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Operating and Maintenance Norms For Cylinders and Servocylinders
Operating and Maintenance Norms For Cylinders and Servocylinders
5 NAMEPLATES
4 3
2
1
5
R
www.atos.com
APPROVED ISO 10100-ISO 4406 18/15
CK-80/36*1360-N041--B2X2
-32 03685071
42/08
1/2
Pos. Description
Series number
Customer code (only if requested)
CE mark (see section )
Marking according to ATEX directive
Cylinder serial number
www.atos.com
R
Pmax 250bar
Tfmax +70C
II 2GD ck IICT85C(T6)
Serial N
TV 09 ATEX 366333
-20C<Tamb<+70C
fmax 5Hz
1
3
2
4
2/2
Pos. Description
Working limit conditions
Notified body and certified number
Nameplate 2 - ATEX (1)(2) Nameplate 1 - Standard (2)
Max pressure
Max fluid temperature Tfmax
Pmax
Tamb
fmax
Sym. Meaning
Ambient temperature
Max frequency
Working conditions - legend
CKA with ex-proof proximity sensors II 3 G II T4 2
Nameplate 1 - Standard Nameplate 2 - ATEX
Cylinders CK, CH and CN - Pmax = 250 bar
Bore [mm] Rod [mm]
Stroke min [mm]
single rod double rod
125
56
70
90
3255
4075
4745
5000
160
70
90
110
1985
2460
2910
3770
200
90
140
1270
1595
2495
250 140 810 1185
320 180 495 725
400 220 315 455
Cylinders CC - Pmax = 320 bar
Bore [mm] Rod [mm]
Stroke min [mm]
single rod double rod
100 70 3975 5000
125 90 2545 5000
140 90 2030 3455
160 110 1550 2945
180 110 1225 1960
200 140 990 1950
250 180 635 1320
320 220 385 735
400 280 245 485
Hydraulic cylinders are considered as pressure vessels and thus they are subject to the PED directive (97/23/CE), point 1.1 of article 3. Particularly
they are designed to be used with fluids of group 2 (oil hydraulic fluids) and they have to be marked if the product Pmax x V (Volume under pressure)
is higher than 10.000 bar x liter. Tables below show the minimum stroke over which the cylinders have to be CE marked. ATEX cylinders are CE
marked according to ATEX directive (94/9/CE).
6 CE MARKING
6
7 ATEX CERTIFICATION
DUST
GAS
8.1 General
- The presence of cushioning can lead to a pick of pressure that can reduce the cylinder working life, ensure that the dissipated energy is less than the
max value reported in tab. B015
- Make sure that the maximum working conditions, shown in section
,
are not exceeded
- Ensure to use hydraulic fluids compatible with the selected sealing system, see tab. B137, B140, B160, B180, B241, B310 and B400
- The rod must be handled with care to prevent damages on the surface coating which can deteriorate the sealing system and lead to the corrosion of the
basic material
- The mounting screws must be free from shearing stress
- Transverse forces on the rods must always be avoided
- When the cylinder has to drive a rotating structure or where little alignment errors are expected, mounting style with spherical bearing should be used
- Contact surfaces, support elements in tolerance, elastic materials and labels must be covered before painting the cylinder
8.2 Proximity sensors
- Proximity sensors are supplied already adjusted, if other regulations are necessary see tab. B137 or contact our technical office
- Ensure not to remove the sensor while the cylinder is under pressure
- The connectors must never be plugged or unplugged when the power supply is switched-on
8.3 Position measuring system
- Position transducers must never be removed, if not otherwise specified in tab. B310, while the cylinder is under pressure
- Observe the information provided in tab. B310 for the electronic connections
- The connectors must never be plugged or unplugged when the power supply is switched-on
8.4 Installation
- Consult tab. P002 for installation, commissioning and maintenance of electrohydraulic system
- The piping have to be dimensioned according to the max pressure and max flow rate required
- All pipes and surfaces must be cleaned from dirt before mounting
- Remove all plug screws and covers before mounting
- Make sure that connections are sealed before giving pressure to the system
- Ensure to not exchange the pipe ports when connecting the cylinders
- Bleed-off the system or the hydraulic cylinder
- Ensure that the cylinder mounting allow easy of acces for the purpose of maintenance and the adjustment of cushioning
4
8 SAFETY NOTES
9 MAINTENANCE
- The max surface temperature indicated in the nameplate must be lower than the following values:
GAS - 80% of gas ignition temperature
DUST - max value between dust ignition temperature - 75C and 2/3 of dust ignition temperature
- The ignition temperature of the fluid must be 50C greater than the maximum surface temperature indicated in the
nameplate
- The cylinder must be grounded using the threaded hole on the rear head, evidenced by the nameplate with ground
symbol. The hydraulic cylinder must be put at the same electric potential of the machine
For details about ex-proof proximity sensors or position transducer refer to the users guide included in the
supply
Maintenance must be carried out only by qualified personnel with a specific knowledge of hydraulics and electrohydraulics
9.1 Preliminary check and ordinary maintenance
Atos hydraulic cylinders dont require any maintenance after commissioning. Anyway it is recommended to take into account the following remarks:
- Results of maintenance and inspection must be planned and documented
- Check oil escaping from oil ports or leakages at the cylinder heads
- Check for damages of the chromeplated surface of the rod: damages may indicate oil contamination or the presence of excessive transverse load
- Determine lubricating intervals for spherical clevises, trunnion and all parts not self-lubricated
- The rod should always be retracted during long stop of the machine or system
- Remove any salt, machining residuals or other dirt cumulated on the rod surface
- Follow the maintenance instructions of the fluid manufacturer
9.2 Repairing
Before beginning any repairing observe the following guidelines:
- Unauthorized opening of the cylinder during the warranty period results in the warranty expiration
- Be sure to use only original spare parts manufactured or supplied by Atos
- Provide all the required tools to make the repair operations safely and not damage the components
- Read and follow all the safety notes given in section
- Ensure that the cylinder is well locked before beginning any operation
- Disassembly or assembly the cylinder with the right order as indicated in section 9.3
- When mounting rod or piston guides and seals observe the correct position as indicated in section 9.4. Any bad positioning can result in oil leakages
- It is strongly recommended the use of expanding sleeves to insert the seals in the proper groove
- Tighten all the screws or nuts as follow: lubricates the threads, insert the screw or the nut by hand for some turns, tighten the screw crosswise with the
tightening torque specified in the technical table (a pneumatic screw driver may be used)
- Rod bearing and piston must be locked respectively to the front head and to the rod by means of special pin to avoid unscrewing
- The replacement of wear parts such as seals, rod bearing and guide rings depends on the operating conditions, temperature and quality of the fluid
8
- Any planned maintenance must be performed only by experienced personnel, authorized by Atos
- Ordinary maintenance of the cylinder consist of cleaning of the external surfaces using a wet cloth to avoid accumulation of dust layer > 5 mm
- Do not use compressed air for cleaning to avoid any dangerous dust dispersion on the surrounding atmosphere
- Any sudden increment in temperature requires immediate stop of the system and inspection of the relevant components
B600
Any repairing must be performed only by experienced personnel, authorized by Atos
Ground
CK, CKA - For spare parts see tab. KTR-B137 CH - For spare parts see tab. KTR-B140 and KTR-B160
10 TRANSPORT AND STORAGE
10.1 Transport
Observe the following guidelines for transport of hydraulic cylinders:
- Cylinders have to be transported using a forklift truck or a lifting gear always ensuring a stable position of the cylinder
- Cylinders have to be transported in horizontal position in their original packaging
- Use soft lifting belts to move or lift the cylinders in order to avoid damages
- Before any movement check the cylinders weight (due to tolerances, the weight may be 10% greater than the values specified in the technical table)
Additional parts such as pipes, subplates and transducers must never be used for lifting
10.2 Storage
Corrosion protection is achieved with epoxy coatings: the primer grants a storage period up to 12 months. Additionally all cylinders are tested with mineral
oil OSO 46; the oil film, presents in the cylinder chambers after testing, ensures the internal corrosion protection.
Anyway be care to observe the following remarks:
- When a storage in the open air is foreseen ensure that cylinders are well protected against water
- The cylinders must be inspected at least once a year and rotated through 90 every six months to preserve the seals
In case of storage period longer than 12 months, contact our technical office
CN - For spare parts see tab. KTR-B180 CC - For spare parts see tab. KTR-B241
PISTON ROD BEARING
G1-G8 G2-G3-G4-G5 G6 G7 G1 G2-G3-G4-G5-G6-G7 G8
Note: this symbol means that a particular equipment is required for mounting, contact our technical office
Single effect
pushing
Single effect
pulling
9.4 Sealing system mounting
07/10
9.3 Cylinders exploded views