AVENTICS Pneumatic piston rod cylinder Owner's manual

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1

Knickkraft F

k

in Abhängigkeit vom Betriebsdruck p und Kolbendurchmesser AL

Buckling force F

k

dependent on the working pressure p and piston diameter AL

Force de flambage F

k

en fonction de la pression de service p et du diamètre de piston AL

F [N]

500 km

3000 km

1000 s [mm]

m/A [kg/cm

2

]

0,5

0,05

1,0

1,5

2,0

2,5

3,0

s [mm]

4

531

2

m [kg]

A [cm

2

]

200 400 600 800

2

Maximale Laufleistung bestimmen

Determining the maximum performance

Détermination de la puissance maximale

1

3

Zylinder und Sensor erden

Grounding the cylinder and sensor

Mise à la terre du vérin et du capteur

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1 About This Documentation

Documentation validity

This documentation applies to the following pneumatic piston rod cylinders with

integrated position inquiry:

W Tie rod cylinder, series TRB

W Tie rod cylinder, series ITS

This documentation is geared toward system planning engineers, system operators,

and assembly technicians.

Required and supplementary documentation

O 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, uniform safety

instructions, symbols, terms, and abbreviations are used in this documentation.

These are described in the following subsections to facilitate your understanding.

Safety instructions

In this document, there are safety instructions preceding the steps whenever there

is a danger of personal injury or damage to the equipment. The measures described

to avoid these hazards must be observed.

Safety instructions are set out as follows:

Warning signs and signal words have the following meanings:

Symbols

Abbreviations

The following abbreviations are used in this documentation:

2 Notes on Safety

About this section

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.

O Read these instructions completely before working with the product.

O Keep this documentation in a location where it is accessible to all users at all

times.

O Always include the documentation when you pass the product on to third parties.

Intended use

The cylinder with integrated position inquiry is a pneumatic system component for

moving masses and transmitting tensile or compressive forces. It is intended for use

in a machine or system.

The cylinder is equipped with a magnetorestrictive position transducer to directly

measure the piston position. Along with a controller, it forms a position

measurement system and may only be used for this task. The product is intended for

professional use only.

SIGNAL WORD

Hazard type and source

Consequences of non-observance

O Precautions

O <List>

CAUTION

Indicates a potentially hazardous situation which, if not avoided,

could result in minor or moderate injury or damage to equipment.

NOTICE

Indicates that damage may be inflicted on the product or the environment.

If this information is disregarded, the product cannot be used or operated

optimally.

Abbreviation Meaning

DC Direct Current

n. c. not connected

FS Full Scale

GND Ground

Improper use

Any use other than that described under Intended use is improper and is not

permitted.

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:

W use of the product as a spring or cushioning element, as this may result in

impermissible loads,

W opening the product,

W use in applications not described in this documentation.

Personnel qualifications

The work described in this documentation requires basic mechanical, electrical, and

pneumatic knowledge, as well as knowledge of the appropriate technical terms. In

order 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

W Observe the regulations for accident prevention and environmental protection.

W Observe the safety instructions and regulations of the country in which the

product is used or operated.

W Only use AVENTICS products that are in perfect working order.

W Follow all the instructions.

W Persons assembling, operating, disassembling, or maintaining AVENTICS

products may not be under the influence of alcohol, other drugs, or medications

that influence their ability to respond.

W To avoid injuries due to unsuitable spare parts, only use accessories and spare

parts approved by the manufacturer.

W Comply with the technical data and ambient conditions listed in the product

documentation.

W If unsuitable products are installed or used in safety-relevant applications,

this may result in unintended system operating states that could 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.

W 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

installed, meet the country-specific provisions, safety regulations, and standards

for the specific application.

W If a malfunction of a sensor could result in danger to personnel or equipment

damage, this must be prevented through additional safety measures such as

plausibility checks, limit switches, emergency-OFF systems, protective

equipment, etc. If the sensor malfunctions, it must be taken out of operation and

secured against unauthorized use.

W Only AVENTICS GmbH is authorized to repair sensors.

W Extensions and changes to the device are not permitted.

Safety instructions related to the product and technology

3 General Instructions on Equipment and

Product Damage

CAUTION

Improperly installed compressed air lines!

Danger of injury!

O 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.

O Always secure the area below a suspended load.

NOTICE

Mechanical loads!

Cylinder damage!

O Do not twist or bend the cylinder, or mount it when it is under tension.

O Avoid mechanical loads when connecting the tubing.

O Make sure that the cylinder is not damaged by falling parts or incorrect tool

usage. Especially avoid damage to the piston rod and seals.

AVENTICS | TRB/ITS | R414006414–BDL–001–AB | English 5

4 Delivery Contents

The delivery contents include:

W 1 cylinder with integrated position inquiry in accordance with catalog or

configurator specifications

W 1 set of operating instructions for the cylinder

W Optional: Guide, locking, or mounting elements

If you have configured a cylinder with mounting elements, these will be

pre-assembled on the cylinder. The accessories and spare parts approved for your

configuration can be found in the online catalog from AVENTICS.

5About This Product

Examples are depicted on the title page of piston rod cylinders with integrated

position inquiry.

6 Assembly

Installation requirements

The cylinder has a lifetime lubrication.

O The preferred medium is oil-free compressed air.

See the online catalog from AVENTICS for the permissible compressed air particle

size.

If you are using oiled compressed air, the oil content of the compressed air must

remain constant over the entire service life.

O Only use oils approved by AVENTICS for oiled compressed air (see the section

“Technical Information” in the online catalog).

O Verify that the pressure dew point is at least 15°C below the ambient and medium

temperatures and does not exceed 3°C.

Mounting cylinders

Depending on your configuration, you can mount the product in different ways. The

delivery contents only include the mounting you selected in your configuration.

O You can find the exact dimensions of the mountings for your cylinder in the online

catalog from AVENTICS.

O Install the cylinder in your system so the pneumatic connections and, if present,

throttle screws for the cushioning are always accessible.

1. Make sure that all relevant system parts are not under voltage or pressure before

installing the cylinder. Ensure that the system cannot be switched on.

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

the housing.

3. Fix the cylinder in the bracket in your system.

Observe the maximum permissible tightening torque values listed in the online

catalog from AVENTICS. General technical standards apply if no information is

given or if you use your own mounting materials.

4. Remove the blanking plugs at the pneumatic connections.

5. Make the pneumatic connections for the cylinder.

CAUTION! Always assembly silencers in single-acting cylinders to avoid hearing

damage due to exhaust and impact noise.

6. Fasten the useful load to the piston rod. Depending on the configuration, you can

fix the useful load to the internal thread, external thread, or a front plate. Observe

the permissible piston forces (see “„Determining the buckling force and max.

permissible stroke“”).

Your cylinder has been individually configured according to your

requirements. Please see the quotation drawing for the exact

configuration.

NOTICE

Open pneumatic connections!

Contamination of the cylinder interior!

O Only remove the blanking plugs just before connecting the tubing.

Incorrect cylinder mounting!

Cylinder damage!

O Make sure that the cylinder and accessory parts are properly installed.

O Observe the maximum tightening torque values and check that all screws

and bolts are properly tightened.

You can find the pneumatic connection technology for cylinder tubing in

the online catalog.

Determining the buckling force and max. permissible stroke

Diagram shows the buckling force F

k

dependent on working pressure p and

piston diameter AL. A safety factor ≥ 3 has been taken into account in the diagram.

PWorking pressure

F

AL

Piston force (cylinder base side) of extending piston rod

S Maximum permissible stroke (cylinder/piston rod stroke)

ØALPiston diameter AL

ØAL*Piston diameter AL for cylinders in acc. with ISO 15552 or DIN ISO 6432

ØMMPiston rod diameter MM

See diagram for the buckling force and maximum permissible stroke. Proceed in

line with the following example.

Example:

The working pressure is 6 bar, the cylinder diameter is 80 mm.

O In the top section of the diagram, move horizontally until you reach the line with

the cylinder diameter ØAL 80.

O From there, move down vertically and read the buckling force. In the example, the

buckling force F

k

is approx. 2900 N.

O In the bottom part of the diagram, look for the point of intersection where the

vertical line crosses with the cylinder diameter ØAL 80*.

O Move horizontally from the point of intersection to the left and read the maximum

permissible stroke. In the example, the maximum permissible stroke is approx.

800 mm.

Determining the maximum performance

Attaching the useful load to the piston rod produces lateral forces that may influence

performance.

Example:

The performance of a cylinder with Ø 80 mm is to be determined. Piston surface A is

approx. 50 cm

2

. The max. permissible stroke is 800 mm. Neither an internal nor an

external guide is available. The useful load is 2.5 kg.

O Calculate the ratio of area and mass m/A.

O m/A = 2.5 kg/50 cm

2

= 0.05 kg/cm

2

O See diagram for the maximum performance.

The maximum performance in the example is 500 km.

The performance can be influenced by changing the max. permissible stroke and the

useful load.

Connecting the sensor

An integrated M12x1 plug, male, 4-pin, is installed in the cylinder housing for the

sensor connection.

O Observe the following table containing the pin assignment of the integrated M12

plug. The integrated plug is shown from the top.

If strong EMC-related interference is present:

O Use shielded cables and connect the cable shield to the cylinder housing.

Grounding the cylinder and sensor

External guides can absorb transverse forces. A smaller cylinder

diameter can be selected as a result.

NOTICE

Danger due to incorrect connections and overvoltage!

The position transducer may be destroyed!

O This is why you should always check the connections carefully before

switching the product on.

O Always use a power pack with safe isolation for the power supply.

Integrated M12x1 plug, male, 5-pin

Pin 1 +12/24 VDC

Pin 2 0/4 ... 20 mA

Pin 3 GND (power supply)

Pin 4 not connected

Rin 5 GND (Signal)

NOTICE

Danger due to differences in potential!

The position transducer may be destroyed.

O Ground the cylinder at the ground screw (see –1).

1

2

12

34

5

3

AVENTICS | TRB/ITS | R414006414–BDL–001–AB | English 6

7 Commissioning

Setting the speed

The speed is normally controlled by throttling the exhaust air from the cylinder

chambers with, for example, check-choke valves with exhaust air throttling (not in

the delivery contents).

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.

O 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 permitted

cushioning energy. Use the calculation tool in the Internet.

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.

CAUTION

Danger of burns caused by hot surfaces!

Touching the surfaces of the cylinder during operation could lead to burns.

O Let the cylinder cool before making any settings.

O Do not touch the cylinder during operation.

Danger due to noise!

Hearing damage due to exhaust and impact noise

O Mount silencers on single-acting cylinders.

Danger due to sudden escaping of compressed air!

Uncontrolled movements, particularly if the measurement device is a part of a

control system whose parameters have not been set yet!

O Ensure that no one can reach into the system’s work area and that no

objects can penetrate it.

O If necessary, assemble a protective barrier.

O Slowly pressurize the system to the stipulated working pressure.

Danger due to a position transducer defect!

Hazardous system states may develop if the position transducer is defective.

O Before commissioning, make sure that a defective position sensor cannot

cause any injuries or damage to equipment.

Danger due to strong magnetic or electromagnetic fields near the position

transducer!

Incorrect sensor signals.

O Make sure that the position transducer is protected against magnetic or

electromagnetic fields.

CAUTION

Risk of injury or damage!

A cylinder that is operated without speed control can reach high speeds,

and may cause injury or machine breakdown.

O Make sure that the cylinder is always operated with speed control.

NOTICE

Danger due to screwing in the check-choke valves too far!

Cylinder damage!

O Note the thread length of the check-choke valves if they are directly

mounted in the cylinder cover and base.

O Observe the wrench flats and wrench sizes.

8 Care and Maintenance

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

O However, the system-specific maintenance intervals must be observed.

O Regularly check the function of the position measurement system and all of the

connected components.

The intervals are specified by the operator depending on the on-site conditions.

O Protocol the results of the check.

If the position measurement system is not working properly,

you must decommission it and secure it against further use.

9 Disassembly, Exchange, and Disposal

Disassembling the cylinder

1. Make sure the relevant system part is not under voltage or pressure.

2. Remove the useful load from the piston rod.

3. Remove the pneumatic and electrical connections.

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

Replacing the cylinder

To exchange the cylinder, you must first remove it as described above and then

mount a new cylinder (see “6 „Montage“”).

Cylinder disposal

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

10 Troubleshooting

O 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:

1. Ensure that the cylinder is not under pressure and disconnect the system part

from the supply voltage.

2. Remedy the malfunction.

3. Restart the system part and cylinder.

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

CAUTION

Danger of burns caused by hot surfaces!

Touching the surfaces of the cylinder during operation could lead to burns.

O Let the cylinder cool before cleaning it.

O Do not touch the cylinder during operation.

Damage to the surface caused by solvents and aggressive detergents!

The seals on the cylinder may age faster under aggressive ambient conditions.

O Never use solvents or strong detergents.

CAUTION

Danger of burns caused by hot surfaces!

Touching the surfaces of the cylinder during operation could lead to burns.

O Let the cylinder cool before disassembling it.

O Do not touch the cylinder during operation.

After exchanging a cylinder with integrated position inquiry, we

recommend manually checking the output values in the start and end

positions of the piston rod due to dispersion caused by production.

Malfunction Possible cause Remedy

Drop in performance

during continuous

operation

Cylinder defective Replace cylinder

Cylinder does not

achieve performance/

compressed air supply

insufficient

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 fittings)

AVENTICS | TRB/ITS | R414006414–BDL–001–AB | English 7

11 Technical Data

No sensor signal Sensor is defective Replace cylinder

Incorrect polarity of

sensor cable

Check the plug and wire

assignments

Sensor cable

defective

Exchange the sensor cable

No sensor connection Connect the sensor

Measured values are

incorrect

Sensor supply voltage

is outside the

tolerance range

Check the supply voltage and

correct if necessary

Sensor electronics

defective

Exchange device

Electromagnetic fields

near the position

transducer

Shield the cylinder

General data

Mounting orientation Any

Operating temperature range Cylinder series TRB: -20 to +80°C

Cylinder series ITS: -20 to +75°C

Cylinder

Type Double-acting cylinder

Working pressure

min./max.

1.5 to 10 bar

Permissible medium Compressed air

Max. particle size 50 μm

Oil content of compressed air 0 to 5 mg/m

3

The pressure dew point must be at least 15°C below the ambient and medium

temperatures and must not exceed 3°C.

The oil content of the compressed air must remain constant over the whole

service life.

Use only the oils approved by AVENTICS.

Sensor

Supply voltage 9 V DC to 34.0 V DC

Only use a power pack with safe isolation

for the power supply

Power consumption Typically 80 mA

Independent linearity ≤ 0.04% FS (min. ±0.2 mm)

Tolerance, electrical zero point Typically ≤ 1 mm

Tolerance, electrical end point Typically ≤ 1 mm

Output signal 4 to 20 mA

Resistance ≤ 500 Ω (24 V DC)

≤ 250 Ω (12 V DC)

Output Short-circuit-proof to supply up to

max.27 V DC and GND

Update rate > 500 Hz

Resolution Unlimited, limited by output ripple

Repeatability ≤ 0.01% FS (min. ± 0.05 mm)

Residual ripple ≤ 0.04% FS

Supply voltage ripple < 1% peak to peak

Power consumption without load < 1 W

Temperature coefficient < 30 ppm/K

Overvoltage protection 48 V DC (without function)

Inverse polarity protection -36 V DC

Electric strength 500 V (GND to housing)

Operating temperature range -40 to 85°C with plug connector

Limited by the cylinder

Operating humidity range 0 to 95% r.h. (no condensation)

Malfunction Possible cause Remedy

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

from AVENTICS.

12 Accessories

The accessories approved for your configuration can be found in the online catalog

from AVENTICS.

Shock acc. to DIN IEC68T2-27 100 g (11 ms) (single hit)

Vibration acc. to DIN IEC68T2-6 25 g (10 to 2000 Hz, A

max

= 0.75 mm)

Protection class according to

DINEN60529

IP67 (M12x1 plug system IP69K)

Pressure range Limited by the cylinder

Adjustment speed for position

sensor

Unlimited

Adjustment acceleration for

position sensor

Unlimited

EMC compatibility EN ISO 14982

ISO 7637-1/2/3

ISO 11452-5 (HF fields up to 200 V/m)

Sensor

AVENTICS | TRB/ITS | R414006414–BDL–001–AB | English 8

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AVENTICS GmbH

Ulmer Straße 4

30880 Laatzen

Phone +49 (0) 5 11-21 36-0

Fax: +49 (0) 511-21 36-2 69

www.aventics.com

[email protected]

Further addresses:

www.aventics.com/contact

The data specified above only serve to

describe the product. No statements

concerning a certain condition or

suitability for a certain application can be

derived from our information. The given

information does not release the user from

the obligation of own judgement and

verification. It must be remembered that

our products are subject to a natural

process of wear and aging.

An example configuration is depicted on

the title page. The delivered product may

thus vary from that in the illustration.

Translation of the original operating

instructions. The original operating

instructions were created in the German

language.

R414006414-BDL-001-AD/09.2014

reserved by AVENTICS GmbH, even and

especially in cases of proprietary rights

applications. It may not be reproduced or

given to third parties without its consent.

AVENTICS Pneumatic piston rod cylinder Owner's manual

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