Festo DNCKE Series, KEC Series, KEC-16 Series, DNCKE-40 Series, KEC-20 Series Operating Instructions Manual

DNCKE-...-S / KEC-...-S

Cylinder with clamping unit/Clamping unit

Instructions | Operat­ing

8098628

8098628
2018-12d
[8098630]

Translation of the original instructions

2 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Table of contents

1 Design.......................................................................................................................... 4

2 Safety........................................................................................................................... 5

2.1 Intended use................................................................................................................ 5

2.2 Foreseeable misuse...................................................................................................... 6

2.3 Specified standards...................................................................................................... 6

2.4 General safety instructions........................................................................................... 6

2.5 Mounting and connecting............................................................................................. 6

2.6 Training of qualified personnel..................................................................................... 6

3 Function........................................................................................................................7

4 Transport..................................................................................................................... 7

5 Installation.................................................................................................................. 7

5.1 Mechanical installation................................................................................................. 7

5.1.1 Mounting the clamping unit.................................................................................... 8

5.1.2 Mounting attachments............................................................................................9

5.1.3 Mounting accessories............................................................................................. 10

5.2 Pneumatic installation.................................................................................................. 10

5.2.1 Requirements......................................................................................................... 10

5.2.2 Functional tests...................................................................................................... 11

5.2.3 Creating a tubing connection to the clamping unit..................................................12

6 Commissioning............................................................................................................ 13

6.1 Dismantling the round material (only required for KEC).................................................13

6.2 Adjustment of the clamping unit................................................................................... 15

6.3 Test run......................................................................................................................... 17

6.4 Checking clamping force/overtravel............................................................................. 18

7 Operation and use....................................................................................................... 23

7.1 Regular adjustment of the clamping unit...................................................................... 24

8 Maintenance and care................................................................................................. 24

9 Disassembly and repair............................................................................................... 24

10 Disposal........................................................................................................................25

11 Accessories.................................................................................................................. 25

12 Fault clearance............................................................................................................ 25

13 Technical data............................................................................................................. 26

14 Characteristic curves................................................................................................... 28

3Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Design

1 Design

NOTICE!

Documentation on the product

All available documents for the product èwww.festo.com/pk

1

Supply port for cylinder next to the adjusting
screws for the pneumatic cushioning (only
for DNCKE)

2

Supply port for releasing the clamp

3

Locking screw with internal hexagon socket
(for adjusting sleeve)

4

Piston rod (DNCKE only)

Fig. 1

5

Adjusting sleeve with spanner flat

6

Hollow bolts with thread for mounting

7

Hole with filter element for exhausting the
clamping chamber

8

Slots for proximity sensors (DNCKE only)

9

Round material for transportation lock (KEC
only)

Festo — DNCKE-...-S / KEC-...-S — 2018-12d4

Safety

Definition

In these operating instructions, the designation “clamping unit” is used for:

• The individual product KEC

• The design type DNCKE integrated in the cylinder
In these operating instructions, the designation “round material” is used for:

• The transportation lock for KEC

• The piston rod for DNCKE

1

DNCKE-...-S

Fig. 2

2

KEC-...-S

2 Safety

2.1 Intended use

The clamping unit KEC is intended to serve both as an individual product and integrated into a cylinder
DNC (for cylinder with clamping unit DNCKE) for the following usage:
– As a safety device for holding and clamping round material.
– As a well-tried component for braking a linear movement (stopping a movement) for processing or

handling procedures in a normal industry environment without substances and ambient condi-

tions that influence the function or materials used.
The product has been checked by the Institute for Occupational Safety and Health and is documented
by a DGUV test certificate.
If used as a braking device, e.g. for interrupting potentially dangerous movements in a danger zone, a
regular check of the overtravel as a factor of the travel speed and the frequency of the braking proced­ures (increased wear) as well as of the ambient operating conditions (min./max. temperature) is
necessary.

5Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Safety

2.2 Foreseeable misuse

The clamping unit is not suitable for positioning tasks or for transmitting torques and lateral forces. A
self-aligning rod coupler (è 11 Accessories) can prevent the transmission of lateral forces and bend­ing moments.

2.3 Specified standards

Version

DINENISO12100:2011-03

DINENISO4414:2011-04

DINENISO13849-1:2008-12

Tab. 1 Standards specified in the document

2.4 General safety instructions

– Observe legal regulations applicable to the destination.
– Only use the product if it is in its original condition and in perfect working order.
– Use the product only within the defined values (è 13 Technical data).
– Observe product labelling.
– Observe further applicable documents.
– Take into consideration the ambient conditions at the location of use.
– Protect the product during storage and operation from the following:

– Wetness or moisture
– Corrosive coolant or other materials (e.g. ozone)
– UV radiation
– Oils, greases and grease-solvent vapours
– Grinding dust

– Glowing chips or sparks
The operating modes must guarantee that the residual risk is smaller/equal to the accepted risk
(èDINENISO12100). The measures for risk reduction are to be taken in accordance with
DINENISO4414, DINENISO12100 and DINENISO13849-1.
Monitor/check the function of the entire system during use in accordance with the measures defined
in the validation report (èDINENISO13849-2).

2.5 Mounting and connecting

Observe tightening torques. Unless otherwise specified, the tolerance is ±20%.

•

2.6 Training of qualified personnel

Only qualified personnel may install, commission, service or disassemble the clamping unit. The
skilled personnel must be familiar with the installation of electrical and pneumatic control systems.

6 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Function

3 Function

Pressurising with compressed air on the supply port 2 (è Fig.1) opens the internal clamping com­ponent through a pneumatically driven release mechanism. The round material can then move freely.

Fig. 3

If the supply port is exhausted, a spring-loaded mechanism generates the clamping force of the clamp­ing component. The round material is then clamped.

Fig. 4

4 Transport

• Take product weight into account (è 13 Technical data).

5 Installation

5.1 Mechanical installation

Requirements

NOTICE!

Lateral loads and bending moments exerted on the round material damage its function and destroy
the internal clamping component.

• Make sure that the loads are only exerted on the round material in the direction of movement. The
use of a self-aligning rod coupler (è 11 Accessories) prevents lateral forces.

NOTICE!

Movement of the round material against the clamping forces leads to heavy wear on the internal
clamping component and the round material.

• Make sure that the holding force is never exceeded. Otherwise, unexpected movement may occur.

– Make sure that the clamping unit is installed as follows:

– Operating elements always accessible
– Product secured free from distortion and deflection

– Direct reaction forces via the mounting components as compressive force. Observe the braking

direction r (è Tab. 2 ).

7Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Installation

– Check whether safety measures (e.g. toothed latches or moving bolts) are also required externally

(èDINENISO12100 and DINENISO13849-1).

– Select the installation type for the desired application. Refer to the Festo catalogue for more

mounting alternatives (è Tab. 2 ) and required accessories.

5.1.1 Mounting the clamping unit

Interfaces for mounting components on the cover

e.g. with foot mounting HNC

1)

(only permitted for use as a holding device)

e.g. with flange mounting FNC
(permitted for use as a holding and braking

1)

device – observe braking direction r)

1)

è www.festo.com/catalogue

Tab. 2

8 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Installation

Dimensions (see catalogue information)

1)

Clamping unit KEC Clamping unit (with cylinder) DNCKE

1)

è www.festo.com/catalogue

1)

èwww.festo.com/catalogue

Tab. 3

DNCKE 40 63 100Size

KEC 16 20 25

1)

L1

[mm] 178 208.5 287

ZJ+ (plus stroke length) [mm] 277 315 408

TG [mm] 38 56.5 89

E [mm] 54 80 126

Screw-in depth [mm] 9.5 ... 15 12.5 ... 14 14 ... 17

Screw M6 (4x) M8 (4x) M10 (4x)

Tightening torque [Nm] 5 13 30

1) Dimension varies depending on setting of the adjusting screw.

Tab. 4

1. Place the clamping unit in the intended position.

2. Tighten screws evenly (tightening torques è Tab. 4).

5.1.2 Mounting attachments

Mounting on the DNCKE

• Mount the attachment component on the piston rod. The spanner flat aJ on the piston rod serves
as a counter holder for the lock nut. If necessary, secure the lock nut with a screw locking agent.

Fig. 5

9Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Installation

5.1.3 Mounting accessories

If proximity sensors are used in the cylinder with clamping unit DNCKE:
– Use Festo accessory proximity sensors (èwww.festo.com/catalogue).
– Place the proximity sensors in the grooves 8 of the cylinder.
– Fasten the proximity sensors in the desired switching positions.

8

Slot

Fig. 6

5.2 Pneumatic installation

5.2.1 Requirements

• Check if the following accessories are required:

Designation Type Function

Check valve HGL

Compensation reservoir VZS Reduction of pressure fluctuations in the follow-

Tab. 5

• Use a one-way flow control valve type (e.g. GRLZ or GRLA) directly in the relevant supply port.
For activating the cylinder with clamping unit:
– Select a suitable activation type for the specific application.

10 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Slow pressure reduction with loss of compressed
air

Redundancy with “stop function”

ing compressed air line

Installation

Example for clamping unit activation

2 functions are possible:
– Protection against unexpected start-up of the piston rod (holding function)
– Stopping a dangerous movement of the piston rod (emergency brake function)
Before the clamping unit is released, measures must be taken to prevent the piston rod from advan­cing suddenly.

Fig. 7

5.2.2 Functional tests

Functional test when used as a holding device (clamping function)

The frequency (test interval) of a static functional test is to be determined based on the applica­tion/risk assessment and the category selected in accordance with DINENISO13849. In addition, the
static functional test, if not required by C-type standards or other regulations, must be performed at
least once per month and every 100,000 switching cycles.

Functional test when used as an emergency braking device (emergency brake/emergency stop func­tion)

In principle, a static functional test and a dynamic braking test are required after every emergency
brake (emergency stop).
The frequency (test interval) of a dynamic braking test is to be determined based on the applica­tion/risk assessment and the category selected in accordance with DINENISO13849. In addition, the
dynamic braking test, if not required by C-type standards or other regulations, must be performed at
least once per year. After the dynamic braking test, a static functional test must be performed.
Information on conducting the static functional test and the dynamic braking test
(è 6.4 Checking clamping force/overtravel).

11Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Installation

5.2.3 Creating a tubing connection to the clamping unit

When operated in normal ambient air (without particles):
– Remove covers (if present) from the supply ports.
– Remove dirt particles and foreign matter from the ports and tubing lines.
– Use the shortest suitable tubing lines. This will reduce switching times.
– Connect the tubing to the supply ports of the clamping unit 2 and to the supply ports of the cylin-

der 1 in accordance with DINENISO4414.

2

Supply port for clamping unit

Fig. 8

Supply port for clamp­ing unit

Supply port for cylinder
(DNCKE only)

Tab. 6

1

Supply port for cylinder

DNCKE 40 60 100Size

KEC 16 20 25

2

1

G 1/8 G 1/4 G 3/8

G 1/4 G 3/8 G 1/2

12 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

When operated in ambient air containing fine dust and mist to prevent dirt particles from entering the
pneumatic system:

1. Use a barbed fitting (e.g. QS-CM-M5) instead of the filter nipple in the exhaust channel 7 of the
spring interior.

2. Route the hose in an area with clean ambient air.

Fig. 9

6 Commissioning

WARNING!

Unexpected movement of components. Injury due to impacts or crushing.

• Protect positioning range from access (e.g. using protective guards).

• Make sure that no foreign objects are present in the positioning range.

NOTICE!

• Ensure that:
– Adjustment is only performed by qualified personnel.
– The holding force corresponds to the specified values

(è 6.4 Checking clamping force/overtravel).

– The critical limit values are not exceeded (è 13 Technical data).

NOTICE!

Clamping without round material will destroy the internal clamping component

• Make sure that the clamping unit KEC is always pressurised when the round material is not inser­ted.
If the clamping unit KEC is exhausted when the round material is not inserted, the high spring
force will deform the internal clamping component until it cannot function.

6.1 Dismantling the round material (only required for KEC)

1. Pressurise the supply port 2 with at least 3.8bar.

13Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

2

Supply port

3

Locking screw

Fig. 10

2. Loosen the locking screw 3 using an Allen key.

DNCKE 40 63 100Size

KEC 16 20 25

Spanner size for intern-

[mm] 6 8

al hexagon socket 3 ß

Tab. 7

5

Adjusting sleeve

9

Round material

Fig. 11

3. Unscrew the adjusting sleeve 5 half a turn in an anticlockwise direction.

4. Pull supplied round material 9 out completely.

NOTICE!

If the round material is inserted at an angle, the scraper and seals might be damaged.

• A 15° chamfer at least 3mm wide at the end of the round material ensures it can be slid on
easily (workpiece quality è 13 Technical data).

14 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

Fig. 12

5. Slide the clamping unit onto the rod of the attachment product carefully.

6. Adjust the KEC to the new round material (è 6.2 Adjustment of the clamping unit).

6.2 Adjustment of the clamping unit

Adjustment is not required for initial start-up of DNCKE.

1. Exhaust the cylinder in a stable position (e.g. if installed vertically, at the lowest point).

2

Supply port

Fig. 13

2. Pressurise the supply port 2 with at least 3.8bar.

3. Loosen the locking screw 3 using an Allen key.

DNCKE 40 63 100Size

KEC 16 20 25

Spanner size for intern­al hexagon socket 1 ß

Tab. 8

[mm] 6 8

3

Locking screw

15Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

5

Adjusting sleeve

Fig. 14

4. Unscrew the adjusting sleeve 5 half a turn in an anticlockwise direction.

5

Adjusting sleeve

Fig. 15

5. Turn the adjusting sleeve 5 clockwise until the round material can no longer move.

6. Turn the adjusting sleeve 5 anticlockwise until the round material is just free to move (approx.

10–30°).

3

Locking screw

Fig. 16

7. Re tighten the locking screw 3. The tightening torque is 7Nm.

8. Exhaust the clamping unit. The round material is then clamped.

16 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

6.3 Test run

• Comply with critical limits for all loads.
For setting the speed and pneumatic cushioning:

11

One-way flow control valve

12

Pneumatic cushioning

Fig. 17

1. First, fully screw in the screws of the upstream one-way flow control valves aA and the pneumatic
cushioning aB on the DNCKE, then loosen by about one turn.

2. Pressurise the complete system slowly, e.g. with the soft-start valve type HEL.

3. Pressurise the cylinders simultaneously at both supply ports (1 è Fig.1, only for DNCKE). This
prevents movement in the direction of the unpressurised cylinder chamber.

4. Pressurise the clamping unit at the supply port (2 è Fig.1) with a minimum of 3.8bar. In some
circumstances, this will be enough for the piston rod to move slowly into the advanced end posi­tion.

5. Start a test run at a low cycle rate and low impact speed.

6. Repeat the test run, increasing the speed incrementally until the operating speed is reached.
If set correctly, the payload (e.g. the moved machine part) should reach the end position without
stopping hard.

7. In the test run, check if the following equipment settings need to be modified:
– Speed of the payload
– Pneumatic cushioning
– Clamping force
After completing the required adjustments:

8. End the test run.

17Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

6.4 Checking clamping force/overtravel

WARNING!

Unexpected movement of components

Injury due to impacts or crushing.
If the clamping force of the clamping unit is no longer sufficient, the movable parts of the pneumatic
components can cause uncontrolled movements. Uncontrolled movements of the connected actuators
can cause personal injury or material damage. Frequent checking of the overtravel will increase wear,
depending on how often it is used.

• Perform a check of the overtravel only if the product is used as a brake.
The overtravel is dependent on the load and the ambient conditions: temperature, oil on the pis­ton rod, number of switching cycles, speed, mass, operating pressure and control (diagrams
è 14 Characteristic curves).

• The overtravel check in a dynamic braking test must be performed beginning with the maximum
possible speed in the application (the maximum permissible travel speed must not be exceeded).

• The clamping force is checked in the resting position.

The specified test examples correspond to cases of application with the maximum amount of stress.
Deviating applications (slanted mounting position) cannot be represented. It may be necessary to
make calculations for a specific application and carry out a specific test for that.

WARNING!

Unexpected movement of components

Injury due to electric shocks, impacts or pinching.

• Make sure that there is a balance of forces acting on the operating cylinder’s piston. There is a
danger of the piston rod advancing suddenly when it is loosened due to the axial force (weight
force) applied, especially with vertical installation.

Observe the following points:
– The test force (test pressure) must be at least equal to the force (pressure) in the application or be

specified in the risk assessment for the application.

– The test force must not be greater than the maximum static holding force (è 13 Technical data).
– The overtravel in the dynamic braking test must be less than the tolerable overtravel from the

application/risk analysis.

– The piston rod must not slip through during a testing period of 60s. Remedy in case of slipping:

readjust the clamping unit (è 6.2 Adjustment of the clamping unit).

18 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

Horizontal mounting position

Case 1: Without additional weight force:

Fig. 18

Size KEC 16 20 25

Test force F

P

[N] 1300 3200 8000

Tab. 9

Static functional test Dynamic braking test

Place the piston rod in the returned end position.

Exhaust the port (2 è Fig.1). The
clamp is active.

Pressurise the cylinder chamber of the DNCKE in the advancing
direction at P=10bar while simultaneously exhausting the cyl­inder chamber in the returning direction.
That corresponds to the following test force (for testing with KEC

è Tab. 9 ).

– The movement begins (danger of crushing).
– The max. permissible travel speed must not be exceeded.

Pressurise the cylinder chamber
of the DNCKE in the advancing
direction at P=10bar while sim­ultaneously exhausting the cylin­der chamber in the returning dir­ection.
Test force for testing with KEC

è Tab. 9 .

Exhaust the port (2 è Fig.1).
– Braking begins.
– The cylinder stops.

Determine the path from the exhaust start signal until the cylin­der is at rest.
– This path equals the overtravel.

The test force (test pressure) should act for 60s. During this time, the piston must not move any fur­ther.

Tab. 10

19Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

Vertical mounting position

Case 2: Test with additional weight force, suspended orientation:

Fig. 19

• Calculate the required test pressure PA using the following equation:

Symbol Description Unit

P

A

F

P

Test pressure [bar]

Test force [N]

m Payload [kg]

g Acceleration due to gravity [9.81]m/s

A Piston area [mm2]

Tab. 11

Size DNCKE 40 63 100

Test force F

Piston area A

P

[N] 1300 3200 8000

[mm2] 1257 3117 7854

advancing direction

Tab. 12

2

20 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

Static functional test Dynamic braking test

Place the piston rod in the returned end position.

Exhaust the port (2 è Fig.1).
The clamp is active.

Pressurise the cylinder chamber of the DNCKE in
the advancing direction at test pressure P

A

(è Tab. 12) while simultaneously exhausting the
cylinder chamber in the returning direction.
– The movement begins (danger of crushing).
– The max. permissible travel speed must not

be exceeded.

Pressurise the cylinder chamber of the DNCKE in
the advancing direction at test pressure P

A

(è Tab. 12) while simultaneously exhausting the
cylinder chamber in the returning direction.

Exhaust the port (2 è Fig.1).
– Braking begins.
– The cylinder stops.

Determine the path from the exhaust start signal
until the cylinder is at rest.
– This path equals the overtravel.

The test force (test pressure) should act for 60s. During this time, the piston must not move any fur­ther.

Tab. 13

Case 3: Test with additional weight force, standing orientation:

Fig. 20

– Calculate the required test pressure P

1)

using the following equation:

A

21Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Commissioning

Symbol Description Unit

P

A

F

P

Test pressure [bar]

Test force [N]

m Payload [kg]

g Acceleration due to gravity [9.81]m/s

2

A Piston area [mm2]

Tab. 14

Size DNCKE 40 63 100

Test force F

Piston area A

P

[N] 1300 3200 8000

[mm2] 1055 2803 7363

returning direction

1)

The test pressure PA must not exceed 10bar (è Technical data). Even with a calculation result of

PA>10bar, only the maximum test pressure of 10bar may be applied.

Tab. 15

Static functional test Dynamic braking test

Place the piston rod in the advanced end position.

Exhaust the port (2 è Fig.1). The clamp is active. Pressurise the cylinder chamber of the DNCKE in

the returning direction at test pressure P

A

(è Tab. 15) while simultaneously exhausting the
cylinder chamber in the advancing direction.
– The movement begins (danger of crushing).
– The max. permissible travel speed must not

be exceeded.

Pressurise the cylinder chamber of the DNCKE in
the returning direction at test pressure P

A

(è Tab. 15) while simultaneously exhausting the
cylinder chamber in the advancing direction.

Exhaust the port (2 è Fig.1).
– Braking begins.
– The cylinder stops.

Determine the path from the exhaust start signal
until the cylinder is at rest.
– This path equals the overtravel.

The test force (test pressure) should act for 60s. During this time, the piston must not move any fur­ther.

Tab. 16

22 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Operation and use

7 Operation and use

Before releasing the clamp:

WARNING!

Unexpected movement of components.

Injury due to impacts or crushing.

• Make sure that there is a balance of forces acting on the operating cylinder’s piston. There is a
danger of the piston rod advancing suddenly when it is loosened due to the axial force (weight
force) applied, especially with vertical installation.

Observe the following after each emergency stop and each adjustment:

NOTICE!

The further operational reliability of the clamping unit may be impaired, depending on the brake load­ing.

• Check the clamping unit for safe function (è 6.4 Checking clamping force/overtravel):
– After every emergency stop
– After every adjustment
– At least once per month

If the clamping unit does not clamp the payload securely:

• Readjust the clamping unit (è 6.2 Adjustment of the clamping unit).

If there are changes in the payload or operating pressure:

NOTICE!

Payloads that have been increased at a later time and a changed operating pressure change the
clamping conditions and might impair operational reliability.

• Ensure that maximum loads are within permissible limits (è 13 Technical data).

If the clamping unit does not clamp the payload securely:

• Readjust the clamping unit (è 6.2 Adjustment of the clamping unit).

If using the product as a braking device:

NOTICE!

Frequent use of the product as a brake will increase wear depending on how often it is used.

• Therefore, check the overtravel regularly (in accordance with the specifications in the chapter
“Validating by checking” in the validation report as per EN13849-2). The overtravel is dependent
on the load and the ambient conditions: temperature, oil on the piston rod, number of switching
cycles, speed, mass, operating pressure and control (diagrams è 14 Characteristic curves).

NOTICE!

A permanently pressurised clamping unit may impair operational reliability.

• Exhaust the clamping unit at least once per day.

23Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Maintenance and care

7.1 Regular adjustment of the clamping unit

• Adjust the clamping unit regularly or if there are signs of wear:

Test procedure Clamping unit as holding

device

Signs of wear – Loud noises

– Clamping unit cannot hold the payload securely.
– Holding force is not achieved (slippage).
If properly set, the payload should always maintain the clamping
position and reach the end positions without stopping hard.

Test cycle Every 100,000 clamping cycles

and at least once per month

Adjusting cycle Every 500,000 clamping cycles

or if there are signs of wear

Adjusting procedure è 6.2 Adjustment of the clamping unit

Tab. 17
– In the following cases, check to determine if more frequent tests are required:

– High thermal stress
– Severe accumulation of dirt
– Grease-solvent fluids or vapours nearby

– Avoid contamination of the round material or exhaust port (7 è Fig.1). This is the only way to

ensure normal function will not be impaired.

Clamping unit as braking
device

The test and adjusting cycle
depends on the specifications of
the application and must be
determined by the machine
manufacturer within the frame­work of the validation report.

8 Maintenance and care

– Clean the clamping unit as required using a soft cloth. Do not use aggressive cleaning agents.
– The clamping unit is lubricated for life. Additional lubrication is not necessary.

9 Disassembly and repair

WARNING!

Unexpected movement of components.

Injury due to impacts or crushing.

• Secure payload and verify load-free status before dismantling.

• Exhaust the clamping unit before working on it.

• Observe transport information (è 4 Transport).

24 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Disposal

WARNING!

Flying parts!

Injury due to impacts or crushing.
Loaded springs may be released suddenly during dismantling. The sudden release of internal spring
forces (e.g. when dismantling the housing cover) poses a risk of injury.

• Do not dismantle the clamping unit.

If repairs are required:
– Send the clamping unit to Festo or contact Festo service (èwww.festo.com).
Information about spare parts and accessories (èwww.festo.com/spareparts).

10 Disposal

• Dispose of the clamping unit and its packaging at the end of its lifecycle according to the valid
provisions for environmentally sound recycling.

11 Accessories

èwww.festo.com/catalogue

12 Fault clearance

Malfunction Possible cause Remedy

Clamp does not
open.

Hard stop at the
cylinder’s end
position

Round material
slips through.

Clamping unit leaky Send clamping unit to Festo with a

description of the fault.

Insufficient operating pressure Increase operating pressure to maxim-

um permitted value.

Clamping unit not correctly adjusted Readjust round material

(è 6.2 Adjustment of the clamping unit
).

Speed too high Reduce impact speed.

Insufficient cushioning

Payload too great

Payload too great Reduce payload.

Operating pressure on cylinder too
high

Increase cushioning or use additional
external cushioning components.

Select lower speed.Speed too high

Apply additional brake force with
power valves.

Reduce operating pressure.

Change activation.

25Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Technical data

Malfunction Possible cause Remedy

Round material
slips through.

Malfunctions in
position sensing
at the DNCKE

Tab. 18

Round material contaminated Clean the round material with a soft

cloth and protect from contamination.

Round material does not meet the
quality requirements

Clamping unit not correctly adjusted or
worn

Clamping component worn or clamping
mechanism defective

Incorrect position of proximity sensors Correct position of proximity sensors.

Incorrect type of proximity sensor used Use suitable proximity sensors

Proximity sensor defective Replace proximity sensor.

Ferritic components in the vicinity of
the proximity sensor.

Comply with specifications for the
quality of the round material
(è 13 Technical data).

Readjust round material
(è 6.2 Adjustment of the clamping unit
).

Replace clamping unit or send it to
Festo with a description of the fault.

(èwww.festo.com/catalogue).

Use components made of non-magnet­ic materials.

13 Technical data

DNCKE-... 40 63 100

KEC-... 16 20 25

Clamping type Clamping through spring force, releasing through com-

pressed air

Mounting position Any

Operating pressure Compressed air to ISO8573-1:2010 [7:4:4]

Operating pressure

– Clamping unit [bar] 3.8 ... 8

– Cylinder DNCKE [bar] 0.6 ... 8

Max. test pressure DNCKE [bar] 10

Round material

– Diameter [mm] 16 [h7 … f7] 20 [h7 … f7] 25 [h7 … f7]

26 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Technical data

DNCKE-... 40 63 100

KEC-... 16 20 25

– Quality

Hardened (min. HRC60) or hard-chromium-plated
(min. thickness 20ìm)

Surface roughness Rt less than 4ìm

3mm wide 15° chamfer on the end of the round mater­ial

Static holding force [N] 1300 3200 8000

Theoretical force for DNCKE

– Advance at 6bar [N] 754 1870 4712

– Return at 6bar [N] 633 1682 4418

– Advance at max.

[N] 1257 3117 7854

test pressure

– Return at max. test

[N] 1055 2803 7363

pressure

Max. permissible travel speed [m/s] 1

Ambient temperature [°C] -10 ... +60

Storage temperature [°C] -20 ... +80

Safety function Stopping a linear movement up to PL c/category 1

B10 value for clamping function with load

– Load [N] 754 1870 4712

– B10 value 1.2million

switching cycles

CE marking (èdeclara-

In accordance with EU Machinery Directive

1.2million
switching cycles

0.4million
switching cycles

tion of conformity)

Vibration and shock (without payload)

– Vibration in accordance with

IEC60068 part 2–6

± 3.5mm deflection at 2–8Hz
10m/s2 acceleration at 8–27Hz
± 0.35mm deflection at 27–60Hz
50m/s2 acceleration at 60–160Hz
10m/s2 acceleration at 160–200Hz

– Shock in accordance with

IEC60068 part 2–27

– Continuous shock in accordance

withIEC60068 part 2–29

± 300m/s2 acceleration with a duration of 11ms
5 shocks per direction

150m/s2 acceleration with a duration of 6ms
1000 shocks per direction

27Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Characteristic curves

DNCKE-... 40 63 100

KEC-... 16 20 25

Materials

– Housing, cover Aluminium

– Piston rod DNCKE Steel (hard-chromium-plated)

– Tie rods, collar

nuts

– Seals TPE-U, NBR

Weight

– Basic weight KEC [kg] 1.9 4.5 16.8

– Basic weight DNCKE [kg] 2.3 5.5 18.2

– Per 10mm stroke DNCKE [kg] 0.045 0.073 0.11

Tab. 19

Steel

14 Characteristic curves

NOTICE!

The following diagrams provide an example of the overtravel dependent on various parameters as an
orientation aid. The overtravel determined in a customer application may deviate from the examples
depicted here. Additional information (è 7 Operation and use).

Overtravel s [mm] with exhausted clamping unit until standstill with vertical mounting position as a
factor of the speed v [m/s] at 6bar

Fig. 21 DNCKE 40 characteristic curve

28 Festo — DNCKE-...-S / KEC-...-S — 2018-12d

Characteristic curves

Overtravel s [mm] with exhausted clamping unit until standstill with vertical mounting position as a
factor of the speed v [m/s] at 6bar

Fig. 22 DNCKE 63 characteristic curve

Fig. 23 DNCKE 100 characteristic curve

29Festo — DNCKE-...-S / KEC-...-S — 2018-12d

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prohibited. Offenders will be liable for damages. All rights
reserved in the event that a patent, utility model or design patent
is registered.

Copyright:
Festo AG & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany

Phone:
[phone]

Fax:
[phone]

e-mail:
[e-mail]

Internet:
www.festo.com