Product Service Life

Survival training for Festo products

Systematic quality that pays for itself.
Festo plug and work®
Festo plug and work® packages
include reliability backed by
long-term functional and endu-
rance testing. This guarantees
millions of operating cycles
for valves and valve terminals,
and thousands of kilometres of
running distance, for example,
with standard cylinders.
In most cases, Festo plug and
work® means: Fit and forget.
2 3
Festo plug and work®:
Plant availability and
preventive maintenance
Festo products can increase your
plant availability. Thanks, for
example, to the fact that they
are made of top-quality materi-
als matched to the conditions of
your application. Furthermore,
they allow you to implement
Total Productive Maintenance,
which prevents unexpected
plant breakdowns.
Endurance testing at Festo is
based on defined test parame-
ters.Under practical conditions,
the service life of any product
is of course directly dependent
on the relevant operating
environment.
Festo plug and work®:
The many aspects of quality
Maximum reliability for optimum
product quality: The objective of
our Quality Management system
is to ensure that all the relevant
processes work together to your
advantage.
Our system is certified by the
DQS in accordance with DIN-ISO
9001/9002 and VDA 6.1 and 6.4.
Quality for a long working life
Before the products of any
series leave the Festo factory,
they must pass long-term
functional and endurance tests,
both during the development
phase and in all phases of the
product life cycle. This results in
constant optimisation, leading
to longer service life and higher
cost-effectiveness. The know-
ledge gained from tests under
standard conditions forms the
central basis for preventive
maintenance activities, resulting
in full plant availability at all
times. In addition, it confirms an
open secret - Festo products are
the benchmark for quality.
In order for quality to deliver
maximum benefit, however,
the right products must be
installed in the right places.
This is why we provide complete
technical and industry-specific
consultancy via our more than
1,000 sales and project
engineers. Through dialogues
with customers, these engineers
ensure that the properties of
both our new and established
products are matched precisely
to the needs of the various
branches of industry.
The aim is simple: To ensure
that Festo delivers first-class
quality for greater profitability.

Quality under test
Welcome to the test marathon!
Festo carries out two kinds of
long-term tests: Functional tests
and endurance tests.
The aim of functional tests is
to determine whether the pro-
duct in question is still capable
of operating after a defined
number of switching cycles or
kilometres travelled.
4 5
The purpose of endurance tests,
on the other hand, is to obtain
statistical data on the service
life of individual products. This
allows conclusions to be rea-
ched regarding service intervals
and preventive maintenance.
All tests are carried out under
standard specific test conditions
and are thus not affected by
variations in time, place or test
samples.
Test conditions
Test parameters
Valves Linear drives Semi-rotary actuators
Switching frequency Stroke frequency Swivel frequency
Volume at output Load on piston rod Load on drive shaft
Stroke length Angle of rotation
Stroke speed Angular velocity
Installation position Installation position
Combination of test conditions, taking the example of rodless drives
Temperature
Pressure -10 °C 23 °C 60 °C
Pmin x
Pnenn (6 bar) x x x
Pmax x
Test conditions Test sequence Typical Festo limit values, for
In the course of endurance example for standard cylinders,
Pressure testing, daily functional checks are leakage greater than 10 l/h
• Dry filtered air are carried out by acoustic, or the need for a pressure of
• Lubricated filtered dry air visual and tactile means. Leaka- more than 1.5 bar before the
ge rates, characteristic pressure cylinder will move.
values, switching times, guide
backlash and minimum opera- Functional tests are terminated
ting pressure are checked befo- after a predefined number of
re and after the test and at switching cycles or kilometres
cyclical intervals during the test. travelled.
Further special measurements
are carried as necessary. Testing
is stopped as soon as either
a total failure has taken place or
certain limits for defined charac-
teristic values are exceeded,
even though the product is
fundamentally still capable of
operating (tolerance failure).
 Probability of failure Probability of survival
in percent in percent

99,9 0,1
99 1

50 10
20
70 30
T 60 40
50 50
40 60
30 70
20 80

B10 10 % 90
5 95
3 97
2 98
1 99
0,5 99,5
0,3 99,7
0,2 99,8

0,1 99,9
0,05

6.000 8.000 10.000 12.000 14.000 16.000

9.150 12.766
Running distance in km

Evaluating the results of
endurance testing
Endurance tests form the basis
for statistic evaluations. The
graph at top right shows the
service life values achieved by
a series of endurance test sam-
ples. The straight line has been
calculated by the Weibull
method and represents the
test sample’s probability of
survival/failure (ordinate) as
a function of the number of
kilometres travelled or the num-
ber of switching cycles comple- 63 %. The B10 value provides Example of a standard cylinder
ted (abscissa). The service-life a reliable indication of service Testing carried out in accordan-
straight-line plots can be used to life, since this value is achieved ce with relevant Festo standard
determine statistical characteri- by 90% of all test samples and B10 Z 9.150 km
stic service-life data such as the is therefore referred to as the T Z 12.766 km
B10 value or T value. These are “reliable service life” value.
the values for the expected servi-
ce life of products. Endurance tests are carried
out under standard conditions
The T value is approximately the at 6 bar and 23°C.
mid-point of the distribution and
corresponds to the characteristic
service life value of a product.
When the numbers of kilometres
or number of switching cycles
indicated by the T value is rea-
ched, the probability of failure is

6 7
 Scope of tests at Festo
The test series cover all our
range of:
• Cylinders
• Valves/valve terminals
• Sensors
• Electric drives
• Handling units
8 9
Festo has been carrying out
long-term testing for over 30
years. We currently have around
1,500 items on test at the same
time. We store the resulting data
on our service life database,
which contains detailed infor-
mation on over 20,000 test
items, which needs to be con-
stantly updated. This includes
data on our “Millionaires’ Club,”
with, for example, valves which
have completed over 1,000 milli-
on switching cycles or cylinders
which have covered a running
distance of over 45,000 km.
Tested quality from Festo
pays for itself.
Technische Hotline
0180 303 3000
E-mail
technicservice@de.festo.com
Characteristic and average
service life
The characteristic service life
value is determined statistically
for test samples of the same type
under constant test conditions.
The average service life value
applies to all the sizes and vari-
ants within a series. This value
may therefore vary for individual
sizes or variants. The calculation
of average service life is based
on all the long-term tests that
Festo has conducted.
Details of the test results for
these products, together with
comprehensive advice on the
subject of service life and
preventive maintenance, is avai-
lable from your Festo partner.
The service life values quoted
by Festo apply only under these
conditions:
• Good air preparation
- Drying of compressed air for
use in heated interior rooms
down to a dew point of 2 °C
(the dew point must be at
least10 K lower than the
medium temperature, DIN-ISO
8573-1 min. class 4)
- Filtration of compressed air
using filters with a mesh size
smaller than 40 µm (DIN-ISO
8573-1 class 5)
- In the case of operation with
unlubricated air, the maxi
mum permissible oil content
is 0.1 mg/m3 (DIN-ISO 8573-
1 class 1)
- In the case of lubricated
compressed air, the volume
of oil added must not exceed
25 mg/m3 (DIN-ISO 8573-1
class 5)
• Cleaner environment (dirty
ambient air can drastically
reduce service life)
Average service in millions of switching cycles Average service life in millions of double strokes

20 - 50 50 - 100 100 - 250 250 - 500 500 - 1000 Cylinder type <5 5 - 15 15 - 25 ≥ 25
Terminal valves Typ 03 Midi x DSNU (stroke < 100 mm) x
Maxi x ESNU x
Typ 04 Größe 1 x DSN, ESN ( stroke < 100 mm) x
ISO-5599/2 Größe 2 x ADN, AEN x
Größe 3 x ADVU x
Typ 14 Größe 02 x AEVU x
VDMA (15407-1) Größe 01 x ADV x
Typ 10 CPV10 x EZH x
CPV14 x DSEU, ESEU x
CPV18 x EG, DG x
Typ 12 CPA10 x DFK x
CPA14 x EGZ x
Average service life in km running distance* DGS x
Typ 15 CDVI x
Typ 24 VTVB x DSL x
Cylinder type < 5.000 km 5 - 10.000 km ≥ 10.000 km
Typ 32 MPA1 x DSM x
MPA2 x DSNU (stroke > 100 mm) x DRQD x
Typ 44 Größe 02 x ESN, DSN x EV x
ISO-Plug In (15407-2) Größe 01 X ESN, DSN (stroke >100 mm) x DNCKE x
Typ 80 CPVSC1 x DNC x DNC-KP x
Typ 82 CPASC1 x DNCB x DSNU-KP x
Individual valves VUVB Größe QS4/6/8/10 x DZH x SLT x
Tiger Classic Größe 1/8 und 1/4 x DGC x SLF x
Größe 1/2 und 3/4 x DGP/DGPL x SLS x
Tiger 2000 Größe 1/8, 1/4 und 3/8 x DGO x DPZ x
Midi Größe 1/8 x SLG x DPZC x
ISO-Ventile Größe 1 x SLE, SLM x HMP-B, HMPL x
5599/1 Größe 2 x DFM x HSP x
Größe 3 x FEN/FENG x HGP, HGR, HGD, HGW x
ISO (VSVA) Norm- Größe 02 x DGEA x HGPT, HGPL x
ventil 15407-1 Größe 01 x DGE-ZR x HGPP x
CPE CPE10 x DGE-ZR-RF x HGDS x
CPE14 x DGE-SP x YSR, YSRW,YSRD x
CPE18 x
CPE24 x * Cylinder with standard stroke length
Miniature Valve MH1 x
Schnellschaltventil MH2, MH3, MH4 x
Prop. valves MPPE Größe 1/8, 1/4 und 1/2 x
MPPE-S Größe 1/8, 1/4 und 1/2 x
VPPE Größe 1/8 x
MPYE Größe M5, 1/8, 1/4, 3/8 x
Shut/off, GRLA GRLA-QS x
pressure and flow GRLA-M5 und ähnliche x
control valves HGL Größe M5... 1/2 x

Average service life of valves Average service life of linear cylinders

Test method Notes on service life data Test conditions

Festo internal standard FN 942 • Values quoted as numbers • Operating pressure 6 bar
012 “Functional and Service Life of switching cycles/double • Ambient temperature 23 ± 5°C
Testing of Valves.” strokes for cylinders with • Additional loads, particularly
standard stroke lengths up with guided drives
Test conditions to 100 mm
• Operating pressure 6 bar • Values quoted as running Criteria for termination
• Ambient temperature 23 ± 5°C distance for cylinders • Leakage (depending on size
• Frequency depending on with standard stroke and cylinder type)
valve type lengths ≥ 100 mm • Worsening of running charac-
teristics, for example
Criteria for termination Test method occurrence of stick/slip, stiff
• Leakage (depending on valve • Festo internal standard operation or jamming
connection size) FN 942 018 or FN 942 016 • Mechanical failure
• Malfunctions such as valves
failing to switch, jamming or
failing to fully pressurise the
output.

Note
The quoted values are not
guaranteed.

10 11
 Festo worldwide

Argentina Estonia Japan Slovakia

Festo S.A. Festo OY AB Eesti Filiaal Festo K.K. Festo spol. s r.o.
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53962 en 09/2006

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