Operating instructions BA_B1282_EN Hydro
Contents
1. If it is not avoided death or very severe injuries will result Person damage Stands for a possibly dangerous situation If it is not avoided death or very severe injuries will result Easy injuries property damage Stands for a possibly dangerous situation If it is not avoided minor injuries or material dam ages will result Hazardous to the environment The symbol stands for important information for the proper handling with materials that are hazardous to the environment Ignoring these notes can lead to heavy damages to the environment Mandatory sign The symbol stands for important information neces sary protection equipment etc a Note This symbol stands for tips for users or especially useful information This is no signal word for a dangerous or harmful situation 5 Safety instructions 5 1 Basic information The operating instructions serve for information and avoidance of dangers when installing the products into the machine as well as information and references for transport storage and maintenance Only in strict compliance with these operating instructions accidents and property damages can be avoided as well as trouble free operation of the products can be guaranteed Furthermore the consideration of the operating instructions will result in e reduced down times and repair costs e increased service life of the products gt gt Note These operating instruct2. comes out Fasten union nuts of the pipe 4 Check tightness o 8 2 Bleeding of manifold mounted types Loosen carefully the bleeding screws of the fixture at low pressure Pump until bubble free oil comes out Fasten the bleeding screws Check correct function Check sealing of the hydraulic connections o_o oe a 8 3 Adjust stroke end cushioning Danger of injury due to high pressure injection Do not completely turn out the throttle pin otherwise hydraulic oil will spill Injury by crushing Components of the product make a movement while they are in operation This can cause injuries Keep parts of the body and items out of the working area Adjustment of the cushioning depends on the viscosity and temperature of the hydraulic oil Adjust in succession the cushi oning for the extended and retracted piston rod e Loosen lock nut see design e1 or e2 e Screw in throttle pin to increase the cushioning or screw out to reduce the cushioning e Hold and tighten lock nut ROEMHELD 9 Maintenance Burning due to hot surface In operating conditions surface temperatures of more than 70 C can appear at the product All maintenance and repair works must only be ef fected in cooled mode or with safety gloves Damage of components Avoid damages of the moved components rods plungers bolts etc as well as of wiper and seal Damage of components The product must no
3. products or seals can be caused e In machines on pallets or machine tool tables that are used to change the characteristics of the material magnetise ra diation photochemical procedures etc e In areas for which special guidelines apply especially in Stallations and machines For the use on fun fairs and in leisure parks In food processing or in areas with special hygiene regu lations For military purposes In mines In explosive and aggressive environments e g ATEX In medical engineering Inthe aerospace industry For passenger transport e For other operating and environmental conditions e g Higher operating pressures than indicated on the data sheet or installation drawing With hydraulic fluids that do not correspond to the speci fications Higher flow rates than indicated on the data sheet or in Stallation drawing Operating instructions BA_B1282_EN Side load acting on the piston rod The application of side loads to the piston rod as well as the use of the product as a guiding element is inadmissible Special solutions are available on request 7 installation Injury by high pressure injection squirting out of hydraulic oil under high pressure Improper connection can lead to escapes of oil under high pressure at the connections Mounting or dismounting of the element must only be made in depressurised mode of the hydraulic sys tem Connection of the hy
4. that the spherical bearing can just be turned on the piston rod thread 3 Clamp the spherical bearing carefully in a vice and tighten piston rod firmly against the spherical bearing by means of a fork spanner 4 Tighten clamping screws By this procedure the thread receives a certain initial tension which prevents loosening with alternating loads For versions with spherical bearings clevis pin fit has to be m6 8 Start up Poisoning due to contact with hydraulic oil Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil Incorrect connection can lead to escapes of oil at the ports For handling with hydraulic oil consider the material safety data sheet Wear protection equipment Damage of components The maximum operating pressure of 200 bar must not be exceeded e Check tight seating check tightening torque of the fixing screws see chapter Technical characteristics Operating instructions BA_B1282_EN e Check tight seating of hydraulic connections check tighten ing torque of the hydraulic connections see chapter Tech nical characteristics e Bleed the hydraulic system Note Without bleeding the clamping time will be considerably prolonged and function problems may occur 8 1 Bleeding of pipe mounted types 1 Loosen carefully at low pressure union nut of the pipe at the hydraulic ports 2 Pump until bubble free oil
5. Operating instructions ROEMHELD ht BA B1282 EN Issue 11 12 Hydro cylinders with optional stroke end cushioning Table of contents 1 o O N O A A Q ND ee ee Ce Cr a FF WwW N OO Description Validity of the documentation Target group of this document Symbols and signal words Safety instructions Application Installation Start up Maintenance Trouble shooting Technical characteristics Accessory Storage Disposal Declaration of manufacture h O O O O N N N O WO WO N N double acting max operating pressure 200 bar 1 Description Double acting hydro cylinders with connecting dimensions according to DIN ISO 6020 The piston rod is provided with an external thread and is har dened and chromium plated For fixing the front and rear housing part is equipped with 4 interior threads Also an effective wiper seal is available The adjustable stroke end cushioning avoids a crash stop of the piston in the cylinder body in case of the following applicati ons 1 High piston speed 2 Additional load at the piston rod and 3 An external stop to compensate the additional load is not possible 2 Validity of the documentation This document applies to the following products Block cylinders of data sheet B 1 282 The following types or part numbers are concerned e 1293 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1294 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1295 10 XXXX 11
6. XXXX 12 XXXX 13 XXXX e 1296 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1297 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1298 10 XXXX 11 XXXX 12 XXXX 13 XXXX XXXX corresponds to the stroke in mm 3 Target group of this document e Specialists fitters and set up men of machines and installa tions with hydraulic expert knowledge Qualification of the personnel Expert knowledge means that the personnel must e be inthe position to read and completely understand tech nical specifications such as circuit diagrams and product specific drawing documents e have expert knowledge electric hydraulic pneumatic knowledge etc of function and design of the correspond ing components An expert is somebody who has due to its professional educa tion and experiences sufficient knowledge and is familiar with the relevant regulations so that he e can judge the entrusted works e can recognize the possible dangers e can take the required measures to eliminate dangers e knows the acknowledged standards rules and guidelines of the technology e has the required knowledge for repair and mounting Romheld GmbH Postfach 1253 35317 Laubach Germany Tel 49 0 6405 89 0 Fax 49 0 6405 89 211 www roemheld de Subject to change without notice Translation of the original German document 1 8 2v ROEMHELD a4 4 Symbols and signal words DANGER Danger of life heavy health damages Stands for an imminent danger
7. atches shrink holes concentric machining marks are inadmissible For some versions 3a Remove socket head cap screws countersunk plugs and sealing rings insert o rings accessories if required 3b Tighten pipe ports with screw plugs accessories if re quired 4 Clean the support surfaces 5 Position and fasten on the fixture 6 Install bleeding screws at the upper ends of the piping a Note The tightening torques for the fixing screws have to be designed with reference to the application e g as per VDI 2230 Proposals and approximate values for the tightening torques see chapter Technical characteristics ROEMHELD 7 6 Connection of the hydraulic equipment 1 Connect hydraulic lines to qualifying standards and pay attention to scrupulous cleanness A Extend B Retract S gt Note See ROEMHELD data sheets A 0 100 F 9 300 F 9 310 and F 9 360 S gt Note Use only fittings screwed plug B and E as per DIN 3852 ISO 1179 gt Note Do not use sealing tape copper rings or coned fittings B gt Note Use hydraulic oil as per ROEMHELD data sheet A 0 100 7 7 Mounting of spherical bearing Damage of components When using spherical bearings the operating pres sure during the cylinder movement may be max 160 bar and in the stroke end position max 200 bar 1 Screw the spherical bearing firmly against the piston rod shoulder 2 Tighten clamping screws so
8. draulic line as per DIN 3852 ISO 1179 Unused connections have to be locked profession ally Use all mounting holes Injury by high pressure injection Squirting out of hydraulic oil under high pressure Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil under high pressure Before using them make a visual control Injury by falling parts Keep hands and other parts of the body out of the working area Wear personal protection equipment Poisoning due to contact with hydraulic oil Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil Incorrect connection can lead to escapes of oil at the ports For handling with hydraulic oil consider the material safety data sheet Wear protection equipment Damage of components Some product types have a considerable weight These have to be secured against working free during transport Weight specifications see chapter Technical char acteristics 3 8 MZ ROEMHELD 7 3 Damage of components Side loads and forced conditions acting on the piston lead to increased wear Operating instructions BA_B1282_EN Admissible oil flow rate Injury due to overload of the element High pressure injection Squirting out of hydrau lic oil under high pressure or flying compo Provide external guides Avoid forced co
9. er Romheld GmbH Friedrichshttte RomheldstraBe 1 5 35321 Laubach Germany Tel 49 0 64 05 89 0 Fax 49 0 64 05 89 211 E mail info roemheld de www roemheld com Operating instructions BA_B1282_EN Declaration of manufacture of the products Block cylinders of data sheet B 1 282 The following types or part numbers are concerned e 1293 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1294 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1295 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1296 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1297 10 XXXX 11 XXXX 12 XXXX 13 XXXX e 1298 10 XXXX 11 XXXX 12 XXXX 13 XXXX XXXX corresponds to the stroke in mm They are designed and manufactured in line with the relevant versions of the directives 2006 42 EC EC MSRL and in com pliance with the valid technical rules and standards In accordance with EC MSRL and EN 982 these products are components that are not yet ready for use and are exclusively designed for the installation in a machine a fixture or a plant According to the pressure equipment directives the products are not to be classified as pressure reservoirs but as hydraulic placing devices since pressure is not the essential factor for the design but the strength the inherent stability and solidity with regard to static or dynamic operating stress The products may only be put into operation after it was as sessed that the incomplete machine machine in which the p
10. in Ax Piston area in cm n Number of elements same dimensions Vz V_ Admissible maximum stroke speed in m s S gt Note The maximum oil volume and or the maximum stroke speed depend on the corresponding product For clamping cylinders see data sheet A 0 100 For clamping elements work supports hydraulic valves power units and other hydraulic elements in dicated on the corresponding data sheets Figure 2 Fixing possibilities 3 Flange mounting at rear 4 Flange mounting at rear g with accessory flange 1 Flange mounting at front 2 Flange mounting at front with accessory flange 4 8 2 ROEMHELD a4 Further things worth knowing about hydraulic cylinders ba sics detailed knowledge and calculations on hydraulic cylin ders see in the Technical library on the internet or download AEO eane 7 3 2 Throttling of the flow rate The throttling always has to be effected in the supply line to the swing clamp Only thus pressure intensification and thereby pressures exceeding the operating pressure are avoided The hydraulic circuit diagram shows flow control valves which allow oil return from the element without any impediments Figure 3 Hydraulic circuit diagram without flow control valves a Throttling direction b Free flow If a return flow throttling is required due to a negative load it must be guaranteed that the max operating pressure see technical characteristics will no
11. ions are not a replacement for the operating instructions of the entire machine 5 2 Operating instructions BA_B1282_EN General safety tips Poisoning due to contact with hydraulic oil Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil Incorrect connection can lead to escapes of oil at the ports For handling with hydraulic oil consider the material safety data sheet Wear protection equipment Injury by high pressure injection squirting out of hydraulic oil under high pressure Improper connection can lead to escapes of oil under high pressure at the connections Mounting or dismounting of the element must only be made in depressurised mode of the hydraulic sys tem Connection of the hydraulic line as per DIN 3852 ISO 1179 Unused connections have to be locked profession ally Use all mounting holes Injury by high pressure injection squirting out of hydraulic oil under high pressure Wear damage of the seals ageing and incorrect mounting of the seal kit by the operator can lead to escapes of oil under high pressure Before using them make a visual control Injury by crushing Components of the product make a movement while they are in operation This can cause injuries Keep parts of the body and items out of the working area Damage of components Side loads and forced conditions on the plunger lead to prematu
12. nditions overdetermination of the piston nents Due to throttling or closing of ports a pressure inten sification can occur Connect the ports professionally 7 1 Design Damage of components The maximum flow rate must not be exceeded 7 3 1 Calculation of the admissible flow rate Admissible oil flow rate The admissible flow rate or the admissible stroke speed is valid for vertical mounting positions in combination with stan dard add on parts as clamping arms or contact bolts etc In case of other mounting positions and or add on parts the flow rate has to be reduced If the pump flow rate divided by the number of elements is larger than the admissible flow rate of one element the flow rate has to be throttled This prevents an overload and therewith an early failure The flow rate can be checked as follows rigue T Components Q lt 0 06 Vz n and or Q 6 v A n for clamping elements and work supports indicated on the a Hydraulic port e1 Stroke end cushioning data sheets A extend B retract extending b Piston rod with external e2 Stroke end cushioning thread retracting Fixing possibilities f Cylinder head Maximum piston speed At specified pump flow rate Q and with the effective piston area A the piston speed can be calculated as follows 7 2 Mounting types Va lt Qr 6 Apn Legend Vz Admissible flow rate of the element in cm s Q Flow rate of the pump in l m
13. onents The product may not be exposed to direct solar ra diation because the UV light can destroy the seals A storage differing from the storage conditions is inadmissible In case of improper storage the seals can embrittle and resinification of the anti corrosive oil or corrosion at the element can occur The elements are tested by default with mineral oil The exterior of the elements is treated with a corrosion inhibitor The oil film remaining after the test provides for a six month interior corrosion protection if stored in dry and uniformly tem pered rooms For longer storage times the element has to be filled with a non resinifying corrosion inhibitor and the outside surfaces must be treated 14 Disposal Hazardous to the environment Due to possible environmental pollution the indi vidual components must be disposed only by an authorised expert company The individual materials have to be disposed as per the existing regulations and directives as well as the environmental condi tions Special attention has to be drawn to the disposal of compo nents with residual portions of hydraulic fluids The instructions for the disposal at the material safety data sheet have to be considered For the disposal of electrical and electronic components e g stroke measuring systems proximity switches etc country specific legal regulations and specifications have to be kept 15 Declaration of manufacture Manufactur
14. ouble shooting T Check and blow Piston does not Hydraulic oil supply extend or return is impeded matey eee l channels piston extends Air in the hydraulic Hydraulic bleeding jerkily system Hydraulic ports leaky Wear of the seals Replace sealing rings Stroke end will Cushioning needs Screw out throttle not be obtained adjusting pin Check cabling Check switching distance and ad just to 0 5 mm System pressu re drops Proximity switch wrongly wired or adjusted Proximity switch does not switch 11 Technical characteristics General characteristics Maximum Maximum Maximum operating force to force to pressure Proposal tightening torques for screws of tensile strength 8 8 10 9 12 9 gt Note The indicated values are approximate values and have to be interpreted according to the user s application See note Thread Tightening torque Nm o 88 109 129 Note Valid for workpieces and set screws made of steel with metric thread and connecting surface dimensions as per DIN 912 931 933 934 ISO 4762 4014 4017 4032 In the table values for tightening torques the following is con sidered Design steel steel friction value uges 0 14 not oiled utilisa tion of the minimum yield point 90 2 ROEMHELD a4 gt Note For further technical data see data sheet 12 Accessory e Position monitoring a Note See ROEMHELD data sheet 13 Storage Damage of comp
15. re failure Provide external guides Avoid forced conditions overdetermination of the plunger Do not introduce any torques Damage of components The maximum operating pressure of 200 bar must not be exceeded 2 8 v ROEMHELD Damage of components With hydraulic pressure very high forces are generated The fixture or machine must be in the position to compensate these forces Note qualification of the user All works may only be effected by qualified personnel familiar with the handling of hydraulic components 6 Application 6 1 Intended use The products are used in industrial applications to transform hydraulic pressure to a linear movement and or force They must only be operated with hydraulic oil Furthermore the following belongs to possible uses e Use within the capacity indicated in the technical character istics see data sheet e Use as per operating instructions e Compliance with service intervals e Qualified and trained personnel for the corresponding activi ties e Mounting of spare parts only with the same specifications as the original part 6 2 Misapplication Injuries material damages or malfunctions Do not modify the product The use of these products is not admitted e For domestic use e On pallets or machine tool tables in primary shaping and metal forming machine tools e If due to vibrations or other physical chemical effects dam ages of the
16. roduct shall be installed corresponds to the machinery direc tives 2006 42 EC The manufacturer commits to transmit the special documents of the products to state authorities on request The technical documentation as per appendix VII part B was prepared for the products Responsible person for the documentation Dipl Ing FH Jurgen Niesner Tel 49 0 6405 89 0 Romheld GmbH Friedrichshutte Laubach 29 11 2012 8 8
17. t be cleaned with e Corrosive or corroding components or e Organic solvents as halogen or aromatic hydro carbons and ketones cellulose thinner acetone etc because this can destroy the seals The product must be cleaned at regular intervals especially the area of the piston or the plunger housing has to be cleaned from swarf and other liquids In the case of heavy contamination the cleaning has to be made in shorter intervals 9 2 Regular checks 1 Check tightness of hydraulic connections visual control 2 Check running surfaces of the piston rod or bolt if there are marks and scratches Traces of marks can be an indica tion for a contaminated hydraulic system or an inadmissible side load of the block cylinder 3 Leakage check at the housing piston rod bolt or flange Clamping force control by pressure control 5 Check if the maintenance intervals are kept a 9 3 Exchange seal kit The exchange of the seal kit is made in case of external leak ages For high availability the seals have to be changed at the latest after 500 000 cycles or 2 years The seal kit is available as spare part An instruction for the exchange of the seal kit is available on request gt Note Do not install seal kits which were exposed to light for a longer time Pay attention to the storage conditions see chapter Technical characteristics Only use original seals Operating instructions BA_B1282_EN 10 Tr
18. t be exceeded 7 4 installation of pipe mounted types 1 Clean the support surfaces 2 Fasten the element support at the flange surface see figure Mounting types Injury by falling products Safety shoes have to be worn to avoid injuries due to falling objects S gt Note To determine the tightening torque of the fixing screws a screw calculation as per VDI 2230 page 1 has to be ef fected The screw material is indicated in the chapter Technical characteristics Note The tightening torques for the fixing screws have to be designed with reference to the application e g as per VDI 2230 gt Proposals and approximate values for the tightening torques see chapter Technical characteristics Operating instructions BA_B1282_EN 7 5 Installation of manifold mounted types Figure 4 Example preparation for hydraulic ports without pipes i gt Note The shown figure is a schematic diagram The arrange ment of the ports depends on the respective product see chapter Design d1 Mounted O ring e Screw plug accessory e1 Mounted screw plug Socket head cap screw Sealing ring Countersunk plug against dirt during transport O ring accessory de pending on the version 1 Drill the holes for hydraulic oil supply and return in the fix ture see also data sheet 2 Grind or finish mill the manifold mounting surface Ra 10 8 and a flatness of 0 04 mm to 1100 mm marks scr
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