Pneumatic Rotary Actuator DSO-P. Hydro-Pneumatic Actuator DSO-H

Transcription

1 Ihr flexibler Problemlöser in der Fluidtechnik Pneumatic Rotary Actuator DSO-P Hydro-Pneumatic Actuator DSO-H DRUMAG GmbH Fluidtechnik Glarnerstrasse Bad Säckingen Telefon: +49 (0)7761 / Fax: +49 (0)7761 / Web: info@specken-drumag.com Operating Instructions Issue 02 /

2 Contents Page 1. Specifications 3 2. Safety 4 3. Application 4 4. General 5 5. Design and operation 5.1 General description Design Modes of operation Special-type pinion shafts Types of cushioning Standard, progressive Shock absorber Accessories Stroke-limiter Limit switch 9 6. Installation Commissioning Operation Maintenance and Servicing 9.1 Maintenance Venting of the hydraulic system Replacement of seals and gaskets Assembly lubrication Troubleshooting Spare parts Disposal 13 Declaration of conformity G 14 Declaration of conformity GD Page 2 of BE_DSO_ATEX.doc

3 1. Specifications Max. operating 10 bar pressure Ambient temperature DSO-P: -10 C to +60 C DSO-H: +15 C to +60 C When operated in the non-ex area, the maximum ambient temperature can be 80 C. Temperature of the DSO-P: -10 C to +60 C medium DSO-H: +15 C to +60 C When operated in the non-ex area, the maximum temperature of the medium can be 80 C. Operating utilities dried compressed air of quality class 5 as per ISO , lubricated or non-lubricated Mineral oils of at least pollution category 20/17 according to ISO Recommendation: Mobil Vactra No.1 or any other slide oil with a viscosity class ISO VG 32 according to DIN Installation position As required Maximum permissible shaft force Actuator size Radial force F R at middle load point; Axial force F A ; F R =0 F A =0 DSO N 1500 N DSO N 2300 N DSO N 3000 N DSO N 5000 N DSO N 7000 N DSO N N DSO N N Materials Housing and end caps: Aluminium alloy Mg<7,5% Cylinder hose: DSO-P: Aluminium alloy Mg<7,5% DSO-H: Steel Shaft: Steel Gear rack: Steel Bolts and nuts: Steel zinc plated Stroke limiter: Brass and Polyamide Seals: NBR Hydraulic fluids For hydro-pneumatic rotary actuators slide oils of a viscosity class ISO VG 32 (32 mm²/s at 40 C) are recommended. The actuators are supplied without any filling. Hydraulic pressure medium, i.e. Mobil Vactra No. 1, is available at SPECKEN DRUMAG Page 3 of BE_DSO_ATEX.doc

4 2. Safety Safety symbol This Caution! symbol is included in the Operating Instructions wherever special care must be exercised. Operational safety The DSO Rotary Actuator is designed and manufactured according to the state of the art, and is operationally safe when properly installed. The operational safety of the overall system is subject to the assessment of the manufacturer of the overall system. Any person involved with the installation of the DSO must have read and understood these Operation Instructions and, in particular, these safety instructions. The manufacturers will not assume any liability for arbitrary alterations and modifications to the unit. The cam centrelines must not be altered to change the tooth clearance. Special care must be exercised with regard to the pinion shaft/machine connection due to oscillations of the pinion occurring during operation. 3. Application DSO Rotary Actuators are driving elements which serve to perform rotary motion in alternating direction and within a limited angle of rotation depending on the piston stroke. Employment of the unit for any other purpose shall not be deemed the intended use. The manufacturers will not assume any liability for damage resulting from any other use than the intended use. These devices can be used under the specified operating conditions in potentially explosive atmospheres, if the respective label is at the unit. Zones 1 and 2 of potentially explosive gas atmosphere: DSO-P: II2GcT4-10 C T a +60 C DSO-H: II2GcT4 +15 C T a +60 C Zones 1 and 2 of potentially explosive gas atmosphere and Zones 21 and 22 of potentially explosive dust atmosphere : DSO-P: DSO-H: II2GDcT4(130 C) -10 C T a +60 C II2GDcT4(130 C) +15 C T a +60 C 0408 Page 4 of BE_DSO_ATEX.doc

5 Its application as a spring or cushioning element does not constitute use as intended. Unacceptable stresses may occur. You must only operate the rotary actuator with the specified operating media. The use of gases does not constitute use as intended. The intake of compressed air must not be drawn from EX-protected areas. Compressed air must not be expelled into areas with potentially explosive dust atmospheres. Lead the exhausted air via hoses out of the dust EX area. You should use the rotary actuator in its original condition, without any alterations of your own. Approval will lapse in the event of any interference with the machine not carried out by the manufacturer. 4. General Basic information The EU machine directive 2006/42/EC does not apply to this device. Therefore, it is also not provided with the CE marking according to the machine guideline. Exception: ATEX units are CE-marked. These operating instructions are intended to enable the manufacturer of the overall operational system to properly install the device and instruct the user about any necessary maintenance. These operating instructions are intended for engineers of the manufacturer providing the overall system, and not for the user of the system. It is assumed that the fundamentals of pneumatics and hydraulics are known. Only if these operating instructions are understood and complied with can installation mistakes can be avoided and trouble-free operation be guaranteed. However, if you do encounter problems please contact our company, field staff or agencies. We reserve the right to make technical modifications Copyright The copyright of these Operating Instructions shall remain with SPECKEN- DRUMAG Page 5 of BE_DSO_ATEX.doc

6 5. Design and Operation 5.1 General description DSO Basic drive (connections shown offset) The DSO Rotary Actuator serves to transform a limited rectilinear motion of the gear rack into a rotary motion of the pinion by using a gear rack/pinion combination. The size depends on the drive chosen as well as the given angle of rotation Angle of rotation The tolerances of the angle of rotation are defined such that the nominal angle of rotation is exceeded by 1 to 5. The position of the key can be returned to the intersection of the axes by means of external stops or the stroke-arresting device. 5.2 Design Fig Housing 2.7 Rack 2.13 O-ring 2.2 Cover 2.8 Shim 2.14 Cam bearing 2.3 Piston 2.9 Fastening screw 2.15 Pinion shaft 2.4 Tube 2.10 Guide band 2.5 Pinion 2.11 Gasket (hydraulic or pneumatic) 2.6 Retaining nut with washer 2.12 O-ring 0408 Page 6 of BE_DSO_ATEX.doc

7 5.3 Modes of operation Depending on its design, the DSO Rotary Drive is operated with different pressure media (compressed air or mineral oil based hydraulic liquids). 5.4 Special-type pinion shafts D Continuous shaft BN Hollow shaft B Bored shaft 5.5 Modes of cushioning Standard / Progressive P Pneumatic standard Progressively hydraulic 6.1 Cylinder cover 6.5 Cushioning seal 6.2 Cushioning bushing 6.6 O-ring 6.3 Throttle 6.7 Toothed ring 6.4 Fastening screw with washer PP Progressively pneumatic 7.1 Cylinder cover 7.6 Fast. screw 7.2 Cushioning bushing 7.7 O-Ring 7.3Cushioning ring 7.8 Toothed ring 7.4 Retaining ring 7.9 Throttle 7.5 Washer The cushioning rates may be exactly adjusted by means of the throttle. For progressive cushioning a higher initial rate is mandatory as, otherwise, an optimum cushioning course, if any, cannot be ensured. A toothed ring is provided to protect the throttle from accidental removal Page 7 of BE_DSO_ATEX.doc

8 5.5.2 Shock absorber OEM Hydraulic shock absorber, adjustable 8.1 Cylinder cover 8.2 Hydraulic shock absorber 8.3 Adjusting knob 8.4 O-ring 8.5 Stop OEM-H Hydraulic shock absorber, adjustable with stroke-arresting device 9.1 Cylinder cover 9.2 Stroke-arresting device 9.3 Grooved nut for stroke arresting 9.4 Hydraulic shock absorber 9.5 Adjusting knob 9.6 Stop 9.7 Retaining ring 9.8 O-ring 9.9 O-ring 9.10 O-ring p max. 7 bar To ensure reliable operation of the shock absorbers, the operating pressure must not exceed 7 bar as, otherwise, the shock absorber cannot exert its intended effect. These shock absorbers are provided for models from DSO-80. The cushioning behaviour may be optimised by setting the adjusting knob Page 8 of BE_DSO_ATEX.doc

9 5.6 Accessories Stroke limiter / stroke limiter with control pin Integration of a stroke-limiting device (10.2) might be necessary to maintain or set a specific angle of rotation. For rotary drives with a strokearresting device the nominal angle of ration equals the maximum angle of rotation. This can be reduced only by 15 on each side. A control pin (10.4) facilitates mechanical determination of the end position, which is only supplied together with the stroke-arresting device. A sealing nut (10.3) is provided to avoid pressure losses Cover 10.4 Control pin 10.2 Stroke-arresting device 10.5 Compression spring 10.3 Sealing nut 10.6 Gasket For the combination shown reducing of the angle of rotation causes a reduction of the cushioning stroke. This may lead to a loss in cushioning for a maximum stroke adjustment of Limit switch To determine specific rotational positions, a piston with an integrated, ring-type permanent magnet and a limit switch facilitates determination of the piston s position. In Ex-environment only ATEXcertified limit switches must be used 11.1 Limit switch 11.4 Permanent magnet 11.2 Plug 11.5 Mounting fixtures, compl Piston 0408 Page 9 of BE_DSO_ATEX.doc

10 6. Installation The DSO Rotary actuator is screw-mounted to the machine on three sides of its housing (bottom, front and rear sides). The machine s assembly surface must be machined. Due to oscillations occurring during operation, special care must be exercised with regard to the connection between the rotary drive pinion shaft and the machine shaft. Fit tightly when using a feather key connection for transmitting torque. Otherwise braking and acceleration torques in end positions may cause deflection of the feather key connection. Any slackness in the feather key connection may cause various problems, e.g. intensified impacts in end positions accelerating the deflection of the feather key connection. This may endanger the positioning repeatability when approaching the cover or the stroke-arresting device. For the unit s operational safety, clearance must be ensured between the gear rack and the pinion. Hence, accurate positioning exceeding the clearance is only possible by means of external stops. The camshafts must not be altered to change the tooth clearing. Any alteration would affect the centring alignment and cause twisting of the gear rack during the stroke and leakages. If the rotary drive is provided with a stroke-limiter, the end position can be adjusted. The unit is delivered such that it is only possible to reduce the angle of rotation. In combination with the hydraulic end position cushioning a reduced angle of rotation would also mean a reduction of the cushioning stroke distance (refer to Section 5.6.1) 7. Commissioning You must comply with the details shown on the nameplate. Installation and commissioning must be carried out by authorised technicians as set out in the operating instructions. You must comply with all applicable national and international regulations Page 10 of BE_DSO_ATEX.doc

11 Discharging of electrostatically charged components can lead to sparks that can cause an explosion. For the operation of the actuator you should use only hoses and bundles of hoses up to a maximum external diameter of 20 mm. Connect conductive metal parts together for potential equalization Earth the entire system. Impacts involving rust and light metals and their alloys may cause sparks. Do not use any tool with corroded surfaces. Protect the product from falling objects. Install the cylinder in such a way that there are no transverse forces acting on the piston rod. Transverse forces may lead to unacceptable heating. If necessary, adjust the cushioning in such a way that the piston arrives safely at the limits of travel and neither impacts abruptly nor springs back. When selecting the materials for installation tools and fastening accessories, you should be alert to corrosion, wear and mutual reactions. Restrict the number and dimensions of detachable connections to a minimum. Use short hoses and pipes. In doing so you should avoid the occurrence of mechanical stresses. Seal any unused orifices with plugs or caps. Ensure that all surfaces that require cleaning are easily accessible. 8. Operation Adhere to the operating conditions and the detailed operating instructions. Adhere to the function mode of your actuator. Do not operate the pneumatic side of the actuator hydraulically, or vice versa. Always remain within the permissible limits. Do not use de-icing fluids (Glycol) when operating in Ex-atmosphere High-frequent operation can cause unacceptable heating of the hydraulic fluid. Monitor and limit the fluid temperature if necessary. Dust deposits on heated surfaces are highly inflammable. Clean the product regularly Page 11 of BE_DSO_ATEX.doc

12 To ensure controlled start-up of the rotary drive, pressure (counter pressure) must be applied to the exhaust chamber of the pneumatic rotary drive whenever the unit is commissioned or recommissioned. Correct venting of the hydraulic system must be ensured for hydraulic rotary drives. Check valve facilitate regulation of the flow rate. The cushioning behaviour of rotary actuator with pneumatic cushioning can be optimised by adjusting the flow control check valves and cushioning throttle valves. Connection diagram 9. Servicing 9.1 Maintenance Comply as necessary with the maintenance intervals of any accessories used. Service the cylinder after 2 million cycles, or after 6 months at the latest. 9.2 Venting of the hydraulic system The hydraulic system is desecrated together with the overall system; special venting facilities are not provided at the DSO drives. 9.3 Replacement of seals and gaskets In general, replacement of seals and gaskets is not necessary if the pressure media are used and filtered as specified. However, when a replacement becomes necessary, it is recommended to have this done by the manufacturers. Only replace the piston gaskets when performing replacement operations on the spot. Any opening of piston fastening nuts would destroy the settings, causing poor motion behaviour, higher leakage and higher wear. Always check the condition of the sliding faces and replace worn parts 9.4 Assembly lubrication For assembly lubrication purposes "Autol TOP 2000" is used. To ensure the unit s operational safety the above grease or compatible greases should be used for maintenance work requiring any re-lubrication Page 12 of BE_DSO_ATEX.doc

13 10. Trouble shooting Fault External damages Loose fit of the fasteners Uneven motion Heavy Actuator does not reach the end position Audible air leakage or oil leakage Increased noise at the4 ball bearings Increased bearing clearance Remedial action 1. Change rotary actuator or 2. send the actuator to SPECKEN- DRUMAG for servicing Tighten fastener bolts. 1. Adjust the exhaust air flow control check valves or 2. vent the hydraulic system 1. Adjust the exhaust air flow control check valves or 2. send the actuator to SPECKEN- DRUMAG for servicing 1. Choose friction-tight connection when feather key connection is deflected (s. 6) 2. send the actuator to SPECKEN- DRUMAG for servicing 1. Change seals and gaskets or 2. send the actuator to SPECKEN- DRUMAG for servicing 1. Change rotary actuator or 2. send the actuator to SPECKEN- DRUMAG for servicing 1. Change rotary actuator or 2. send the actuator to SPECKEN- DRUMAG for servicing 11. Spare parts When ordering spare parts please indicate the model designation and part number of the desired unit. Seals and gaskets are available in complete sets only. 12. Disposal Any lubricant residues from maintenance operations, e.g. cleaning rags, sealing materials, etc. must be disposed of in compliance with the applicable regulations of the user s country Page 13 of BE_DSO_ATEX.doc

14 Ihr flexibler Problemlöser in der Fluidtechnik Gas (G) Declaration of Conformity (according to EC Directive 94/9/EC, Appendix VIII) DRUMAG GmbH declares in sole responsibility that the Rotary actuators DSO-P and DSO-H with piston diameters 50, 63, 80, 100, 125, 160, 200 mm in category 2G that are subject to this declaration are meeting the requirements set forth in Directive 94/9/EC Applicable standard: DIN EN : , DIN EN : , DIN EN : The products are marked with the following characteristics: II 2G c T4-X DRUMAG GmbH will archive the documents required according to 94/9/EC at the following location: TÜV Product Service GmbH, EC-Code 0123 EC-Certificate No. EX DRUMAG GmbH Bad Säckingen, den Place and date of issue Function: Managing director U. Ziegler Drumag GmbH Fluidtechnik P.O. box 1142 D Bad Säckingen Glarnerstraße 2 D Bad Säckingen Phone 07761/55050 Fax 07761/ Internet: technik@specken-drumag.com 0408 Page 14 of BE_DSO_ATEX.doc

15 Ihr flexibler Problemlöser in der Fluidtechnik Gas and Dust (GD) Declaration of Conformity (according to EC Directive 94/9/EC, Appendix VIII) DRUMAG GmbH declares in sole responsibility that the Rotary actuators DSO-P and DSO-H with piston diameters 50, 63, 80, 100, 125, 160, 200 mm in category 2G and 2D that are subject to this declaration are meeting the requirements set forth in Directive 94/9/EC Applicable standard: DIN EN : , DIN EN : , DIN EN : The products are marked with the following characteristics: II 2GD c T4 (130 C)-X DRUMAG GmbH will archive the documents required according to 94/9/EC at the following location: TÜV Product Service GmbH, EU-Code 0123 EC-Certificate No. EX DRUMAG GmbH Bad Säckingen, den Place and date of issue Function: Managing director U. Ziegler Drumag GmbH Fluidtechnik P.O. box 1142 D Bad Säckingen Glarnerstraße 2 D Bad Säckingen Phone 07761/55050 Fax 07761/ Internet: technik@specken-drumag.com 0408 Page 15 of BE_DSO_ATEX.doc