INSTRUCTION MANUAL HEAVY DUTY TYPE PNEUMATIC CYLINDER 10A-3 SERIES

Transcription

1 03-P055-1 INSTRUCTION MANUAL HEAVY DUTY TYPE PNEUMATIC CYLINDER 10A-3 SERIES <<For safe use of product>> Wrong operation of the product may result in unavailability of exhibition of full performance of the product or lead to a serious accident. To prevent occurrence of an accident, be sure to read the Instruction Manual of the product carefully to completely understand the contents given therein before operating the product. Those described as precautions are items to which your careful attention has to be paid. Operators or products may be injured or damaged, unless these precautions are strictly observed. Accordingly, be sure to operate the product in strict conformance with the instructions given therein. If you find any unclear point, contact us. TAIYO, LTD Kitaeguchi, Higashiyodogawa-ku Osaka JAPAN URL:

2 2/14 LIST OF CONTENT 1. FOR SAFE USE PRES FOR OPERATION OF PNEUMATIC CYLINDERS... 4 PRES ON RELATED LEGISLATION... 4 PRES ON RELATED DESIGN... 4 PRES ON SELECTION... 4 PRES ON AIR PRESSURE SOURCE... 5 PRES ON OPERATING ENVIRONMENT... 5 PRES ON INSTALLATION... 6 PRES ON PIPING... 6 PRES ON LUBRICATION... 7 PRES ON TRIAL OPERATION AND ADJUSTMENT... 7 PRES ON MAINTENANCE AND INSPECTION... 7 PRES ON STORAGE... 8 PRES ON SCRAPING INSTRUCTIONS FOR USE... 9 ENVIRONMENTAL CONDITIONS... 9 MOUNTING... 9 MOUNTING OF ROD END IN THE CASE OF FIXED TYPE MOUNTING OF CYLINDER...10 OPERATION PIPING OTHER NOTES MAINTENANCE (MAINTENANCE AND INSPECTION)... 14

3 1. FOR SAFE USE Cautionary descriptions given here are for correct use of the products and for prevention of hazard on you and other people in vicinity and damage with equipment. These descriptions are divided into three items of DANGER, WARNING and depending on the severity of hazard or damage and level of imminence. All bear important descriptions pertaining to safety. Strictly observe the instructions in addition to those of ISO4414*1), JISB8370*2) and other safety rules. DANGER : WARNING : : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which could result in death or serious injury, if the equipment is operated wrongly. Indicates a potentially hazardous situation which may result in injury and machine damage, if the equipment is operated wrongly. *1) ISO4414: Pneumatic Fluid Power - Recommendations for the application of equipment to transmission control systems. *2) JISB8370: General Rules of Pneumatic System. WARNING For decision of conformity of pneumatic equipment, the designer of a pneumatic system or a person deciding the specifications is requested to render judgment. 3/14 Since pneumatic equipment is used in many kind of situation, the decision for adaptability of system is depended on the designer or a person deciding the specifications to judge by the result of analysis and testing report if necessary. The guarantee of the performance and security which expected is up to the responsibility of the person who decides the adaptability of system. Construct the system with consideration of the possibility of machinery trouble by checking up the details specifications through latest product catalog and others documents. Operators with sufficient knowledge and experiences should operate the equipment. Compressed air, if handled wrongly, will cause a hazard. Personnel with sufficient knowledge and experiences only are requested to assemble, operate or maintain machines and devices which use pneumatic equipment. Do not handle the machines and devices or remove the equipment until safety is confirmed. 1) Inspect or service the machines and devices after making sure of measures taken securely for prevention of drop of driven bodies and out-of-control run of them. 2) Remove the equipment after making sure of the safety measures mentioned above duly taken and exhausting compressed air in the system. 3) When restarting the machines and devices, make sure of a measure taken for prevention of protrusion in advance. Use the product in environment conforming to the specifications. You are requested to be sure to inform us in advance, when you intend to use the product outdoors or for applications likely to have large effects on people and properties and requiring safety in particular such as atomic energy, railways, aircraft, rolling stocks, medical equipment, equipment to be in touch with beverage and foodstuff, amusement equipment, emergency shut-off devices, press safety devices, brake circuits and safety equipment.

4 2. Precautions for Operation of Pneumatic Cylinders Precautions on related legislation 4/14 WARNING When using a compressor that the rated discharge pressure is over 5Mpa, or an air pressure that is supplied from an air tank over 1Mpa are covered in High Pressure Gas Safety Law. When using a single gas such as Nitrogen, using a container of over 1Mpa as an air pressure source is also covered in High Pressure Gas Safety Law. WARNING Precautions on related design General purpose pneumatic cylinder DC7 series is designed to be used in an air system only. If working with fluid other than air, an accident or trouble may be caused. An air cylinder may jump out at a speed higher than expected, if its mechanical sliding area is disordered. Design the cylinder so that the machine may operate smoothly and the cylinder may not damage persons or machines. Fit a protective cover when the cylinder or driven body is likely to cause a hazard to persons. When required frequency of operation is high or the cylinder is mounted on a place exposed too much vibration, adopt a fastening method not to allow the fixed area or connection of the cylinder to loosen. Take safety measures with power failure and possible trouble with the power source taken into consideration. Conduct design so the motions of the cylinder may not cause damages to persons and machines and devices at the occasion of emergency stop, systems error or restarting. WARNING Precautions on selection This cylinder is designed to be used in an industrial compressed air system only. Confirm the specifications and do not use out of the range of specifications. Use the cylinder in a proper working pressure within the pressure range. Do not apply exceeded pressure that over the upper limit of working pressure range. Use the cylinder in a proper temperature environment within the working temperature range. Confirm the temperature is within this range even when the cylinder is heated by radiant heat or heat transfer. Supply an air pressure to the cylinder that commensurate with the loads. If the supply pressure is minimized, it may cause instable operation. In the case of an air cylinder, accurate interim stopping accuracy such as that of a hydraulic cylinder cannot be obtained because of compressibility of air.

5 5/14 Zero leak of an air cylinder and air valve is not guaranteed. Do not use the cylinder in environments or for applications where leak of air from a cylinder or valve poses a problem. Be sure to calculate the cylinder buckling. The strength in the case that the piston rod is regarded as a long column, the buckling strength, cannot be enhanced by adopting highly tension-proof steel or heat treatment. When buckling occurs to a cylinder, the cylinder rod may be bent, causing malfunctions or serious accidents. If cylinders are used in the places under unfavorable conditions, where are subjected to wind, rain, and dusts, the piston rod especially needs to be protected. When selecting the boots, consider the environment conditions and temperature. If the boots are provided, the length of extended cylinder rod is changed. Be sure to check the dimension drawing. The volume of boots will change by move of piston rod, and therefore there is a window for air flow (with filter) in the boots, through which small foreign matters of liquid and particle might be entered with air flow. In such a case the boots does not work. Boots type and resistible temperature Code Name Material Resistible temperature J Nylon tarpaulin Vinyl-coated nylon cloth 80ºC JN Chloroprene Nylon cloth coated with chloroprene 100ºC JK Conex Silicon-coated Conex cloth 200ºC Note 1. Remember that the resistible temperatures in the table above are for the boots, not for the cylinder. 2. Conex is the registered trademark of Teijin Ltd. 3. Neoprene, the older name of chloroprene, is the registered trademark of DuPont-Showa Denko Co., Ltd. Thus, we have adopted general name, chloroprene. Precautions on air pressure source Use clean compressed air. Air containing chemicals or corrosive gas will cause break or malfunction of the cylinder. Mount an air filter to remove foreign matter in compressed air. Set an after-cooler, air dryer or air filter to remove drain in compressed air. WARNING Precautions on operating environment Do not use the cylinder in environment under corrosive gas or a place exposed to splash of corrosive chemicals or solutions. For cylinder material, see the catalog. Attach a cover to the piston rod in a much dusty place or a place exposed to water drops or oil drops. It is dangerous that the strength of material may be decreased by corrosive in a salty atmosphere. Be

6 6/14 sure to use a cylinder with corrosion proof or corrosion resistant material in such kind environment. In the case of use in the places where splashed with solvent, cutting oil and coolant may deteriorate the quality of seal parts and may cause air leakage at the early stage. Be sure to check the adaptability of packing material. Precautions on installation Be sure to couple the rod with the rod axial center adjusted to the rod moving direction. Otherwise, the bush and rod surfaces, tube inner surface and packing will be worn out or broken. When a cylinder is mounted with fixed (Foot type or Flange type), we recommend using the floating joint with self-aligning function. Do not bump things against the cylinder tube, piston rod, etc. to scratch them. Scratched sliding area will cause wear of packing. For the mounting of cylinders, use bolts of the specified size, and fix with the bolts of the strength class. And, be sure to fix the bolt by using a tool that can get an adequate clamping torque. Install an external stopper to the mounting base when using foot type mounting to prevent direct application of impact. Apply grease to rotary areas of trunnion accessories and clevis accessories to prevent seizure. If the boots are provided, conduct mounting with care not to twist the boots Precautions on piping Flush the piping sufficiently to remove foreign matters. Be careful so that no seal tape or sealing material may enter the pipe. When wrapping a seal tape around threaded area of the piping or joint, wrap the tape leaving 1 to 2 threads at the end as untapped. Conduct the piping work in conformance with the regulations of the applicable country. Proper torque for piping When fastening a joint, tighten the joint to the torque shown below. Connecting thread Proper tightening torque (Nm) Connecting thread Proper tightening torque (Nm) M to 1.5 Rc 1/2 28 to 30 Rc 1/8 7 to 9 Rc 3/4 60 to 65 Rc 1/4 12 to 14 Rc 1 70 to 75 Rc 3/8 22 to 24

7 Precautions on lubrication 7/14 Use the lubricating oil of Turbine Oil Class 1 ISO VG32 or equivalent. Do not use a spindle oil or machine oil, since they will shorten the life of seals to cause malfunction of the equipment. Be sure to continue lubrication to the last, once started. Stop of lubrication on the way will cause malfunction of the equipment due to loss of initial lubrication. Precautions on trial operation and adjustment When starting up a device, increase the supply pressure from a low pressure gradually to check that the device operates smoothly. Be sure to attach a speed controller on the cylinder to adjust setting speed from the low speed side gradually. The cylinder with pneumatic cushion is adjusted to the intermediate speed position before shipment. Adjust the cushion needle position from the low speed side gradually according to the operating condition. If energy higher than the capacity of the pneumatic cushion should apply, collision of the cover with the piston will take place in some cases, resulting in damage with the machine or device. Check whether there is any abnormal motion, noise or friction heating during the trial run of cylinder. If any abnormality is found, do not use the equipment until specified countermeasures are taken. WARNING Precautions on maintenance and inspection To remove or disassemble equipment, take measures for prevention of drop of components and run out of control of the equipment, exhaust compressed air in the system, and make sure of safety in advance. There still may be residual pressure even when the supply pressure is exhausted depending on the working circuit. Remember to exhaust the compressed air completely before removing the cylinder for disassembling. Drain the pneumatic system periodically. Check the pneumatic equipment periodically. If any abnormality is found, do not use the equipment until specified countermeasures are taken. Before disassembling a cylinder, the operator has to completely understanding the inner structure by structural drawing or assembly drawing.

8 Precautions on storage 8/14 Consider following points under storage of product. 1. Become rusty 2. Permanent stress of packing Store the product as followings. 3. Store the product in a cold and dark place (37ºC max.) protected from direct sunlight and moisture in position 30cm above the floor level. 4. Transportation causes a hazard, if collapse of cargo should take place due to excessive vibration. Further, parts may be damaged due to excessive vibration. Precautions on scraping Disassemble cylinders, sort the disassembled components by material (iron, copper, aluminum, resin, rubber, waste oil, etc.), and then, dispose them. Piston rods are hard chrome plated. When disposing them, consult with a disposal company. Dispose resin base and rubber base components as nonflammable wastes.

9 Temperature 3. Instructions for use Environmental conditions Use cylinders only within the allowable working temperature range. Otherwise, troubles below may occur. 1. When cylinders are used at the temperature lower than the lower limit of the working temperature range: Brittle fracture due to lowered stretch of cylinder material Air leak due to lowered elasticity of packing 2. When cylinders are used at the temperature higher than the upper limit of the working temperature range: Rust-proof measures Damage due to lowered strength of cylinder material Damaged packing Galling due to thermal expansion in the slipping part 9/14 The use and storage of cylinders in the places where are highly humid, or are splashed with water or sea water require the consideration of rust-proof and anticorrosion measures. In such a case, contact us. Installation location 1. Use cylinders only indoors. 2. Avoid the use in the places where are subjected to dusts and vibrations. DO NOT use them under the environmental conditions shown below. The use under these conditions requires the protection of the rod part, rust-proof measures, review of part material, magnetic shield, and vibration proof measures. If any countermeasure required for the cylinder side, contact us. Working environmental conditions Sands, dusts, soil, chips, welder spatter, etc. Rain, water, sea water, oil, chemicals, etc. Direct sunlight (ozone), humidity, etc. High temperature, low temperature, freezing, etc. Highly magnetic field Vibrations Mounting For the mounting of cylinders, use bolts of the specified size, and fix with the bolts of the strength class. In the case of the rotary type, use pins of the specified size. Otherwise, screws may be loosened or damaged due to cylinder driving force or its reaction force. When a cylinder is mounted with fixed, the performance of the cylinder largely depends on the hardness of the mounting material. Therefore, insufficient hardness of mounting material may lead to a warp in mounting material due to the driving force of the cylinder and the disordered piston rod and bush, causing premature wear and the damaged thread of the piston rod. Use the mounting material with sufficient hardness.

10 (LB, FA, FB types) Mounting of rod end in the case of fixed type 10/14 The movement direction of articles moved by a cylinder must be always aligned with the axis center of the piston rod movement. If the axis center is run out, premature wear of the bush, baking or galling of the cylinder tube may occur. To check the run out of the axis center, be sure to measure the core deviation of mounting part of the article at the position where the piston rod is fully ejected, and align the core. Then, connect the cylinder with the article. Mounting of cylinder Consider the following points when mounting cylinders. We cannot take responsibility for malfunctions due to wrong cylinder mounting. In the case of fixed type 1. LB type To mount LA and LB types, fix the attachments with clamping bolts. However, remember that this procedure is not perfect for the move in the axial direction when a load is applied. Therefore, install the stopper to the mounting base, as shown in the figures below.

11 2. FA, FB types 11/14 Fix cylinders as shown in the figures below. In the case of rotary type For the cylinder of which mounting part moves inside a plane, be sure to connect the connection fittings of the rod end with pins, so that the mounting part can move inside the plane. For the plane and rectangular direction, perform centering similarly to the fixed type. Be sure to apply lubricant to the bearing part of the connection fittings. DO NOT use floating joints for rod end attachments. 1. CA, CC, CB type attachments Use pins of the size specified in this catalogue. In the case of a long stroke (1000 mm or longer), avoid horizontal mounting. Otherwise, a lateral load is applied to the bush part due to the weight of the cylinder, causing uneven abrasion, substantially shorter service life, or galling. 2. TA, TC type attachment Mount counterpart attachments at a right angle so that they are vertical with the trunnion boss. If they are mounted slantingly, uneven abrasion may occur in the boss bearing area, causing a substantially shorter service life.

12 12/14 Leave a minimum space between trunnion and counterpart attachments. And, to avoid bending moment boss bearing must be always aligned with the axis center of the pin. Conformation of air supply Operation 1. Confirm the cooler and dryer are working properly when those devices are connected. 2. Drain the pneumatic system periodically. Conformation of working pressure range 1. Table below shows the working pressure range. Confirm the pressure is within this range even when the pressure fluctuates greatly. Cylinder type Standard Working pressure range 0.1 to 1.0Mpa 2. When starting up a device, increase the supply pressure from a low pressure gradually to check that the device operates smoothly. Conformation of working temperature range Table below shows the working temperature range. Confirm the temperature is within this range even when the cylinder is heated by radiant heat or heat transfer. Cylinder type Standard Working temperature range -10 to +70ºC Adjustment of cushion valve Adjust the cushion valve as followings. Even if the cushion is adjusted when delivery, the change of damping effect of cushion will occurs depend on the speed and load of cylinder. 1. Loosen the cushion lock nut with a spanner. 2. Turn the cushion valve only with an Allen wrench. a) Turn clockwise: the cushion stroke speed decreases. b) Turn counterclockwise: the cushion stroke speed increases. 3. After the adjustment of the cushion valve is complete, fix the cushion valve with an Allen wrench, and clench the cushion lock nut.

13 13/14 Allowable shock absorbed range of cushioning The cushioning mechanism decreases piston speed by applying back-pressure in the interval of about 20mm from stroke end (interval length varies depending on bore). Therefore, beware of the mechanism s limitations, shown in the graph at right. Adjustment of cylinder speed Maximum cylinder operating speed is 700mm/sec. If this speed is exceeded, the rod gland and seals will rear rapidly and the shock at stroke end will increase. The result is shortened cylinder life time and susceptibility to malfunction. If cylinder speed is too low, the result will be sticking, slipping and unstable operation. Cylinder speed varies depending on pipe diameter, air pressure, flow rate and load, and therefore must be adjusted to suit the intended use. Adjustment is normally done using a speed control valve, but this is not always enough, and other factors may have to be considered (air pressure, load etc.). Piping Take sufficient care to avoid dusts and chips of pipes in the piping. When piping, avoid any air accumulation in pipes. When connecting with a rubber hose, do not bend it with the bending radius smaller than the specified level. Be sure to perform piping flushing. After flushing is complete, connect to the cylinder. Otherwise, the cylinder may be malfunctioned or leak may occur due to dusts in the piping. Other notes When welding near a cylinder, it may be subjected with spatters. Protect the cylinder rod to avoid spatters. When welding during mounting, take sufficient care to avoid an electric current in the cylinder. Any electric current in the cylinder may lead to arcs between the rod and bush or between the piston and tube, causing the damaged cylinder parts.

14 Maintenance (maintenance and inspection) 14/14 To use cylinders without an accident for a long time, daily and regular inspections are required. 1) Daily inspection For the daily inspection, check the points described below. (1) Check that the cylinder set bolts and nuts are not loosened. (2) Check that the working conditions are normal. (3) Check that there is no external leakage. (4) Check that there is no abnormality in other parts of the cylinder (tie rod, flange, etc.) 2) Regular inspection (disassembly inspection) Decide the interval of the regular inspection depending on the working conditions and requirement, and perform according to the decided schedule. It is recommended to perform it once a year. Replace packing and gasket with fresh ones at regular inspections. Do not use packing which have been stored for two years or more. Notes on fitting of valve seals Valve seals must be fit in the specified direction and sequence. Wrong fitting direction and sequence will lead to the damaged packing, causing oil leak.