EMERSON AVentics Pneumatic Piston Rod Cylinders Instruction Manual

EMERSON AVentics Pneumatic Piston Rod Cylinders

About This Documentation

Documentation validity

This documentation applies to the following double-acting pneumatic piston rod cylinders:

• Tie rod cylinder series ITS and TRB acc. to ISO 15552
• Profile cylinder series CCL-IS and PRA acc. to ISO 15552
• Compact cylinders, KPZ series
• Compact cylinder series CCI and CCL-IC acc. to ISO 21287
• Mini cylinder series MNI acc. to ISO 6432,
• Round cylinder series CSL-RD and RPC

This documentation is geared toward system planning engineers, system opera- tors, and assembly technicians.
Read this documentation carefully, especially the section “Notes on Safety”, before working with the product.

Required and supplementary documentation

Only commission the product once you have obtained the system documentation and understood and complied with its contents.

Presentation of information

To allow you to begin working with the product quickly and safely, standard warnings, symbols, terms, and abbreviations are used in this documentation. For better understanding, these are explained in the following sections.
Warnings
In this documentation, there are warning notes before the steps whenever there is a risk of personal injury or damage to equipment. The measures described to avoid these hazards must be followed.
Safety instructions are set out as follows:
Structure of warnings
SIGNAL WORD
Hazard type and source Consequences of non-observance
Meaning of the signal word
DANGER
Immediate danger to the life and health of persons.
Failure to observe these notices will result in serious health consequences, including deaths
CAUTION
Possible dangerous situation.
Failure to observe these notices may result in minor injuries or damage to property.
NOTICE
Possibility of damage to property or malfunction.
Failure to observe these notices may result in damage to property or malfunc- tions, but not in personal injury.

Notes on Safety

About this chapter

The product has been manufactured according to the accepted rules of current technology. Even so, there is risk of injury and damage to equipment if the following chapter and safety instructions of this documentation are not followed.

1. Read these instructions completely before working with the product.
2. Keep this documentation in a location where it is accessible to all users at all times.
3. Always include the documentation when you pass the product on to third parties

Intended use

• The product is a pneumatic system component for moving masses and transfer-ring tensile or compressive forces.

• The product is intended for professional use only.
  The product fulfills the requirements specified in the ATEX Directive 2014/34/EU and may be used in accordance with the installation regulations currently in effect for devices and systems in explosive areas as follows:

• In zones 1 and 2 (gas explosion protection, category 2G and 3G) in the explosion groups IIA, IIB, and IIC, temperature class 4

• In zones 21 and 22 (dust explosion protection, category 2D and 3D) in the ex-plosion groups IIIA, IIIB, and IIIC, temperature class 135°C

Intended use includes having read and understood this documentation, especially the “Notes on safety” chapter.

Improper use

Any use other than that described under Intended use is improper and is not per-mitted.
AVENTICS GmbH is not liable for any damages resulting from improper use. The user alone bears the risks of improper use of the product.
Improper use of the product includes:

• use in firedamp protection areas,
• use of the product as a spring or cushioning element, as this may result in im-permissible loads.

Personnel qualifications

The work described in this documentation requires basic mechanical and pneumatic knowledge, as well as knowledge of the appropriate technical terms. In or-der to ensure safe use, these activities may therefore only be carried out by qualified technical personnel or an instructed person under the direction and supervision of qualified personnel.
Qualified personnel are those who can recognize possible hazards and institute the appropriate safety measures, due to their professional training, knowledge, and experience, as well as their understanding of the relevant regulations pertaining to the work to be done. Qualified personnel must observe the rules relevant to the subject area.

General safety instructions

• Observe the regulations for accident prevention and environmental protec-tion.
• Observe the national regulations for explosive areas.
• Observe the safety instructions and regulations of the country in which the product is used or operated.
• Only use AVENTICS products that are in perfect working order.
• Follow all the instructions on the product.
• Persons who assemble, operate, disassemble, or maintain AVENTICS products must not consume any alcohol, drugs, or pharmaceuticals that may affect their ability to respond.
• To avoid injuries due to unsuitable spare parts, only use accessories and spare parts approved by the manufacturer.
• Comply with the technical data and ambient conditions listed in the product documentation.
• If unsuitable products are installed or used in safety-relevant applications, this may result in unintended system operating states that may lead to injuries and/or equipment damage. Therefore, only use a product in safety-relevant applications if such use is specifically stated and permitted in the product documentation.
• You may only commission the product if you have determined that the end product (such as a machine or system) in which the AVENTICS products are in-stalled meets the country-specific provisions, safety regulations, and standards for the specific application.

Safety instructions related to the product and technology
DANGER

• Danger of explosion while operating in explosive atmospheres!
  If the system in which the product is to be installed is located in an explosive atmosphere, it may ignite during operation.

  • Always comply with local installation regulations.
  • Carry out tasks in non-explosive atmospheres only with a fire permit for these tasks. Use only non-sparking tools if you still need to deal with the presence of an explosive atmosphere.

• Danger of explosion due to electrostatic charge!
  Electrostatic charging on the product can cause sparks to form and presents an explosion hazard in explosion protection zones.

  • Avoid electrostatic charging, e.g. by grounding the product.

• Spark formation due to mechanical loads!
  Mechanical loads lead to the formation of sparks and present an explosion hazard.

  • Never twist or bend the cylinder, or mount it when it is under tension.
  • Never expose the cylinder to impacts during transportation, assembly, or operation.
  • Install the cylinder so that it is protected from the energy of external im-pacts to the housing that can occur during operation.
  • Avoid vibrations, e.g. by installing the system on a cushioned base.

• Danger of explosion due to spark formation!
  Some piston rod attachments and mounting elements permit oscillating rotary or swivel movements of the cylinders. The use of these elements as a radial friction bearing with circumferential speeds above 1 m/s leads to impermissible heating. Overheating can cause friction sparks, which present an ex-plosion hazard.

  • Make sure that the circumferential speed on the friction surfaces does not exceed 1 m/s.

CAUTION

• Improperly installed compressed air lines !
  Danger of injury!

  • Lay the compressed air lines so that no one can trip over them.

• Falling useful load!
  With a vertical installation position of the cylinder, a suspended load can fall when the compressed air supply is switched off.

  • Always secure the area below a suspended load.

Obligations of the system owner

As the owner of a system that will be equipped with ATEX cylinders, you are responsible for

• ensuring intended use,
• ensuring that operating employees receive regular training,
• ensuring that the operating conditions are in line with the requirements for the safe use of the product,
• ensuring that cleaning intervals are determined and complied with according to environmental stress factors at the operating site,
• ensuring that ignition hazards that develop due to the installation of system equipment are observed,
• ensuring that no unauthorized repairs are attempted if there is a malfunction.

General Instructions on Equipment and Product Damage

NOTICE

• Mechanical loads! Cylinder damage!

  • Do not twist or bend the cylinder, or mount it when it is under tension.
  • Avoid mechanical loads when connecting the tubing.
  • Make sure that the cylinder is not damaged by falling parts or incorrect tool usage. Especially avoid damage to the piston rod and seals. Provide protected installation for the cylinder if necessary.

• Unintended separation of the through piston rod!
  If the cylinder’s through piston rod is screwed-on, it may be accidentally loos-ened during assembly.

  • Always apply opposing pressure to an acting point on the piston rod on the same cylinder side during tightening jobs.
  • Never perform opposing countering or rotating motions on both piston rod ends.
  • Observe the warning label.

Use in Explosive Areas

Cylinders with an ATEX ID on their rating plate are designed for use in explosive areas. All exterior materials are low-spark materials.

1. Always observe the technical data and limits indicated on the rating plate, particularly the data from the ATEX identification.
2. As the pressure medium, use compressed air generated and prepared outside the explosive area in accordance with ISO 8537-1.
3. As the pressure medium, use only compressed air that does not corrode the cylinder and its sealing materials.

ATEX identification

• II 2G Ex h IIC T4 Gb
• II 2D Ex h IIIC T135°C Db X

The product meets the requirements in the ATEX Directive 2014/34/EU. Characteristics and applications that are derived from the ATEX ID are explained in the following:

flammable material > 135°C Max. permissible surface temperature 135°C
IIIC| Suitable for IIIA, IIIB, and IIIC explosive areas
T135°| Maximum surface temperature (dust explosion protection)
Gb, Db| Device category and device protection level
X| For special features see 12. Technical Data (Temperature range)

Delivery Contents

• 1 cylinder in accordance with catalog or configurator specifications
• 1 set of operating instructions
• Optional: mounting elements

If you have configured a cylinder with mounting elements, these elements will be pre-assembled on the cylinder. The accessories and spare parts approved for your configuration can be found in the online catalog.
Your cylinder has been individually configured according to your requirements. You can find the exact configuration in the Internet con-figurator under your order number.

About This Product

Piston rod cylinder examples are depicted on the title page.

Product identification

On the standard name plate, you will find the following information (the name plates shown are only samples):

1. Manufacturer log
2. Manufacturing plant
3. Production date
4. Manufactured in
5. Maximum pressure
6. Stroke
7. Serial number (Part no.)
8. Series

1. Manufacturer logo
2. Serial number (Part no.)
3. QR code (optional)
4. Maximum pressure
5. Manufacturing plant
6. Stroke
7. Manufactured in
8. Production date
9. Series

On the name plate for mechanical explosion protection, you will find the following information:

1. TFR (Technical File Reference number)
2. CE mark
3. Note: Special features
4. ATEX identification
5. ATEX symbol

Check that the cylinder matches your order using the material number printed on the housing.

Assembly

DANGER

• Danger of explosion through overheating!
  The product generates heat during operation. Incorrect installation can cause the product to overheat.

  • 1. Ensure sufficient distance to adjacent components to permit adequate air circulation around the product.
  • Shield the product if it is installed near heat sources.

• Danger of explosion if not grounded!
  Compensation and residual currents could increase the temperature of the components and possibly generate sparks.

  • Ground the housing and the piston rod so they are electroconductive with the system.
  • Ground the system in accordance with the applicable regulations.

• Danger of explosion due to electrostatic charge on the tubing surface!
  Large tubing diameters increase the risk of an electrostatic charge on the tubing surface. Electrostatic discharge can lead to explosions.

  • Only use tubing with the following external diameters to connect the cylinders:
  • Cylinder Ø up to 25 mm: max. 6 mm
  • Cylinder Ø 32 mm or above: any

• Danger of explosion due to impermissible tubing!
  Long tubing often overheats during operation. Overheated tubing can lead

  • Use the following tubing lengths:
  • Cylinder Ø up to 25 mm: max. 5 m
  • Cylinder Ø 32 mm or above: max. 10 m to explosions.

• Danger of explosion due to dust clouds!
  Dust clouds can lead to explosions.

  • Make sure that the compressed air and exhaust are either evacuated from the dust protection area through tubing lines or that the exhaust lines are mounted to permit the continuous controlled exit of penetrating dust.

• Danger of explosion due to circulating currents!
  Stray magnetic fields may cause circulating currents, e.g. near electrical drives with asymmetrical loads, during arc welding, if the ground is conducted via the system and not via a 0 V line, or if there is cathodic corrosion protection.

  • Make sure that there is protection against the possible effects of circulating currents, e.g. by grounding the product.

NOTICE

• Incorrect cylinder mounting!
  Cylinder damage!

  • Make sure that the cylinder and accessory parts are properly installed.
  • Observe the maximum tightening torque values and check that all screws and bolts are properly tightened.

Installation conditions

The cylinder has a lifetime lubrication.
The preferred medium is oil-free compressed air. Compressed air quality: see “Technical Data”.

Assembling the cylinder

1. Make sure that all relevant system parts are not under voltage or pressure before mounting the cylinder. Protect the system against being restarted.
   Depending on your configuration, you can mount the product in different ways. The content of delivery only includes the mounting you selected in the configurator.

   • You can find the exact dimensions of the mountings for your cylinder in the online catalog.
   • Install the cylinder in your system so the pneumatic connections and, if present, throttle screws for the cushioning are always accessible.

2. Fix the cylinder on the bracket in your system part so that it is not under tension. Observe the maximum permissible tightening torque values listed in the online catalog. General technical standards apply if no information is given or if you use your own mounting materials.

3. Remove the blanking plugs at the pneumatic connections.

4. Make the pneumatic connections for the cylinder. You can find the pneumatic connection technology for cylinder tubing in the online catalog.

5. Mount the useful load onto the piston rod. Depending on the configuration, you can mount the useful load onto the internal or external thread. Observe the permissible piston forces. You can find the maximum possible piston forces in the online catalog.
   On double-acting cylinders, the effective piston surface and piston force are lower during retraction than extension due to the cylinder piston rod. This does not apply to cylinders with a through piston rod.

Commissioning

DANGER

• Danger of explosion due to heat generation!
  The cylinder generates heat during operation. Explosion protection is no longer guaranteed when specified limits are exceeded.

  • Observe the limits specified under “Technical Data” and on the rating plates.

• Danger of explosion due to excessive operating frequencies and piston speeds!
  Excessive operating frequencies and piston speeds overheat the cylinder and present an explosion hazard.

  • Never exceed the maximum permissible double-stroke frequency: Cylinder Ø up to 25 mm: 0.33 Hz
  • Cylinder Ø 32 mm or above: 0.4 Hz
  • Never exceed the maximum piston speed of 1 m/s.

CAUTION

• Danger of burns caused by hot surfaces!
  Touching the surfaces of the product during operation could cause burns.

  • Let the product cool off before working on it.
  • Do not touch the product during operation.

• Danger due to noise!
  Hearing damage due to exhaust and impact noise

  • Correctly adjust the cushioning.

• Danger due to sudden escaping of compressed air! Uncontrolled piston rod movement!

  • Ensure that no one can reach into the system’s work area and that no ob-jects can penetrate it.
  • If necessary, assemble a protective barrier.
  • Slowly pressurize the system to the stipulated working pressure.

Setting the speed

DANGER
Danger of explosion due to heat generation!
Excessive piston speeds overheat the cylinder and present an explosion hazard.

• Never exceed the maximum piston speed of 1 m/s.

CAUTION
Risk of injury or damage!
A cylinder that is operated without speed control can reach high piston speeds, and may cause injury or machine breakdown.

• Make sure that the cylinder is always operated with speed control, e.g. by using check-choke valves with exhaust air throttling.

The speed is normally controlled by throttling the exhaust air from the cylinder chambers with, for example, check-choke valves with exhaust air throttling.
NOTICE
Damage to the cylinder due to screwing in the check-choke valves too far!

1. Note the thread length of the check-choke valves if they are directly mounted in the cylinder covers.
2. Observe the wrench flats and wrench sizes.

When the speed is being set, the cylinder must be loaded as in normal service and the speed must be increased gradually to the desired operating speed.

• Do not set the operating speed higher than necessary. The speed must be adapted to the load of the cylinder in order to not exceed the maximum per-mitted cushioning energy. Use the calculation program in the online catalog.

Set the piston speed as follows:

1. Make sure that the pressure is zero and then increase the pressure slowly to the desired working pressure.
2. Slightly open the check-choke valves.
3. Increase the piston speed by opening the check-choke valves gradually to reach the desired operating speed.

Adjusting pneumatic cushioning

If you change the piston speed, the moving mass, or the working pressure, you have to adjust the pneumatic cushioning.
Depending on the configuration, your cylinder may be equipped with two pneumatic cushions. The cushioning is adjusted using throttle screws at both ends of the cylinder.
Basic setting

• Turn the two flow control screws clockwise up to the stop and then turn them back out a full rotation.
• This will prevent the piston from impacting without cushioning.

NOTICE
High mechanical cylinder load due to incorrect basic settings!
The cylinder may be damaged if the piston impacts without cushioning.

• Always perform basic setting adjustment

Settings for both sides.
Cushioning always has to be adjusted on both sides of the cylinder. The order does not matter.

• Left Arrow Retracting piston rod
• Right Arrow Extending piston rod

1. Repeatedly move the piston from end position to end position. Pay attention to the piston impact noise (hereinafter referred to as noise level) and the vibration behavior (hereinafter referred to as moving mass) of the overall sys-tem upon entering the cushioning phase.

   • The noise level is clearly audible.
   • The moving mass vibrates noticeably.

2. Slowly turn the throttle screws out. This lowers the cushioning.
   

3. Repeatedly move the piston from end position to end position. Pay attention to the noise level of the piston impact and the vibration behavior of the moving mass:

   • The noise level increases.
   • The mass vibrates less during piston impact.

4. Continue slowly turning the throttle screws out. This lowers the cushioning further. After every change to the throttle screws, move the piston from end position to end position.

   • The noise level initially continues to increase, but then decreases significantly.
   • The required number of turns for the two throttle screws can differ.

5. Repeat this process until you have achieved the ideal operating points for both cushions. How to recognize the ideal operating points for both cushions:

   • The piston impact is barely audible.
   • The vibration of the mass is minimal.

6. If you now continue to turn out the throttle screws even further, you will abandon the ideal operating points:

   • The piston impact becomes louder.
   • The vibration of the mass increases.
   • Turn the throttle screws in and return to the ideal operating points.
     

Care and Maintenance

DANGER
Danger of explosion through overheating caused by dust deposits!
The accumulation of dust can cause the product to overheat. The surface can no longer cool down and is heated at an uncontrollable rate. The resulting heat build-up presents an explosion hazard. Dust clouds can lead to explosions.

• Regularly remove dust deposits. Set binding cleaning intervals.

CAUTION
Danger of burns caused by hot surfaces!
Touching the surfaces of the product during operation could cause burns.

1. Let the product cool off before working on it.
2. Do not touch the product during operation.

Damage to the surface caused by solvents and aggressive detergents!
The seals on the product may age faster under aggressive ambient conditions.

• Never use solvents or aggressive detergents.

1. Make sure that all relevant system parts are not under voltage or pressure.
2. Clean the cylinder at regular intervals only using a slightly moist cloth. Only use water to do this and, if necessary, a mild detergent.

The cylinder has a lifetime lubrication and is thus maintenance-free.
However, the system-specific maintenance intervals must be observed.

Disassembly and disposal

Disassembling the cylinder

CAUTION
Danger of burns caused by hot surfaces!
Touching the surfaces of the product during operation could cause burns.

• Let the product cool off before working on it.
• Do not touch the product during operation.

1. With a vertical installation: move the piston into the lower end position.
2. Secure the useful load.
3. Make sure the relevant system part is without pressure and voltage. Slowly ventilate the system to avoid uncontrolled piston movements.
4. Remove the useful load from the piston rod.
5. Remove the pneumatic connections.
6. Remove the ground connection.

The cylinder can now be taken out of the bracket and removed.

Cylinder disposal

Careless disposal of the cylinder will lead to pollution of the environment. Furthermore, the materials can no longer be recycled.

• Dispose of the cylinder in accordance with your country’s national regulations.

Troubleshooting

• Check the connections, operating voltage of the system part, and working pressure if malfunctions occur.

If this is the cause of the malfunction, proceed as follows:

• Ensure that the cylinder is not under pressure and disconnect the system part from the supply voltage.
• Remedy the malfunction.
• Restart the system part and cylinder.

Additional help for malfunctions can be found in the following table:

Malfunction

| Possible cause|

Remedy

---|---|---
Loud impact or product vibrates in end position| Cushioning too weak or product under dimensioned| Correct the cushioning
8.2 Adjusting pneumatic cushioning
Drop in performance during continuous operation| Product defective| Replace product
Product does not achieve out- put, compressed air supply in- sufficient| Supply lines too long| Shorten supply lines
Tubing diameter dimensioned too small| Select a larger tubing diameter
| Possible throttle points in the system| Remove throttle points (mounted fittings/elbow fit- tings)

Technical Data

General data

|
---|---
Version| Double-acting cylinder
Temperature range| -20 °C … +60°C
Mounting orientation| Any
ATEX classification|   4.1 ATEX identification
Operating pressure min./max| KPZ/MNI/CCI/CCL-IC/CSL-RD/RPC: 1… 10 bar

PRA/TRB/CCL-IS/ITS: 1.5 … 10 bar

Permissible medium| Compressed air prepared outside the explo- sive area
Max. particle size| 50 µm
Oil content of compressed air| 0 … 5 mg/m3

The medium dew point must be at least 15°C below the ambient and medium temperatures and must not exceed 3°C. The oil content of compressed air must remain constant during the service life. Use only the oils approved by AVENTICS.

Tubing length max.| For cylinder Ø ≤ 25 mm: 5 m
For cylinder Ø ≥ 32 mm: 10 m
Tubing diameter max.| For cylinder Ø ≤ 25 mm: 6 mm
For cylinder Ø ≥ 32 mm: any
Max. permissible operating frequency (double stroke)| For cylinder Ø ≤ 25 mm: 0.33 Hz
For cylinder Ø ≥ 32 mm: 0.4 Hz
Max. permissible piston speed| 1 m/s
Max. permissible circumferential speed on the wearing surface| 1 m/s

Further technical data for your configuration can be found in the online catalog.

Accessories

The accessories approved for your configuration can be found in the online cata-log.

References

• AVENTICS – Smart, reliable solutions for pneumatic automation | Emerson US
• Contact Us | Emerson US
• Contact Us | Emerson US

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