin DIN 913-M12×12-45H Tightening torque 5 Nm13 Clamping plate14 Socket head screw DIN 912-M8×40-10.915 Lubrication nipple16 Clamping body17 Retaining ring DIN 471-25×1.218 Centring screw Tightening torque 80 Nm, use LOCTITE 24319 Eccentric screw Adjustment torque 5 Nm, use LOCTITE 24320 Set of wiper seals Impregnated with oil21 Track roller22 Fitting washer23 Buffer24 Slide module25 Slide26 Washer DIN 125-A-13-A227 Hex nut DIN 439 B-M12 Tightening torque 40 Nm, use LOCTITE 24328 Cover cap29 Cylinder barrel Aluminium profile with roller-swaged guide rods

(surface-hardened), size 25 shown30 Cover cap31 Cover cap32 Socket head screw DIN 912-M8×90-10.9 Tightening torque 24 Nm33 Sealing cap34 Coupling housing35 Centring ring36 Coupling housing module See operating instructions for assembly37 Coupling module See operating instructions for assembly38 Socket head screw DIN 912-M5×20-10.9 Tightening torque 25 Nm39 Coupling


4 Repair steps

This chapter describes how to dismantle, repair and assemble the toothed belt axis DGE-…-ZR-RF. This is done by first dismantling the device into individual modules (subsequent sections deal with the repair of these modules). Depending on the cause of the defect to be eliminated it may be necessary to exchange several components. The cause of a defect must therefore always be determined before starting a repair.

NoteThe repair should preferably be carried out on a stable and flat work surface with storage for small parts. It is also possible to repair the toothed belt axis in installed condition, if required.

4.1 Renewing the toothed belt

NoteThe toothed belt can be renewed with the toothed belt axis in installed condition if it is not torn or if the location of the tear is visible as in that case it is not necessary to disassemble the drive covers. The drive covers must be removed if the tear is located in the drive covers or the cylinder barrel (see section 4.2.1 “Removing the drive covers”).

Should it be necessary to change the toothed belt, the cause of the failure must be investigated to prevent premature and repeated failure. A toothed belt axis that has been used as intended and sized correctly will not normally exhibit any premature signs of failure.

This is not necessary in the case of non-premature failure (fatigue time). However, the condition of the toothed belt pulley module (wear to the surface/shape of the teeth, radial play of the bearing inner raceway with respect to the bearing seat: tight fit in new condition) and also the condition of the deep-groove ball bearings (e.g. perceptible bearing clearance, impaired roll-off behaviour and increased operating noise, etc.) should always be checked. In case of uncertainty, it is recommended to replace all the components mentioned so as to rule out reciprocal effects during later operation.

Possible visible signs of wear to the toothed belt:

• Tears on the back of the toothed belt are signs of wear, for example caused by operation outside the permitted tem-perature range, impermissible chemical influences or possibly fatigue.

• Wear to the nylon fabric (fabric coating) on the tooth side of the belt. This is indicated by lint formation and bobbling, for example, and constitutes primary wear (abrasion of the fabric).

• Visible individual glass fibre tensile strands in the tooth base are secondary signs of wear due to primary wear to the nylon fabric. If this happens, the toothed belt pulley module must be carefully examined for wear since visible glass fibre tensile strands may have had a severe abrasive effect on the tooth tip sides of the toothed belt pulleys.

A description of how to replace the toothed belt pulley module together with the corresponding deep-groove ball bearings can be found in section 4.2.2 “Dismantling the drive covers”.

If the toothed belt suffers premature failure, the operating conditions should be looked at more closely.

The following possibilities should be considered among others:

• Overloading

The elasticity of the toothed belt retards the acceleration and braking behaviour of the toothed belt axis and results in greater acceleration and deceleration than set in the controller (spring effect).

Block-shaped acceleration and deceleration profiles (no jerk limitation) cause high peaks in the drive force that can lead to overloading of the drive. Positions outside of the permissible range can also occur. An acceleration and de-celeration specification with jerk limitation reduces oscillations in the entire system and has a positive effect on the stresses to which the mechanical system is subjected.

– Check which closed-loop controller settings can be adapted (e.g. jerk limitation, smoothing of the acceleration profile).


Incorrect set values for the braking ramp during STOP conditions (e.g. emergency stop, quick stop) result in overload-ing of the toothed belt axis and can destroy it or dramatically reduce its service life.

– Check the settings for all braking ramps in your controller or the higher-order control system (deceleration values and jerk).

– Make sure that the deceleration values (braking deceleration, deceleration times) for the speed, the load to be moved and the mounting position (horizontal/vertical) as well as the specified maximum driving torque or the feed force correspond to the permissible values for the toothed belt axis used.

– Use the Festo “Positioning Drives” sizing software, available via the Festo website (www.Festo.com).

• Ambient conditions/material resistance

Check whether the ambient temperature is within the permissible range.

Check the chemical and physical ambient conditions for hazardous substances such as dust, abrasive particles, cool-ing lubricants, solvents, ozone, radiation, water-soluble greases and oils, etc.

4.1.1 Replacing the toothed belt

NoteThis description presupposes that the toothed belt is not torn or that the tear is located in the visible area. The drive covers must be removed if the tear is located in the drive covers or the cylinder barrel (see section 4.2.1 “Removing the drive covers”).

Do not pull the old toothed belt out of the axis before you have joined it to the new toothed belt, as otherwise you will also need to remove the drive covers.

• Place the toothed belt axis on the work surface as shown with the slide facing upwards.

• Lever off the cover caps at both ends from the drive covers.

NoteThe screw heads of the socket head screws are filled with locking paint. You can ensure a secure fit for the Allen key by carefully tapping it into the screw head using a hammer.

• Loosen the socket head screw in the clamping bodies and unscrew it.

• Move the slide to the left and right to release the clamping bodies from the slide.


• Push the two clamping bodies out of the axis through the recesses in the cylinder barrel.

• Loosen the threaded pins in the clamping bodies at both ends of the toothed belt and unscrew them.

NotePay attention to the clamping plate in the clamping body as it could fall out.

• Pull the clamping bodies sideways from the toothed belt.

• Remove the clamping plates from the toothed belt.

NoteDo not pull the old toothed belt out of the axis before you have joined it to the new toothed belt, as otherwise you will need to remove the drive covers.

• Join the ends of the old and new toothed belts using adhesive tape.

DocumentsA description of how to determine the correct toothed belt length can be found in section 4.1.4 “Cutting the toothed belt to length”.

• Pull the old toothed belt carefully out of the axis until the new belt is pulled through it.

• Separate the old toothed belt from the new one.


• Place the clamping plate on the left-hand end of the new toothed belt.

NoteThe clamping plate must be aligned axially with the centre of the toothed belt to prevent damage to the toothed belt during operation.

• Align the clamping plate axially with the centre of the toothed belt.

X1

X1

WarningThe toothed belt must be placed correctly on the clamping plate. It must not protrude and must make contact with four teeth.

NoteThe tapped holes of the clamping bodies must be recut before the threaded pins are screwed in. Residues from the old locking agent in the tapped holes result in uneven and increased torques for the threaded pins, which means they may not be correctly tightened.

• Insert the left-hand end of the toothed belt together with the clamping plate into the clamping body.

• Align the toothed belt axially with the centre of the clamping body.

• Apply Loctite 243 to the threaded pin and screw it into the clamping body.

• Push the clamping plate against the stop (a) on the clamping body.

NoteThe clamping plate must make contact with the stop as otherwise the toothed belt pretension will diminish during operation.

• Tighten the threaded pin using the appropriate torque (see table).

NoteIt is critical that the torques be observed. Excessive torques will bend the clamping body.

Type Torque

DGE-25 0.5 NmDGE-40 4.0 NmDGE-63 5.0 Nm


WarningDo not bend or fold the toothed belt, as this can result in damage to the tensile bodies and shorten its service life by tearing it. Note the minimum bending radius for assembly and storage (see section 4.1.4 “Cutting the toothed belt to length”).

• Insert the clamping body into the axis through the recess in the cylinder barrel.

• Move the clamping body to the left to just before the recess in the cylinder barrel.

• Repeat the steps on the other end of the axis to insert the second clamping body.

• Push the clamping bodies into the guide in the slide.

WarningThe clamping bodies must not touch the slide when they are being screwed in as otherwise the toothed belt could become overstretched and the service life of the toothed belt would be reduced. Slowly increase the toothed belt pretension to the correct value.

• Steadily screw the socket head screws through the clamping bodies into the slide.

• Pretension the toothed belt by steadily tightening the socket head screws by feel.

NoteIf the toothed belt is cut to the correct length, the clamping bodies should at least be flush with the slide.

If the clamping bodies protrude, the socket head screws will not reach the minimum screw-in depth and could be torn out.

NoteSet the toothed belt pretension as described in section 4.1.2 “Checking and setting the toothed belt pretension”.


4.1.2 Checkingandsettingthetoothedbeltpretension

The toothed belt pretension is determined by measuring the basic oscillation (natural frequency) of the toothed belt with a fixed and freely oscillating strand length (L). Since the freely oscillating strand length (L) cannot be measured directly, the distance (L1) from the clamp piece (a)/clamping body (b) to one of the drive covers is set by moving the slide. The oscillation measurement is then carried out at this point.

WarningThe toothed belt pretension has a direct influence on the service life of the toothed belt and the performance of the toothed belt axis. Extreme care must therefore be exercised when checking it.

Before the toothed belt pretension can be measured, the slide must be moved back and forth a number of times so that the toothed belt can fully settle and differences in tension are equalised.

DGE-25/40

L

L1

DGE-63

L

L1

ab

b

DocumentsThe easiest way to check the toothed belt pretension is using the toothed belt pretension test equipment (see section 6.3 “Devices and meters”). The work instructions required for this as well as the setting values can be found in the associated operating instructions in the appendix to this document.

Checkingthetoothedbeltpretension



Note (DGE-25 and DGE-40)It is necessary to attach an additional clamp piece (see section 6.4 “Devices for in-house assembly”) with the axes DGE-25 and DGE-40 so that the toothed belt can oscillate freely and does not strike the cylinder barrel.

• If necessary, push the relevant clamp piece through the recess in the cylinder barrel between the toothed belt and cylinder barrel. It must touch the clamp-ing body.


NoteThe longer strand length should preferably be set if possible. A longer freely oscillating strand length reduces the variation of the measurement results.

The clamp piece (DGE-25 and DGE-40 only) must touch the clamping body.

• Set the distance (L1) between the drive cover and clamp piece (a)/clamping body (b) (see table).

Type Distance L1

DGE-25 222 mm/50 mm1)

DGE-40 222 mm/50 mm1)

DGE-63 222 mm/50 mm1)

1) Alternatives for toothed belt axes with very short stroke.

DGE-25/40L1

DGE-63L1

ab

b

• Direct the acoustic frequency meter towards the centre of the toothed belt as described in the accompanying operating instructions.

• Make the toothed belt oscillate by striking it with a narrow and heavy ob-ject, for example an Allen key or pin punch.

NoteThe belt must be able to oscillate freely. To assess the toothed belt pretension, several measurements should be made to balance out any measurement tolerances.

• Compare the measurement with the specified value (see table).

Type Frequency (f )

DGE-25 155+4 Hz/515+14 Hz1)

DGE-40 143+4 Hz/439+12 Hz1)

DGE-63 136+3 Hz/366+10 Hz1)

1) Alternatives for toothed belt axes with very short stroke.

Setting the toothed belt pretension

WarningThe pretension of the toothed belt is not an indicator of wear!

The values specified here are based on a new toothed belt.

The pretension of the toothed belt diminishes during storage and operation. This is a normal process and not an indication of wear.


If the measured natural frequency of the toothed belt is outside the specified range, the toothed belt pretension must be set as follows:

• Adjust the toothed belt pretension by turning the socket head screws.

• Before you measure the toothed belt pretension again, the slide must be moved back and forth a number of times so that the toothed belt can fully settle and differences in tension are equalised.

NoteTurning the socket head screw clockwise increases the tension in the toothed belt, and with this its oscillation frequency.

Turning the socket head screw anticlockwise decreases the tension in the toothed belt, and with this its oscillation frequency.

• Place the cover caps in the drive covers at both ends.

4.1.3 Additionalinformationoncheckingthetoothedbeltpretension

The correct toothed belt pretension is of critical importance for the service life of the toothed belt as well as the positioning accuracy and performance of the toothed belt axis.

The conventional method for measuring the toothed belt pretension via the deflection force is too inaccurate and can therefore not be used. Accurate results are achieved by measuring the oscillation frequency. The natural frequency of a belt is based on its tension (strand force), mass and strand length.

NoteThe strand length is the oscillating length of a belt.

Since the strand length cannot be determined directly at the toothed belt axis by easy means, the length L1 is used instead for positioning the clamping body/clamp piece.

A pulse is applied to the toothed belt to start it oscillating. The natural frequency of the toothed belt generated in this way is recorded using a meter and displayed as a frequency value in hertz.

NoteThe frequency value is calculated using the specified values for strand force (pretension force), belt mass and length of the free belt strand according to the following formula:

f Natural frequency of the freely oscillating strand [Hz]

L Strand length [m]

FV Pretension force [N]

m Weight per metre of the toothed belt [kg/m]


The frequency to be set can be calculated using the data from the following table:

Type Weight per metre m Freely oscillating strand length L Pretension force FV

DGE-25 0.0459 kg/m 24 mm + L11) 267 - 282 NDGE-40 0.1179 kg/m 33 mm + L11 628 - 663 NDGE-63 0.2789 kg/m 51 mm + L11 1,528 - 1,612 N

1) See section 4.1.2 “Checking and setting the toothed belt pretension”

Note on measurement using the acoustic belt tension meter

If the toothed belt is excited by means of a force stimulus, the strand oscillates with its natural frequency; this dies down reasonably quickly depending on the attenuation.

The frequency meter measures the natural frequency generated (transverse oscillation) using the acoustic operating principle. In addition to the basic oscillation (natural frequency), harmonic oscillation can also occur. From experience it is always the first harmonic oscillation. In other words, a further oscillation node is generated and therefore in addition to the basic oscillation frequency, values that are twice the natural frequency can also be measured.

For this reason, several measurements should always be carried out to differentiate the necessary basic oscillation (natural frequency) from the harmonic oscillation. Only this frequency can be used to extrapolate the force acting along the strand.

4.1.4 Cutting the toothed belt to length

The toothed belt is ordered from the online spare parts catalogue (spareparts.Festo.com) using the appropriate part number (dependent on the size and version of the toothed belt axis).

The part number is a module number and is dependent on the size of the toothed belt axis. You must specify the stroke and the type of slide required for your toothed belt axis in addition to the part number when ordering. The necessary specifications can be determined from the type codes on the name plate of the toothed belt axis (see order example below). Using this information you can calculate the necessary toothed belt length.

Cutting the new toothed belt to length

The exact length of the toothed belt in mm is twice the product of the stroke of the toothed belt axis and a factor (F). The factor is dependent on the size and type of slide used (see table).

The stroke and the slide type can be determined from the type codes on the name plate. Check the length of the new toothed belt and shorten it if necessary to the calculated length (2 × (stroke + factor)), see order example:

Type Factor F

DGE-25-…-GK 330DGE-25-…-GV 377.5DGE-40-…-GK 506.5DGE-40-…-GV 576.5DGE-63-…-GK 834DGE-63-…-GV 949

Example: DGE-25-300-ZR-RF-LV-RK-GK

Stroke: 300 mm

Factor F: see table

Toothed belt length = 2 × (stroke + F) = 1,260 mm

NoteSturdy general purpose scissors or metal shears are best for cutting the toothed belt.

WarningDo not bend or fold the toothed belt, as this can result in damage to the tensile bodies and shorten its service life by tearing it. Note the minimum bending radius for assembly and storage:

DGE-25: R min = 6 mm

DGE-40: Rmin = 10 mm

DGE-63: Rmin = 20 mm



4.2 Dismantling the toothed belt axis

The toothed belt axis DGE-…-ZR-RF comprises the following modules:

• Drive cover with toothed belt pulley and drive.

• Cylinder barrel with slide with roller bearings on guide rods, driven via clamping bodies at the toothed belt.

4.2.1 Removing the drive covers



NoteThe screw heads of the socket head screws are filled with locking paint. You can ensure a secure fit for the Allen key by carefully tapping it into the screw head using a hammer.

• Loosen the socket head screw in the clamping bodies and unscrew it.

• Move the slide to the left and right to release the clamping bodies from the slide.

• Push the two clamping bodies out of the axis through the recesses in the cylinder barrel.


• Loosen the threaded pins in the clamping bodies at both ends of the toothed belt and unscrew them.

NotePay attention to the clamping plate in the clamping body as it could fall out.

• Pull the clamping bodies sideways from the toothed belt.

• Remove the clamping plates from the toothed belt.

• If the toothed belt is to be replaced, pull it carefully out of the axis.

• Loosen the socket head screws in the drive cover and unscrew them.

• Pull the drive cover away from the cylinder barrel.

NoteThe drive covers are connected to the cylinder barrel using spring pins. A certain amount of force is required to pull them away.


• Repeat the steps on the other end of the axis to remove the second drive cover.

4.2.2 Dismantling the drive covers

Clamping sleeves

The clamping sleeves are inserted into the drive covers, however they can also be located in the cylinder barrel following disassembly of the drive covers. Pull out these parts to replace them.

Toothed drive shafts

The toothed drive shaft sits in a clearance fit in the drive cover with two pressed-on deep-groove ball bearings and is axially secured by two retaining rings.

Removing the toothed drive shafts

• Lever the sealing discs out of the drive cover.

• Remove the retaining ring opposite the drive trunnion.

NoteIn the case of toothed drive shafts with two or no drive trunnions, you can remove any retaining ring.


• Push the toothed drive shaft with the two deep-groove ball bearings out of the drive cover.

NoteYou do not need to pull off the deep-groove ball bearings as the spare part comprises the two bearings and the shaft.

• Check the inner raceways of the deep-groove ball bearings for a secure fit on the toothed drive shaft. If a bearing is not fitting securely, replace the module.

Installing the toothed drive shaft

• Apply a light coating of grease to the outside of the deep-groove ball bearings and push the toothed drive shaft into the drive cover with the drive trunnion in front. If necessary, use a plastic hammer to carefully insert the toothed drive shaft into the drive cover.

NoteAny installation direction can be chosen for toothed drive shafts with two or no drive trunnions.

• Insert the retaining ring.

NoteCheck that the retaining ring is correctly positioned.

• Press the sealing discs into the drive cover so that the deep-groove ball bearings have extra protection against soiling.


4.3 Profiletrackrollerguide

The track roller guide system consists of two guide rods, also called track shafts, and four profile track rollers (roller bear-ings). The two guide rods are surface-hardened and are mechanically coupled in the cylinder barrel by means of roller swaging. This means that it is not technically possible to replace the guide rods. If a defect occurs in the guide rods, the entire toothed belt axis must be replaced.

The guide system has negative operating clearance, i.e. it is pretensioned and therefore has no mechanical play. This results in load bearing capacity in all system directions, as well as more precise guiding. The guide system is adjusted without backlash and pretensioned at two of four roller bearings with the help of eccentric trunnions. The specified pre-tension is realised via the adjustment torque of the two eccentric trunnions.

Affixed fleece wiper seals for lubricating the bearing surface of the outer ring of the roller bearings are used at the two outer roller bearings. These are impregnated with oil and their semicircular profile press against the guide rods. This lubricates the guide rods and wipes off any dirt.

1 2 23 4

5 56

1 Guide rods

2 Non-adjustable track rollers

3 Adjustable track rollers

4 Slide

5 Centric trunnions

6 Eccentric trunnions

NoteFesto recommends, as a basic principle, that you always replace the entire drive if a defect occurs in the profile track roller guide.

Replacement of the roller bearings is undertaken by users at their own risk.

Replacement of the toothed belt axis may be necessary under the following circumstances, for example:

The end of the profile track roller guide's useful life has been reached as a result of material fatigue and wear. Signs of fatigue appear on the material areas of the rolling components. Fine tears, pores and pits (depending on the wear condi-tion) in the bearing surfaces. Pitting on the bearing surfaces of the guide rods and the roller bearings can be observed visually as the bearing surface is noticeably uneven. This can result in perceptible bearing clearance, impaired roll-off and increased operating noise, etc.

NoteTheapplicationmustbecheckedforthefollowingcausesintheeventofprematurefailureduetoincreasedwear:

• Lack of lubrication; lubrication interval not adhered to (unlubricated operation).

• Use of an oil not contained in the specification.

• Dirty and corrosive ambient conditions (dust, etc.).

• Impact and vibration.

• Technical limit data exceeded (torques, forces, speed, temperature range, etc.).


NoteIncorrectsetvaluesforthebrakingrampduringSTOPconditions(e.g.emergencystop,quickstop)resultinover-loading of the toothed belt axis and can destroy it or dramatically reduce its service life.

• Check the settings for all braking ramps in your controller or the higher-order control system (deceleration values and jerk).

• Make sure that the deceleration values (braking deceleration, deceleration times) for the speed, the load to be moved and the installation position (horizontal/vertical) as well as the specified maximum drive torque or the feed force correspond to the permissible values for the toothed belt axis used.

• Use the Festo “Positioning Drives” sizing software, available via the Festo website (www.Festo.com), to size the toothed belt axis.

NoteBlock-shaped acceleration profiles (no jerk limitation) cause high peaks in the drive force that can lead to overloading of the drive. Positions outside of the permissible range can also occur.

A smoothed acceleration specification reduces vibrations in the entire system and has a positive effect on the stresses and strains to which the mechanical system is subjected.

• Check which closed-loop controller settings can be adapted (e.g. jerk limitation, smoothing of the acceleration profile).

4.3.1 Dismantling the slides

Replacing the stop buffers

NoteYou can replace the stop buffers without removing the slide.

• Lever the stop buffers out of both front sides of the slide and replace them.

Replacingthetrackrollers

NoteThe track rollers should at least be replaced in pairs, or ideally all four at the same time.

Check the guide rails for damage before replacing the track rollers. Defective guide rails cannot be replaced.

NoteA drive cover must be removed to replace the track rollers. To do this, carry out the steps described in section 4.2.1 “Removing the drive covers”.


• Push the slide out of the axis.

Note (DGE-63 only)The wiper seals are secured with a retaining ring so they cannot fall down-wards.

DGE-63 only

• Remove the retaining rings from the outer track rollers.

All sizes

• Remove the two wiper seals from the outer track rollers.

• Lever both covers out of the slide.

• Loosen the two hex nuts and unscrew them.

NoteYou may need to hold the eccentric screw from underneath. Alternatively you can use an Allen socket and a socket with milled spanner flat (see section 6.1 “Standard tools” and section 6.4 “Devices for in-house assembly”).

• Remove the flat washers from the hole.


• Pull the eccentric screws with the track rollers out of the slide holes.

• Remove the fitting washers and track rollers from the eccentric screws.

• Loosen the two centring screws and unscrew them.

• Remove the fitting washers and the track rollers from the centring screws.

• Clean the fitting holes in the slide and the eccentric screws.

NoteThe eccentric screws must be easy to turn in the fitting holes in the slide so that the adjustment torque is not falsified when setting the toothed belt pretension.

NoteDo not mix up the fitting washers and flat washers.

The mounting directions can be disregarded since the track rollers are sym-metrical.

• Push the new track rollers followed by the fitting washers onto the centring screws.


• Apply Loctite 243 to the centring screws and screw them into the slide.

• Tighten the centring screws using the appropriate torque (see table).

Type Torque

DGE-25 9.9 NmDGE-40 24 NmDGE-63 80 Nm

NoteDo not mix up the fitting washers and flat washers.

The mounting directions can be disregarded since the track rollers are sym-metrical.

• Push the new track rollers followed by the fitting washers onto the eccentric screws.

• Insert the eccentric screws into the fitting holes in the slide.

NoteDo not apply Loctite 243 to the eccentric screws. This is done just before the roller pretension is set.

• Place the flat washer and the hex nut on the eccentric screw and hand tighten the hex nut.

• Press the wiper seals onto the outer track rollers.

NoteThe oil-impregnated wiper seals are important for the operating performance of the roller guide and must not be omitted. If they are not fitted, the wear on the roller guide will be increased and the toothed belt axis will suffer premature failure.


DGE-63 only

• Insert the retaining ring.

NoteCheck that the retaining ring is correctly positioned.

All sizes

• Clean the inside of the cylinder barrel and guide rods using a cloth and air gun.

• Carefully push the slide onto the guide rails in the cylinder barrel.

4.3.2 Settingthetrackrollerpretension

The roller bearings must be set using the eccentric screws so that the displace-ment resistance for the slide is as low as possible and it can move without backlash.

NoteThe track roller pretension is set with the two inner track rollers via eccentric screws. It requires a high degree of mechanical awareness.

The pretension is set without the toothed belt attached.

• Unscrew the hex nuts of the eccentric screws and apply Loctite 243 to them.

• Replace the hex nuts on the eccentric screws, but do not tighten them yet.


NoteThe two track rollers are set one after the other.

• Place the socket with the milled spanner flat (see section 6.4 “Devices for in-house assembly”) on the hex nut.

• Place the Allen socket on the eccentric screw through the socket.

• Pretension the eccentric screw anticlockwise to the specified adjustment torque using a torque wrench with drag indicator (see table).

Type Adjustment torque


• Tighten the hex nuts slightly so that the pretension of the eccentric is main-tained.

NoteThe pretension will be changed if the hex nuts are overtightened.

• Place a rigid hex driver in the eccentric screw and hold it in position.

• Tighten the hex nuts using the appropriate torque (see table).

Type Torque


• Repeat the setting process on the second track roller.

• Check the pretension setting by measuring the displacement force of the slide (see section 4.3.3 “Measuring the displacement force of the slide”).


4.3.3 Measuring the displacement force of the slide

NoteThe displacement force is measured across the entire stroke without the toothed belt attached.

• Check the guide backlash and the displacement force (see table) by moving the slide a number of times.

• The slide must move smoothly and without jerking on the guide rail.

Type Min. displacement force Max. displacement force

DGE-25 5 N 12 NDGE-40 5 N 35 NDGE-63 5 N 30 N

NoteThe displacement force can be determined using an electronic hand-held force measuring device (pressure and tensile force meter).

In general, the mechanical awareness of the user is important when setting the linear guide. Poor operating behaviour manifests itself through operating noise. Excessive pretensioning manifests itself through harsh, increased operating noise.

• Adjust the track roller pretension until the operating behaviour is perfect (see section 4.3.2 “Setting the track roller pretension”).

4.4 Assembling the toothed belt axis

4.4.1 Preparing the cylinder barrel

• Clean the outside of the cylinder barrel using a cloth and air gun.

• Blow out the toothed belt throughfeed using an air gun.

NoteCheck the guide rails for damage before assembling the toothed belt axis. Defective guide rails cannot be replaced.

4.4.2 Installing the drive covers

• Place the cylinder barrel on the work surface as shown.

• Guide the toothed belt through the toothed belt guide in the cylinder barrel as shown. The toothed profile must be facing upwards.

WarningNote the minimum bending radii when handling the toothed belt (see section 4.1.4 “Cutting the toothed belt to length”).


• Guide the left-hand end of the toothed belt through the prepared drive cover for the left-hand side as shown.

• Place the clamping plate on the left-hand end of the toothed belt.

NoteThe clamping plate must be aligned axially with the centre of the toothed belt to prevent damage to the toothed belt during operation.

• Align the clamping plate axially with the centre of the toothed belt.

X1

X1

WarningThe toothed belt must be placed correctly on the clamping plate. It must not protrude and must make contact with four teeth.

NoteThe tapped holes of the clamping bodies must be recut before the threaded pins are screwed in. Residues from the old locking agent in the tapped holes result in uneven and increased torques for the threaded pins, which means they may not be correctly tightened.

• Insert the left-hand end of the toothed belt together with the clamping plate into the clamping body.

• Align the toothed belt axially with the centre of the clamping body.


• Apply Loctite 243 to the threaded pin and screw it into the clamping body.

• Push the clamping plate against the stop (a) on the clamping body.

NoteThe clamping plate must make contact with the stop as otherwise the toothed belt pretension will diminish during operation.

• Tighten the threaded pin using the appropriate torque (see table).

NoteIt is critical that the torques be observed. Excessive torques will bend the clamping body.

Type Torque


NoteThe drive cover is centred with respect to the cylinder barrel by means of two clamping sleeves. A certain amount of force may need to be applied for assembly.

• Place the left-hand drive cover on the cylinder barrel.

• Apply Loctite 243 to the socket head screws and screw them into the cylin-der barrel through the drive cover.

• Tighten the socket head screws using the appropriate torque (see table).

Type Torque


WarningDo not bend or fold the toothed belt, as this can result in damage to the tensile bodies and shorten its service life by tearing it. Note the minimum bending radius for assembly and storage (see section 4.1.4 “Cutting the toothed belt to length”).

• Push the clamping body into the axis through the recess in the cylinder barrel.


• Move the clamping body to the left-hand end of the cylinder barrel.

• Repeat the steps on the other end of the axis to install the second drive cover.

• Push the clamping bodies into the guide in the slide.

WarningThe clamping bodies must not touch the slide when they are being screwed in as otherwise the toothed belt could become overstretched and the service life of the toothed belt would be reduced. Slowly increase the toothed belt pretension to the correct value.

• Steadily screw the socket head screws through the clamping bodies into the slide.

• Pretension the toothed belt by steadily tightening the socket head screws by feel.

NoteIf the toothed belt is cut to the correct length, the clamping bodies should at least be flush with the slide.

If the clamping bodies protrude, the socket head screws will not reach the minimum screw-in depth and could be torn out.

NoteSet the toothed belt pretension as described in section 4.1.2 “Checking and setting the toothed belt pretension”.

4.5 Assemblyandfunctioncheck

After completing the assembly work on the toothed belt axis, check the components for correct functioning as follows.

4.5.1 No-loadtorque

It must be possible to move the slide without much resistance or jerking when idle, without a drive attached or load con-nected.

This check is based on the technician's instinct and experience. It is not possible to specify precise test values.


5 Maintenance

This chapter contains key technical information about how to carry out maintenance work on the toothed belt axis. A detailed description of the steps for care and maintenance can be found in the operating instructions. Additional infor-mation on assembly aids and lubricants can be found on the Festo website (www.Festo.com).

5.1 Cleaning and lubricating the toothed belt axis

No machine components need to be greased when repairing the toothed belt axis.

5.2 Checkingandlubricatingtherollerbearingguide

Check whether the roller bearing guide is free from backlash and distortion during each maintenance operation.

The track rollers have a life-time filling. They do not need to be relubricated.

The guide rods of the roller bearings are lubricated by oil-impregnated fleece wiper seals during operation. The wiper seals must be relubricated every 10,000 km. The relubrication interval must be reduced in dusty and dirty environments as well as with very short working strokes. The maximum capacity of the wiper seals is approx. 5 ml.

Recommended oil Manufacturer/supply Comment

Constant OY 390 Klüber (www.klueber.com)

Available in a 200 ml container via Festo, purchase details on request

Oils from other manufacturers with the same specification can also be used

NoteThe lubrication nipples pressed in on both sides for relubricating the wiper seals are miniature funnel-type lubrication nipples based on DIN 3405 (not fully compatible).

Relubrication must always take place at both lubrication nipples.

Festo offers a one-hand high-pressure grease gun with a suitable pinpoint nozzle for relubrication using these lubrication nipples (see section 6.2 “Special tools”). A grease or oil gun with pointed nozzle connection C5 for funnel-type lubrication nipples according to DIN 3405 cannot be used be-cause the smallest diameter of the tapered nozzle is too big and the spring ball of the funnel-type lubrication nipple cannot be pushed in.

Lubrication nipple

5.3 Toothed belt pretension

WarningThe toothed belt is set to the specified value in the factory and is thus maintenance-free over its entire service life.



6 Tools

This chapter provides an overview of the tools and aids required to repair and maintain the toothed belt axis.

6.1 Standard tools

The following standard tools are required to repair and maintain the toothed belt axis:

Designation Additional information

Plastic hammer –Screwdriver bits With ¼" square drive, for 3, 4 and 6 mm socket head screws, length of the hexagon

min. 30 mm (long version)Pliers for retaining rings (interior protection for hole)

19 – 100 mm

Pliers for retaining rings (exterior protection for pin)

20 – 30 mm

Ruler –Internal hexagon screwdriver (Allen key)

2 – 10 mm

Torque wrench 1 – 80 NmTorque wrench with dial gauge and/or drag indicator

With ¼" square drive, 50 – 600 Ncm

Tensile and pressure force measuring device

Electronic hand-held force measuring device, measuring range: 0 – 50 N

Screwdriver bits Internal hexagon socket (Allen socket): 2 – 10 mmFlat pliers –Sturdy general purpose scis-sors or metal shears

For cutting the toothed belt to length

6.2 Special tools

The following special tools are required to repair and maintain the toothed belt axis:

Designation Additional information

Festo order no. Photo

One-hand high-pressure grease gun

Pinpoint nozzle for miniature funnel-type lubrication nipple

647 9581)

1) See “Assembly aids” in the online spare parts catalogue on the Festo website (www.Festo.com).


6.3 Devices and meters

The following devices and meters are required to repair and maintain the toothed belt axis:

Part no.

Type

Description Photo

760458

TB-TE-EQ2

Basic device for checking the toothed belt pretension, in a Systainer with foam insert.

Suitable for toothed belt axes of the type DGE-25/40/63-ZR-(KF), DGE-25/40/63-ZR-RF, EGC-TB-KF.

Holds the test probe of the acoustic frequency meter of the type TB-TE-EQ3 and excites the toothed belt by means of a plunger.

760459

TB-TE-EQ-3

Acoustic belt tension meter (frequency meter) for measurement with and without test equipment.

Special bonding of the test probe for use with the test equipment.

Order alternatives:

Type: Optibelt TT mini S plus

Available exclusively from Schaefer Technik GmbH www.schaefer-technik.de

– Acoustic belt tension meter (frequency meter) for measurement without test equipment.

Not available via Festo.

Manufacturer/supply:

Optibelt GmbH www.optibelt.com or comparable meter from other manufacturers.

200926

O-ring 10x1

Mounts the acoustic test probe in the test equipment by means of clamping friction.

Included in the scope of delivery of the frequency meter TB-TE-EQ3.

760457

TB-TE-EQ0

Empty Systainer with foam insert.

Space for basic test equipment TB-TE-EQ2/760458 (DGE-25/40/63-ZR-(KF), DGE-25/40/63-ZR-RF, EGC-TB-KF), frequency meter TB-TE-EQ3/760459, mounting kit TB-TE-EQ4/760460 (ELGA-TB) and test equipment TB-TE-EQ5/760461 (ERMB/EHMB).


6.4 Devices for in-house assembly

Designation Dimensions DGE-25

Dimensions DGE-40

Dimensions DGE-63

Photo

Socket with milled spanner flat

For tightening the hex nuts of the eccentric screws

Spanner flat 10 with 1/4" square drive

Max. outer diameter: 14.5 mm

Spanner flat 10 mm



Spanner flat 10 mm



Spanner flat 10 mm

Hole dimensions of the slide for manufacturing the socket

d = 14.7 -0.1 mm

t = 16 mm

d = 18.8 +0.1 mm

t = 20 mm

d = 31.6 +0.1 mm

t = 20 mm

d

t

Clamp piece for toothed belt pretension (in-cluded in the device for checking the toothed belt pretension)

a=10 mm

b=15-0,1 mm

c=R 5 mm

d=1.85 mm

e=11 mm

f=0.95-0,05 mm

g=20 mm

a=15 mm

b=25-0,1 mm

c=R 6 mm

d=2.6 mm

e=14 mm

f=0.95-0,05 mm

g=30 mm

Clamp piece not required

g

f

e

d

ca

b

7 Liability

The General Terms and Conditions of Festo AG & Co. KG, which can be viewed on the Festo website (www.Festo.com) apply.


Conditions of use for “electronic documentation”

I. Protection rights and scope of use

The file of your choice is subject to protec-tion provisions. Festo or third parties have protection rights concerning this electronic documentation which Festo makes available on portable data storage devices (floppy disks, CD-ROM, removable disks) as well as on the Internet and/or Intranet, hereinafter referred to as electronic documentation. Provided third parties are entitled to partial or full rights concerning this electronic docu-mentation, Festo shall have the correspond-ing rights of use. Festo permits the user to use the electronic documentation under the following conditions:

1. Scope of use

a) The user of the electronic documenta-tion is allowed to use this documentation for his own, exclusively company-internal purposes on any number of machines within his business premises (location). This right of use includes exclusively the right to save the electronic documentation on the central processors (machines) used at the location.

b) The electronic documentation may be printed out on a printer at the location of the user as often as desired, providing this printout is printed with or kept in a safe place together with these conditions of use and other user instructions.

c) With the exception of the Festo logo, the user has the right to use pictures and texts from the electronic documentation for creat-ing his own machine and system documen-tation. The use of the Festo logo requires written consent from Festo. The user himself is responsible for ensuring that the pictures and texts used match the machine/system or the relevant product.

d) Further uses are permitted within the fol-lowing framework:

Copying exclusively for use within the frame-work of machine and system documentation from electronic documents of all documented supplier components. Demonstrating to third parties exclusively under guarantee that no data material is stored wholly or partly in other networks or other data storage devices or can be reproduced there.

Passing on printouts to third parties not covered by the provision stated in item 3, as well as any processing or other use, is not permitted.

2. Copyright note

Every “electronic document” receives a copyright note. This note must be included on every copy and every printout.

Example: E 2003, Festo AG & Co. KG, D-73726 Esslingen

3. Transferring the authorisation of use

The user can transfer the authorisation of use in the scope of and with the limitations of the conditions in accordance with items 1 and 2 completely to a third party. The third party must be made explicitly aware of these conditions of use.

II. Exporting the electronic documentation

When exporting the electronic documenta-tion, the licence holder must observe the export regulations of the exporting country and those of the purchasing country.

III. Warranty

1. Festo products are being continuously developed with regard to hardware and soft-ware. The hardware status and, where appli-cable, the software status of the product can be found on the name plate of the product. If the electronic documentation, in whatever form, is not supplied with the product, i. e. is not supplied on a portable data storage device (floppy disk, CD-ROM, removable disk), Festo does not guarantee that the elec-tronic documentation corresponds to every hardware and software status of the product. In this case, the printed documentation from Festo accompanying the product alone is decisive for ensuring that the hardware and software status of the product matches that of the electronic documentation.

2. The information contained in this electronic documentation can be amended by Festo without prior notice and does not commit Festo in any way.

IV. Liability/Limitations of liability

1. Festo supplies this electronic documenta-tion in order to assist the user in creating his machine and system documentation. In the case of electronic documentation that does not directly accompany a product in the form of portable data storage devices (floppy disk, CD-ROM, removable disk), i. e. that is not automatically supplied together with that product, Festo does not guarantee that the electronic documentation available/supplied separately matches the product actually used by the user.

The latter applies particularly to extracts of the documents for the user’s own documenta-tion. The guarantee and liability for separately available/supplied data storage devices, i. e. except for the electronic documentation available via the Internet/Intranet, is limited exclusively to proper duplication of the software, whereby Festo guarantees that in each case the data storage device or software contains the latest update of the documenta-tion. Concerning electronic documentation available on the Internet/Intranet, there is no guarantee that it will have the same version status as the last printed edition.

2. Furthermore, Festo cannot be held liable for the lack of economic success or for dam-age or claims by third parties resulting from the use of the documentation by the user, with the exception of claims arising from infringement of the protection rights of third parties concerning the use of the electronic documentation.

3. The limitations of liability as per para-graphs 1 and 2 do not apply if, in cases of intent or gross negligence or the lack of warranted quality, liability is compulsory. In such a case, Festo’s liability is limited to the damage discernable by Festo when the defini-tive circumstances are made known.

V. Safety guidelines/documentation

Warranty and liability claims in conformity with the aforementioned regulations (items III and IV) may be raised only if the user has observed the safety guidelines of the docu-mentation in conjunction with the use of the machine and its safety guidelines. The user himself is responsible for ensuring that the electronic documentation, when not supplied with the product, matches the product actu-ally used by the user.

Operating instructions (en)

Toothed belt pretension test equipment

7Tension01_TBb_en

2 / 20 Festo 7Tension01_TBb_en

Imprint

Version: 7Tension01_TBb_en (11.2011)

Copyright: ©Festo AG & Co. KG P.O. Box D-73726 Esslingen

Editorial team: SC-S

Tel.: +49 (0) 711/347-0

E-mail: [email protected]

Internet: http://www.festo.com

The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without explicit authorisation is prohibited. Offenders will be liable for damages. All rights reserved, in particular the right to file patent, utility model or registered design applications.

All product designations and brand names used are the property of the owners and not explicitly identified as such.

All technical data subject to change according to technical updates.

3 / 20Festo 7Tension01_TBb_en

ForewordThese operating instructions are valid for the toothed belt pretension test equipment listed on the title page to the exclusion of any liability claims.

Deviations compared to the descriptions in these operating instructions may arise depending on the modification status of the toothed belt pretension test equipment. The user must check this prior to setting the toothed belt preten-sion and take any deviations into consideration.

These operating instructions have been prepared with care.

Festo AG & Co. KG does not, however, accept liability for any errors in these operating instructions or their consequences. Likewise, no liability is accepted for direct or consequential damage resulting from improper use of the product.

More detailed information on this can be found in chapter 12 “Liability”.

The relevant regulations on occupational safety, safety engineering and interfer-ence suppression as well as the stipulations contained in these operating instructions must be observed when working on the products.


Table of contents

1 Important information 5

1.1 About these operating instructions 5

1.2 Pictograms used in these operating instructions 5

1.3 General safety information 6

2 Control elements and connections 6

2.1 Test equipment 6

2.2 Mounting kit for ELGA-TB 6

3 Function and application 7

4 Storage 7

5 Test requirements 7

6 Application and operation 8

6.1 Preparing the toothed belt axis 86.1.1 Checking the piston distance (DGE-…-ZR(-KF) only) 86.1.2 Inserting clamp pieces (DGE-25/40-ZR-RF only) 8

6.2 Preparing the test equipment 96.2.1 Attaching the extension sleeves 96.2.2 Attaching the stop bolts 106.2.3 Attaching the test equipment 11

6.3 Checking and setting the toothed belt pretension 146.3.1 Checking the toothed belt pretension 146.3.2 Setting the toothed belt pretension 156.3.3 Additional information on checking the toothed belt pretension 15

7 Quick guide 16

7.1 DGE-…-ZR(-KF) 16

7.2 DGE-…-ZR-RF 16

7.3 EGC-…-TB-KF 16

7.4 ELGA-TB-G-… 17

8 Maintenance and care 17

9 Accessories and ordering data 18

10 Assembly and function check 18

11 Tools 19

12 Liability 19


1 Important information

1.1 About these operating instructions

This document contains important information on how to use the toothed belt pretension test equipment professionally. Before checking the toothed belt pretension, these instructions must be read in full and followed consistently.

The same applies when setting and checking the toothed belt pretension.

1.2 Pictograms used in these operating instructions

WarningThis sign indicates a dangerous situation for persons and/or the product. Failure to observe this warning can result in injury to persons and/or damage to the device.

NoteThis sign provides important tips and information that can make your work easier.

EnvironmentThis sign provides information on the steps required for environmentally friendly use of materials and equipment, as well as the guidelines and regulations that may need to be observed.

DocumentsThis sign contains references to other sections or documents containing additional information.


1.3 General safety information

WarningThe toothed belt pretension must only be set by authorised and trained persons in accordance with the specifications in the technical documentation.

Setting of the toothed belt pretension by persons without the necessary authorisation and training as well as without the technical documentation required is dangerous and therefore not permitted.

Setting of the toothed belt pretension using the toothed belt pretension test equipment must only be carried out in conjunction with these operating instructions as well as the respective repair instructions for the device.

EnvironmentComponents and equipment replaced as part of a repair must be disposed of in accordance with the locally valid envi-ronmental protection regulations.

2 Control elements and connections

2.1 Test equipment

6 7 8

1

2

3

4

5 9

aJ

aA

aCaD

aE

aF

aB

1 Position stop for DGE-25/40/63

2 Extension sleeve 10 mm

3 Stop bolt 8 × 22 mm

4 Extension sleeve 25 mm

5 Slide mechanism, indexing by means of spring pressure elements

6 Measurement head holder for acoustic belt tension meter

7 Plunger with 2-spring package

8 Plunger housing

9 Clamp piece for DGE-25-ZR-RF

aJ Stop bolt 13 × 22 mm

aA Clamp piece for DGE-40-ZR-RF

aB Stop bolt 11 × 22 mm

aC Knurled screw for securing the position stop

aD Test equipment

aE Recesses for the elastomer buffers

aF M5 threaded holes for the stop bolts

2.2 Mounting kit for ELGA-TB

2 3

7

1

6

4

5

1 Position stop bolt

2 Position stop, left

3 Position stop, right

4 Distance piece for ELGA-TB-G-120



7 Transport holder for distance pieces


3 Function and application

A plunger attached to the toothed belt pretension test equipment makes the toothed belt oscillate by applying a force stimulus. The natural frequency of the toothed belt generated in this way is recorded using a meter and displayed as a frequency value in hertz.

The freely oscillating toothed belt strand length defined by the toothed belt pretension test equipment enables accurate comparison of the specified measured values without the risk of measuring errors during positioning of the slide/piston.

This toothed belt pretension test equipment can be used for the following toothed belt axes:

• DGE-25/40/63-ZR(-KF)

• DGE-25/40/63-ZR-RF

• EGC-…-TB-KF

• ELGA-TB-G-70/80/120

4 Storage

Store the toothed belt pretension test equipment in a dry place where it is protected from corrosion, ideally in the match-

ing Systainer (see section 9 “Accessories and ordering data”).

5 Test requirements

WarningChecking and setting the toothed belt pretension is only required and permissible after a new toothed belt is installed. The pretension of the toothed belt diminishes during storage and operation. This is a normal process and not an indication of wear. Retensioning the toothed belt can result in premature wear.

Before the toothed belt pretension can be measured, the slide/piston must be moved back and forth a number of times to allow the toothed belt to fully settle and differences in tension to be equalised.

Checking and setting the toothed belt pretension must only be performed on toothed belt axes whose electric power units have been disconnected.

The information in the corresponding repair instructions for the respective toothed belt axis apply to the steps described in these operating instructions.


6 Application and operation

NoteExcitation of the natural oscillation of the toothed belt via the plunger by means of a force stimulus is possible with the test equipment in all positions due to the absence of non-captive parts and the 2-spring system in the plunger housing. Space permitting, there are no restrictions with respect to the position of the toothed belt axis when using the test equipment.

The test equipment can be secured using fastening clamps if necessary for testing from below or with the toothed belt axis in an inclined or vertical installation position.

The toothed belt pretension is determined by measuring the basic oscillation (natural frequency) of the toothed belt with a fixed and freely oscillating strand length (L). The distance from the clamping body to one of the drive covers (L1) is set by inserting the test equipment and the corresponding stop bolt. The oscillation measurement is then performed using the test equipment.

L

L1

6.1 Preparing the toothed belt axis

6.1.1 Checking the piston distance (DGE-…-ZR(-KF) only)

• Check the distance between the piston and clamp piece (X) and adjust it if necessary (see table).

Type Distance X

DGE-25-…-ZR(-KF) 2 mmDGE-40-…-ZR(-KF) 3 mmDGE-63-…-ZR(-KF) 5 mm

6.1.2 Inserting clamp pieces (DGE-25/40-ZR-RF only)

NoteIt is imperative to attach an additional clamp piece to the toothed belt axes DGE-25-ZR-RF and DGE-40-ZR-RF so that the toothed belt can oscillate freely and does not strike the cylinder barrel.

• If necessary, push the relevant clamp piece through the recess in the cylinder barrel between the toothed belt and the cylinder barrel. It must touch the clamping body.


6.2 Preparing the test equipment

Depending on the design and size of the toothed belt axis, different extension sleeves and stop bolts must be attached at different points on the test equip-ment and different settings must be made.

6.2.1 Attaching the extension sleeves

NoteThe distance from the test equipment to the rear of the toothed belt varies depending on the toothed belt axis. The different distances are compensated by the extension sleeves to optimise the force stimulus applied by the plunger.

• Loosen the plunger housing and then unscrew it from the test equipment.

• Screw the appropriate extension sleeve onto the plunger housing (see table).

Type Extension sleeve length

DGE-25-ZR(-KF) 10 mmDGE-40-ZR(-KF) 10 mmDGE-63-ZR(-KF) No extension sleeveDGE-25-ZR-RF 25 mmDGE-40-ZR-RF 25 mmDGE-63-ZR-RF 25 mmEGC-50-TB-KF 25 mmEGC-70-TB-KF 25 mmEGC-80-TB-KF 25 mmEGC-120-TB-KF 25 mmEGC-185-TB-KF 25 mmELGA-TB-G-70 25 mmELGA-TB-G-80 25 mmELGA-TB-G-120 25 mm

• Screw the plunger housing back into the test equipment.


6.2.2 Attaching the stop bolts

NoteThe test equipment is placed on the left or right of the slide/piston on the toothed belt axisdepending on the size and design of the toothed belt axis (see table in section 6.2.3 “Attaching the test equipment”). Observe the prescribed test position when screwing the respective stop bolt into the test equipment.

The designations in the table refer to the side where the slide/piston is at-tached to the test equipment or the stop bolt. S.L. means that the slide/piston is attached on the left of the test equipment, S.R. means that the slide/piston is attached on the right of the test equipment. The designations are engraved into the test equipment.

• Unscrew the relevant stop bolt from the top of the test equipment and screw it into the specified thread on the front side of the test equipment (see table).

Type Stop bolt diameter Item

DGE-25-ZR(-KF) 13 mm EDGE-40-ZR(-KF) No stop bolt -DGE-63-ZR(-KF) No stop bolt -DGE-25-ZR-RF 13 mm EDGE-40-ZR-RF 13 mm EDGE-63-ZR-RF 13 mm FEGC-50-TB-KF 8 mm AEGC-70-TB-KF 11 mm BEGC-80-TB-KF 13 mm CEGC-120-TB-KF 13 mm S.L.: C, S.R.: F EGC-185-TB-KF 13 mm EELGA-TB-G-70 11 mm EELGA-TB-G-80 11 mm EELGA-TB-G-120 11 mm E


6.2.3 Attaching the test equipment

WarningRead the test requirements in chapter 5 “Test requirements”.

Note (DGE-…-ZR(-KF) only)The test equipment must be positioned on the side where the piston distance was set. This is the only way to ensure that the freely oscillating strand length is correct.

• Refer to the table for the position of the test equipment.

Type Test equipment position

DGE-25-ZR(-KF) S.L. or S.R.DGE-40-ZR(-KF) S.L. or S.R.DGE-63-ZR(-KF) S.L. or S.R.DGE-25-ZR-RF S.L. or S.R. 1)

DGE-40-ZR-RF S.L. or S.R. 1)

DGE-63-ZR-RF S.R.EGC-50-TB-KF S.L.EGC-70-TB-KF S.R.EGC-80-TB-KF S.L.EGC-120-TB-KF S.L. or S.R. 1)

EGC-185-TB-KF S.L. or S.R. 1)

ELGA-TB-G-70 S.L. or S.R. 1)



1) Note the position of the stop bolt

Depending on the design of the toothed belt axis, the following methods can be used to ensure the correct position of the test equipment on the toothed belt axis:

With position stops (DGE-…-ZR-…)

NoteThe position stops are necessary to align the test equipment with the toothed belt axis.

• Place the position stops on the test equipment as appropriate to the size of the toothed belt axis.

• Secure the position stops using the knurled screws.

• Place the test equipment on the toothed belt axis to the left or right of the slide/piston (S.L. or S.R.) in accordance with the table.

• Push the test equipment forwards so that the position stops on the cylinder barrel touch the toothed belt axis.

Note (DGE-…-ZR-KF)The guide rail of the toothed belt axis must be pointing forwards to check the toothed belt pretension.


With position stops and distance pieces (ELGA-TB-G-…)

NoteThe position stops are necessary to align the test equipment with the toothed belt axis.

• Place the position stops for the ELGA toothed belt axis on the test equipment and secure it using the knurled screws.

• Place the position stop bolts in the position stops as appropriate to the size of the toothed belt axis.

• Place the appropriate distance piece for the size of the toothed belt axis on the free side of the test equipment and secure it at the position “E” using the 7 mm ø stop bolt.

• Place the test equipment to the left or right of the slide/piston (S.L. or S.R.) as appropriate to the position of the distance piece (must be facing the slide) in accordance with the table.

• Push the test equipment forwards so that the position stops on the cylinder barrel touch the toothed belt axis.

Without position stops (EGC-…-TB-KF)

• Remove the position stops from the test equipment.

• Place the test equipment on the toothed belt axis in front of the guide rail to the left or right of the slide in accordance with the table.

• Push the test equipment backwards so that it is touching the guide rail.

NoteThe test equipment is attached to the guide rail by means of integrated magnets.


All variants

NoteThere must be no visible gap between the individual components, as other-wise the length of the freely oscillating strand and the toothed belt pretension measurement will be incorrect.

• Move the test equipment outwards until it touches the drive cover without any visible gap.

• Push the slide/piston against the test equipment until (depending on the toothed belt axis) the stop bolt or the front side of the test equipment is touching the piston, the clamping body or the clamp piece with no visible gap.

• Move the holder for the plunger housing so that the plunger is centred above the toothed belt or profile slot.

WarningInserted in the groove of the measurement head is an O-ring that also holds the meter inverted in the holder. This O-ring must have lubricating grease applied to it as otherwise the measurement head can be damaged by the high force applied when it is pulled out.

• Push the measurement head of the acoustic belt tension meter all the way into the holder on the test equipment.


6.3 Checking and setting the toothed belt pretension

WarningChecking and setting the toothed belt pretension is only required and permissible after a new toothed belt is installed. The pretension of the toothed belt diminishes during storage and operation. This is a normal process and not an indication of wear. Retensioning the toothed belt can result in premature wear.

The toothed belt pretension has a direct influence on the service life of the toothed belt and the performance of the toothed belt axis. Extreme care must therefore be exercised when checking it.

Before the toothed belt pretension can be measured, the slide/piston must be moved back and forth a number of times to allow the toothed belt to fully settle and differences in tension to be equalised.

6.3.1 Checking the toothed belt pretension

Note on measurement using the acoustic belt tension meter

If the toothed belt is excited by means of a force stimulus, the strand oscillates with its natural frequency; this dies down reasonably quickly depending on the attenuation.

The frequency meter measures the natural frequency generated (transverse oscillation) using the acoustic operating principle. In addition to the basic oscillation (natural frequency), harmonic oscillation can also occur. From experience it is always the first harmonic oscillation. In other words, a further oscillation node is generated and therefore in addition to the basic oscillation frequency, values that are twice the natural frequency can also be measured.

For this reason, several measurements should always be carried out to differentiate the necessary basic oscillation (natural frequency) from the harmonic oscillation. Only this frequency can be used to extrapolate the force acting along the strand.

• Pull the plunger upwards and then release it.

NoteThe distance that the plunger has to be pulled out to generate the optimum force stimulus depends on the size and design of the toothed belt axis and must be established during the test.

The magnitude of the force stimulus does not influence the measured na-tural frequency oscillation, it only changes the magnitude of the oscillation amplitude.

Smaller toothed belt axes tend to require a smaller force stimulus.

NoteThe belt must be able to oscillate freely. Push clamp pieces into the toothed belt axis if necessary (see section 6.2 “Preparing the test equipment”).

To assess the toothed belt pretension, several measurements should be made to balance out any measurement tolerances.


• Compare the measurement with the specified value (see table).

Type Frequency (f )DGE-25-ZR(-KF) 172+7 HzDGE-40-ZR(-KF) 209+7 HzDGE-63-ZR(-KF) 176+7 HzDGE-25-ZR-RF 155+4 HzDGE-40-ZR-RF 143+4 HzDGE-63-ZR-RF 136+3 HzEGC-50-TB-KF 119+2 HzEGC-70-TB-KF 108+4 HzEGC-80-TB-KF 183+4 HzEGC-120-TB-KF 153+3 HzEGC-185-TB-KF 179+4 HzELGA-TB-G-70 146+2 HzELGA-TB-G-80 133+3 HzELGA-TB-G-120 138+2 Hz

6.3.2 Setting the toothed belt pretension

WarningThe toothed belt is set to the specified value in the factory and is thus maintenance-free over its entire service life.


DocumentsIf the measured natural frequency of the toothed belt is outside the specified range, adapt the toothed belt pretension as specified in the relevant chapter in the respective operating instructions.

6.3.3 Additional information on checking the toothed belt pretension

The correct toothed belt pretension is of critical importance for the service life of the toothed belt as well as the position-ing accuracy and performance of the toothed belt axis.

The conventional method for measuring the toothed belt pretension via the deflection force is too inaccurate and can therefore not be used. Accurate results are achieved by measuring the oscillation frequency. The natural frequency of a belt is based on its tension (strand force), mass and strand length.

NoteThe strand length is the oscillating length of a belt.

Since the strand length cannot be determined directly at the toothed belt axis by easy means, the toothed belt pretension test equipment is used to position the clamping body.

A force stimulus is applied to the toothed belt to start it oscillating. The natural frequency of the toothed belt generated in this way is recorded using a meter and displayed as a frequency value in hertz.


7 Quick guide

This chapter contains all the relevant information for the individual toothed belt axes at a glance.

7.1 DGE-…-ZR(-KF)

NoteThe test equipment must be positioned on the side where the piston distance was set. This is the only way to ensure that the freely oscillating strand length is correct.

Note (DGE-…-ZR-KF only)The guide rail of the toothed belt axis must be pointing forwards (compared to the position stops) to check the toothed belt pretension.

Type Frequency (f ) Sleeve for plunger Slide position Stop bolt ø/position Distance between piston and clamp piece1)

DGE-25-ZR(-KF) 172+7 Hz 10 mm S.L. or S.R. 13 mm/E 2 mmDGE-40-ZR(-KF) 209+7 Hz 10 mm S.L. or S.R. – 3 mmDGE-63-ZR(-KF) 176+7 Hz – S.L. or S.R. – 5 mm

1) See section 6.1 “Preparing the toothed belt axis”

7.2 DGE-…-ZR-RF

NoteIt is imperative to attach an additional clamp piece to the toothed belt axes DGE-25-ZR-RF and DGE-40-ZR-RF so that the toothed belt can oscillate freely and does not strike the cylinder barrel (see section 6.1.2 “Inserting clamp pieces (DGE-25/40-ZR-RF only)”).

Type Frequency (f ) Sleeve for plunger Slide position Stop bolt ø/position

DGE-25-ZR-RF 155+4 Hz 25 mm S.L. or S.R. 13 mm/EDGE-40-ZR-RF 143+4 Hz 25 mm S.L. or S.R. 13 mm/EDGE-63-ZR-RF 136+3 Hz 25 mm S.R. 13 mm/F

7.3 EGC-…-TB-KF

NoteThe test equipment is positioned without position stops using the magnets inserted in the test equipment on the guide rail.


EGC-50-TB-KF 119+2 Hz 25 mm S.L. 8 mm/AEGC-70-TB-KF 108+4 Hz 25 mm S.R. 11 mm/BEGC-80-TB-KF 183+4 Hz 25 mm S.L. 13 mm/CEGC-120-TB-KF 153+3 Hz 25 mm S.L. or S.R. 13 mm/S.L.: C, S.R.: FEGC-185-TB-KF 179+4 Hz 25 mm S.L. or S.R. 13 mm/E


7.4 ELGA-TB-G-…

NoteThe “Mounting kit for toothed belt axis ELGA-TB” is needed to position the test equipment (see section 2.2 “Mounting kit for ELGA-TB”).


ELGA-TB-G-70 146+2 Hz 25 mm S.L. or S.R. 11 mm/EELGA-TB-G-80 133+3 Hz 25 mm S.L. or S.R. 11 mm/EELGA-TB-G-120 138+2 Hz 25 mm S.L. or S.R. 13 mm/E

8 Maintenance and care

If necessary, clean the toothed belt pretension test equipment using a soft cloth and gentle detergent.


9 Accessories and ordering data

You will need the following accessories to measure the toothed belt pretension.

Part no.

Type

Description Photo

760458

TB-TE-EQ2

Basic device for checking the toothed belt pretension, in a Systainer with foam insert.

Suitable for toothed belt axes of the type DGE-25/40/63-ZR-(KF), DGE-25/40/63-ZR-RF, EGC-TB-KF.

Holds the test probe of the acoustic frequency meter of the type TB-TE-EQ3 and excites the toothed belt by means of a plunger.

760460

TB-TE-EQ4

Mounting kit for toothed belt axis ELGA-TB.

Additionally requires the basic device of the type TB-TE-EQ2 for checking the toothed belt pretension.

760459

TB-TE-EQ-3

Acoustic belt tension meter (frequency meter) for measurement with and without test equipment.

Special bonding of the test probe for use with the test equipment.

Order alternatives:

Type: Optibelt TT mini S plus

Available exclusively from Schaefer Technik GmbH www.schaefer-technik.de

200926

O-ring 10x1

Mounts the acoustic test probe in the test equipment by means of clamping friction.

Included in the scope of delivery of the frequency meter TB-TE-EQ3.

760457

TB-TE-EQ0

Empty Systainer with foam insert.

Space for basic test equipment TB-TE-EQ2/760458 (DGE-25/40/63-ZR-(KF), DGE-25/40/63-ZR-RF, EGC-TB-KF), frequency meter TB-TE-EQ3/760459, mounting kit TB-TE-EQ4/760460 (ELGA-TB) and test equipment TB-TE-EQ5/760461 (ERMB/EHMB).

10 Assembly and function check

After completing the setting work on the toothed belt axis, the correct function must be checked using the relevant chap-ters in the repair instructions.


11 Tools

DocumentsRefer to the repair instructions for the respective toothed belt axis for an overview of the tools and aids for setting the toothed belt pretension.

12 Liability

The General Terms and Conditions of Festo AG & Co. KG, which can be viewed on the Festo website (www.Festo.com) apply.

www.Festo.com


Conditions of use for “electronic documentation”

I. Protection rights and scope of use

The file of your choice is subject to protec-tion provisions. Festo or third parties have protection rights concerning this electronic documentation which Festo makes available on portable data storage devices (floppy disks, CD-ROM, removable disks) as well as on the Internet and/or Intranet, hereinafter referred to as electronic documentation. Provided third parties are entitled to partial or full rights concerning this electronic docu-mentation, Festo shall have the correspond-ing rights of use. Festo permits the user to use the electronic documentation under the following conditions:

1. Scope of use

a) The user of the electronic documenta-tion is allowed to use this documentation for his own, exclusively company-internal purposes on any number of machines within his business premises (location). This right of use includes exclusively the right to save the electronic documentation on the central processors (machines) used at the location.

b) The electronic documentation may be printed out on a printer at the location of the user as often as desired, providing this printout is printed with or kept in a safe place together with these conditions of use and other user instructions.

c) With the exception of the Festo logo, the user has the right to use pictures and texts from the electronic documentation for creat-ing his own machine and system documen-tation. The use of the Festo logo requires written consent from Festo. The user himself is responsible for ensuring that the pictures and texts used match the machine/system or the relevant product.

d) Further uses are permitted within the fol-lowing framework:

Copying exclusively for use within the frame-work of machine and system documentation from electronic documents of all documented supplier components. Demonstrating to third parties exclusively under guarantee that no data material is stored wholly or partly in other networks or other data storage devices or can be reproduced there.

Passing on printouts to third parties not covered by the provision stated in item 3, as well as any processing or other use, is not permitted.

2. Copyright note

Every “electronic document” receives a copyright note. This note must be included on every copy and every printout.

Example: E 2003, Festo AG & Co. KG, D-73726 Esslingen

3. Transferring the authorisation of use

The user can transfer the authorisation of use in the scope of and with the limitations of the conditions in accordance with items 1 and 2 completely to a third party. The third party must be made explicitly aware of these conditions of use.

II. Exporting the electronic documentation

When exporting the electronic documenta-tion, the licence holder must observe the export regulations of the exporting country and those of the purchasing country.

III. Warranty

1. Festo products are being continuously developed with regard to hardware and soft-ware. The hardware status and, where appli-cable, the software status of the product can be found on the name plate of the product. If the electronic documentation, in whatever form, is not supplied with the product, i. e. is not supplied on a portable data storage device (floppy disk, CD-ROM, removable disk), Festo does not guarantee that the elec-tronic documentation corresponds to every hardware and software status of the product. In this case, the printed documentation from Festo accompanying the product alone is decisive for ensuring that the hardware and software status of the product matches that of the electronic documentation.

2. The information contained in this electronic documentation can be amended by Festo without prior notice and does not commit Festo in any way.

IV. Liability/Limitations of liability

1. Festo supplies this electronic documenta-tion in order to assist the user in creating his machine and system documentation. In the case of electronic documentation that does not directly accompany a product in the form of portable data storage devices (floppy disk, CD-ROM, removable disk), i. e. that is not automatically supplied together with that product, Festo does not guarantee that the electronic documentation available/supplied separately matches the product actually used by the user.

The latter applies particularly to extracts of the documents for the user’s own documenta-tion. The guarantee and liability for separately available/supplied data storage devices, i. e. except for the electronic documentation available via the Internet/Intranet, is limited exclusively to proper duplication of the software, whereby Festo guarantees that in each case the data storage device or software contains the latest update of the documenta-tion. Concerning electronic documentation available on the Internet/Intranet, there is no guarantee that it will have the same version status as the last printed edition.

2. Furthermore, Festo cannot be held liable for the lack of economic success or for dam-age or claims by third parties resulting from the use of the documentation by the user, with the exception of claims arising from infringement of the protection rights of third parties concerning the use of the electronic documentation.

3. The limitations of liability as per para-graphs 1 and 2 do not apply if, in cases of intent or gross negligence or the lack of warranted quality, liability is compulsory. In such a case, Festo’s liability is limited to the damage discernable by Festo when the defini-tive circumstances are made known.

V. Safety guidelines/documentation

Warranty and liability claims in conformity with the aforementioned regulations (items III and IV) may be raised only if the user has observed the safety guidelines of the docu-mentation in conjunction with the use of the machine and its safety guidelines. The user himself is responsible for ensuring that the electronic documentation, when not supplied with the product, matches the product actu-ally used by the user.

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