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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
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
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
Subject to modifications. © All rights
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.
/
