DESIGN-TITE Nitrogen Gas Springs. They truly are... Better by Design

Transcription

1 DESIGN-TITE Nitrogen Gas Springs They truly are... Better by Design

2 DESIGN-TITE - Expanded & Improved Index We are proud to offer our new and expanded line of nitrogen gas springs. Now the manufacturer of the world s finest die spring, SuperSpring, can supply you with the world s finest nitrogen gas spring, DESIGN-TITE. Like SuperSpring, DESIGN-TITE is completely engineered by us. We gave our engineers the following mission: 1. Simplify the design to improve performance and ease repair, 2. Design a more solid construction to extend life and increase safety, Take A Closer Look... DANLY Now Offers Five Distinct Lines of Nitrogen Gas Springs NEW! The Performance Line RLP Series Greater initial force in a smaller diameter body. NEW! The North American Line RLS Series Our proven ISO gas spring redesigned for the North American market. IMPROVED! The ISO Line RL Series Performance Gas Springs RLP-5... RLP-75, 1... Sub Compact Gas Springs RLSC-1... RLSC-18, North American Gas Springs RLS-5,... RLS-75, ISO Gas Springs RL-75, RL-3, Micro Gas Springs RLM RLM RLM RLM Pre-mounted Systems Assembling Fittings Control Panels Assembly Hose Research and incorporate only the finest materials to offer the highest quality product on the market. Our original gas spring now meets ISO and VDI requirements. Fittings... 1 Junction Block... 2 Good Design We believe a better design produces a better product, and we are confident we have met our design goals. Try DESIGN-TITE and experience for yourself the benefits of this superior line of nitrogen products. NEW! The Sub Compact Line RLSC Series NEW! The Micro Line RLM Series Accessories... Service Gauge Assembly... Ease of Repair... Better by Design They truly are... Better by Design. Short stroke, high force in a compact body. All new, all rebuildable. 2 3

3 RLP-5 Here s How To Order The RLP: RLP-1 x 25 RLP-75, 1 The Performance Line (RLP Series) Model Size Length in mm (refer to specific model page) Every DESIGN-TITE Performance gas spring provides greater force in a smaller body than the RLS and RL series gas springs. RLP-5 (.8) RLP-75 ø 25 mm (1.) RLP-1 ø 2 mm (1.16) RLP gas springs are shipped charged at 15 bar (2175 psi)..5 mm (.37) 13.5 mm (.54) 12.5 mm (.4) Better by Design... RLP gas springs are designed for easy service and safety Larger Diameter Provides Greater Force Hollow piston rod lowers pressure rise Highly polished Patented Lubrication Chamber Design RLP-75 & 1 Provides long, maintenance-free life Upper Clamping Groove For type C clamping Solid Bronze Top Cap Designed with greater bearing area for improved support and guiding Threaded construction creates a mechanical solid for greater structural strength and safety 4 mm (.16) 3.5 mm (.) M6 x 1. (.7) ø 33 mm (1.3) ø 3 (1.5) RLP-5 Lengths Model x mm (inch) M6 x 1. (2) 4 mm (.16) 3.5 mm (.) (.7) ø 4 mm (1.6) ø 45 mm (1.8) RLP-75 Lengths Model x mm (inch) M8 x 1.25 (2) (.32) 4 mm (.16) (.28) Model x mm (inch) (.7) ø 43 mm (1.6) ø 5 mm (1.7) RLP-1 Lengths M8 x 1.25 (2) Quickest to rebuild Easiest to maintain Inlet Valve Port Plug RLP-75 & 1 Standard ISO charge port O-ring face style 37 JIC style RLP-5 x 13 mm (.51 inch) RLP-5 x 25 mm (.8 inch) RLP-5 x 3 (1.5 inch) RLP-5 x 5 mm (1.7 inch) RLP-5 x 63 mm (2.48 inch) RLP-5 x (3.15 inch) 63 (2.48) 75 (2.6) 88 (3.47) 13 (5.12) 76 (2.) 126 (4.6) 21 (8.27) RLP-75 x 13 mm (.51 inch) RLP-75 x 25 mm (.8 inch) RLP-75 x 3 (1.5 inch) RLP-75 x 5 mm (1.7 inch) RLP-75 x 63 mm (2.48 inch) RLP-75 x (3.15 inch) 63 (2.48) 75 (2.6) 88 (3.47) 13 (5.12) 76 (2.) 126 (4.6) 21 (8.27) RLP-1 x 13 mm (.51 inch) RLP-1 x 25 mm (.8 inch) RLP-1 x 3 (1.5 inch) RLP-1 x 5 mm (1.7 inch) RLP-1 x 63 mm (2.48 inch) RLP-1 x (3.15 inch) 63 (2.48) 75 (2.5) 88 (3.47) 13 (5.12) 76 (2.) 126 (4.6) 21 (8.27) Fill port for RLP-5 located on base Lower Clamping Groove ISO standard provides user flexibility RLP-5 Die Forces RLP-75 Die Forces 473 dan (163 lbs) 78 dan (1753 lbs) 73 dan (1661 lbs) 135 dan (333 lbs) RLP-1 Die Force 4 dan (36 lbs) 13 dan (4337 lbs) 4 Force is based on longest stroke. Force increase is less with shorter strokes. Force is based on longest stroke. Force increase is less with shorter strokes. 5

4 RLSC-1 Here s How To Order The RLSC: RLSC-47 x 25 RLSC-18, 47 The Sub Compact Line (RLSC Series) Model Size Length in mm (refer to specific model page) Every DESIGN-TITE Sub Compact gas spring combines the convenience of a self-contained gas spring with the increased on-contact force and shorter body height of a bore seal cylinder. RLSC-1 ø 25 mm (1.) RLSC-18 ø 35 mm (1.4) RLSC-47 ø 55 mm (2.2) RLSC gas springs are shipped charged at 15 bar (2175 psi). Better by Design... RLSC gas springs are designed for easy service and safety Hollow piston rod lowers pressure rise Highly polished M6 x 1. Solid Bronze Top Cap Designed with greater bearing area for improved support and guiding Threaded construction creates a mechanical solid for greater structural strength and safety ø 1 (.67) ø 3 (1.52) M6 x 1. (2) ø 26 mm (1.4) ø 5. (2.) M6 x 1. (2) ø 4 mm (1.6) ø 75. (3.) M8 x 1.25 (2) Quickest to rebuild Easiest to maintain RLSC-1 Lengths Model x mm (inch) RLSC-18 Lengths Model x mm (inch) RLSC-47 Lengths Model x (mm, inch) Highly Polished and Hardened Bore Extends seal life RLSC-1 x 6 mm (.24 inch) RLSC-1 x 1 mm (.3 inch) RLSC-1 x 16 mm (.63 inch) 55 (2.17) 68 (2.68) 84 (3.31) 61 (2.4) 78 (3.7) RLSC-18 x 6 mm (.24 inch) RLSC-18 x 1 mm (.3 inch) RLSC-18 x 16 mm (.63 inch) 6 (2.36) 7 (2.76) (3.54) 66 (2.6) 8 (3.15) 16 (4.17) RLSC-47 x 1 mm (.3 inch) RLSC-47 x 16 mm (.63 inch) RLSC-47 x 25 mm (.8 inch) 7 (2.76) (3.54) 11 (4.33) 8 (3.15) 16 (4.17) 135 (5.32) Inlet Valve RLSC-1 x 25 mm (.8 inch) 11 (4.33) 135 (5.32) RLSC-18 x 25 mm (.8 inch) 11 (4.33) 135 (5.32) RLSC-47 x 3 (1.26 inch) 135 (5.31) 167 (6.57) Port Plug Standard ISO charge port RLSC-1 x 3 (1.26 inch) RLSC-1 x 4 mm (1.57 inch) 135 (5.31) 155 (6.1) 167 (6.57) 15 (7.68) RLSC-18 x 3 (1.26 inch) RLSC-18 x 4 mm (1.57 inch) 13 (5.12) 162 (6.38) 1 (7.48) RLSC-47 x 4 mm (1.57 inch) RLSC-47 x 5 mm (1.7 inch) 16 (6.3) 1 (7.48) 2 (7.87) 24 (.45) RLSC-1 x 5 mm (1.7 inch) 18 (7.) 23 (.6) RLSC-18 x 5 mm (1.7 inch) 17 (6.6) (8.66) RLSC-47 Die Force RLSC-1 Die Force 163 dan (238 lbs) 15 dan (3572 lbs) RLSC-18 Die Force 183 dan (451 lbs) 3251 dan (735 lbs) 4767 dan (1711 lbs) 717 dan (16131 lbs) 6 Force is based on longest stroke. Force increase is less with shorter strokes. Force is based on longest stroke. Force increase in less with shorter strokes. 7

5 RLS-5 Here s How To Order The RLS and RL: RLS or RL-15 x 25 RLS-75, 15 Model Size Length in mm The North American Line (RLS Series) (refer to specific model page) Every DESIGN-TITE North American gas spring meets all ISO and VDI piston rod and body diameter standards, in addition to mounting and charge port specifications and features the shorter body height common in North America. RLS-5 (.8) 13.5 mm (.54) RLS-75 3 mm (.12) ø 25 mm (.8) 12.5 mm (.4) RLS-15 3 mm (.12) ø 36 mm (1.42) 15.5 mm (.61) RLS gas springs are shipped charged at 15 bar (2175 psi). Better by Design... RLS and RL gas springs are designed for easy service and safety 4 mm (.16) 5 mm (.2) Hollow piston rod lowers pressure rise Highly polished 3.5 mm (.) (.28) (.28) Patented Lubrication Chamber Design Provides long, maintenance-free life Upper Clamping Groove For type C clamping 4 mm (.16) (.7) ø 4 mm (1.6) ø 45 mm (1.8) M8 x 1.25 (2) (.32) (.7) ø 43 mm (1.6) ø 5 mm (1.7) M8 x 1.25 (2) (.32) ø 4 mm ( 1.6) ø 6 (2.64) ø 75 mm (2.5) M8 x 1.25 (4) Solid Bronze Top Cap Designed with greater bearing area for Improved support and guiding creates a mechanical solid for greater structural strength and safety RLS-5 Lengths Model x mm (inch) RLS-5 x 13 mm (.51 inch) 63 (2.48) 76 (2.) RLS-75 Lengths Model x mm (inch) RLS-75 x 13 mm (.51 inch) 63 (2.48) 76 (2.) RLS-15 Lengths Model x mm (inch) RLS-15 x 25 mm (.8 inch) (4.8) (5.7) Quickest to rebuild Easiest to maintain RLS-5 x 25 mm (.8 inch) RLS-5 x 3 (1.5 inch) RLS-5 x 5 mm (1.7 inch) 75 (2.5) 88 (3.47) 126 (4.6) RLS-75 x 25 mm (.8 inch) RLS-75 x 3 (1.5 inch) RLS-75 x 5 mm (1.7 inch) 75 (2.6) 88 (3.46) 126 (4.) RLS-15 x 3 (1.5 inch) RLS-15 x 5 mm (1.7 inch) RLS-15 x 63 mm (2.48 inch) 13 (5.47) (5.7) 164 (6.46) 177 (6.7) 21.6 (7.4) 7 (8.4) Inlet Valve Port Plug Standard ISO charge port O-ring face style 37 JIC style RLS-5 x 63 mm (2.48 inch) RLS-5 x (3.15 inch) RLS-5 Die Force 13 (5.12) 21 (8.27) RLS-75 x 63 mm (2.48 inch) RLS-75 x (3.15 inch) RLS-75 x 1 mm (3.4 inch) RLS-75 Die Force 13 (5.12) 15 (5.) 21 (8.27) 25 (.84) RLS-15 x (3.15 inch) RLS-15 x 1 mm (3.4 inch) RLS-15 x 125 mm (4.2 inch) RLS-15 Die Force (7.15) 21.6 (7.4) 6.6 (8.2) (1.3) 31.6 (11.87) (13.84) Lower Clamping Groove ISO standard provides user flexibility 473 dan (163 lbs) 681 dan (153 lbs) 73 dan (1661 lbs) 118 dan (2651 lbs) 1532 dan (3442 lbs) 4 dan (533 lbs) 8 Force is based on longest stroke. Force increase is less with shorter strokes. Force is based on longest stroke. Force increase is less with shorter strokes.

6 RL-75, 15 The ISO Line (RL Series) Every DESIGN-TITE ISO gas spring meets all ISO and VDI piston rod, body and height standards, in addition to mounting and charge port specifications. RL gas springs are shipped charged at 15 bar (2175 psi). See page 8 for a detailed illustration with features and page for an order example. RL-3, 5 RL-75 ø 25 mm (.8) RL-15 ø 36 mm (1.42) RL-3 ø 5 mm (1.7) RL-5 ø 65 mm (2.56) 3 mm (.12) 12.5 mm (.4) 3 mm (.12) 15.5 mm (.61) 3 mm (.12) 18.5 mm (.73) 3 mm (.12) 2 mm (.7) 4 mm (.16) 5 mm (.2) 5 mm (.2) 5 mm (.2) (.28) (.28) (.28) (.28) (.46) (.32) (.7) ø 43 mm (1.6) ø 5 mm (1.7) M8 x 1.25 (2) (.32) ø 4 mm (1.6) ø 6 (2.64) ø 75 mm (2.5) M8 x 1.25 (4) (.32) ø 6 mm (2.36) ø 8 (3.43) ø 5 mm (3.74) M8 x 1.25 (4) (.32) ø (3.15) ø 11 (4.41) ø 12 mm (4.72) M1 x 1.5 (4) RL-75 Lengths RL-15 Lengths RL-3 Lengths RL-5 Lengths Model x mm (inch) Model x mm (inch) Model x mm (inch) Model x mm (inch) RL 75 x 25 mm (.8 inch) 12 (4.72) 5 (5.7) RL 15 x 25 mm (.8 inch) 135 (5.31) 16 (6.2) RL 3 x 25 mm (.8 inch) 5 (5.7) 17 (6.6) RL 5 x 25 mm (.8 inch) 165 (6.4) 1 (7.47) RL 75 x 3 (1.5 inch) 133 (5.24) 171 (6.73) RL 15 x 3 (1.5 inch) 8 (5.83) 186 (7.32) RL 3 x 3 (1.5 inch) 158 (6.) 16 (7.72) RL 5 x 3 (1.5 inch) 178 (7.1) 216 (8.51) RL 75 x 5 mm (1.7 inch) 5 (5.7) 15 (7.68) RL 15 x 5 mm (1.7 inch) 16 (6.2) 21 (8.26) RL 3 x 5 mm (1.7 inch) 17 (6.6) (8.65) RL 5 x 5 mm (1.7 inch) 1 (7.47) 24 (.44) RL 75 x 63 mm (2.48 inch) 158 (6.) 1 (8.7) RL 15 x 63 mm (2.48 inch) 173 (6.81) 236 (.2) RL 3 x 63 mm (2.48 inch) 183 (7.27) 246 (.6) RL 5 x 63 mm (2.48 inch) 23 (7.) 266 (1.47) RL 75 x (3.15 inch) 175 (6.88) 255 (1.3) RL 15 x (3.15 inch) 1 (7.47) 27 (1.62) RL 3 x (3.15 inch) 2 (7.87) 28 (11.1) RL 5 x (3.15 inch) (8.65) 3 (11.8) RL 75 x 1 mm (3.4 inch) 15 (7.67) 25 (11.6) RL 15 x 1 mm (3.4 inch) 21 (8.26) 31 (12.1) RL 3 x 1 mm (3.4 inch) (8.65) 32 (12.5) RL 5 x 1 mm (3.4 inch) 24 (.44) 34 (13.37) RL 75 x 125 mm (4.2 inch) (8.65) 345 (13.57) RL 15 x 125 mm (4.2 inch) 235 (.24) 36 (.16) RL 3 x 125 mm (4.2 inch) 245 (.64) 37 (.55) RL 5 x 125 mm (4.2 inch) 265 (1.42) 3 (15.34) RL 75 x 16 mm (6.3 inch) 255 (1.3) 415 (16.32) RL 15 x 16 mm (6.3 inch) 27 (1.62) 43 (16.1) RL 3 x 16 mm (6.3 inch) 28 (11.1) 44 (17.31) RL 5 x 16 mm (6.3 inch) 3 (11.8) 46 (18.1) RL-75 Die Force RL-15 Die Force RL-3 Die Force RL-5 Die Force 73 dan (1661 lbs) 15 dan (2372 lbs) 1532 dan (3442 lbs) dan (4813 lbs) 255 dan (664 lbs) 428 dan (637 lbs) 44 dan (112 lbs) 726 dan (1634 lbs) 1 Force is based on longest stroke. Force increase is less with shorter strokes. Force is based on longest stroke. Force increase is less with shorter strokes. 11

7 RLM- The Micro Line (RLM Series) Here s How To Order The RLM- and 18: RLM-18 x 25 - YELLOW Model Size Length in mm Force by Colour (yellow, red, blue, green) RLM-18, Mounting Styles Every DESIGN-TITE Micro and 18 gas spring is adjustable, rechargeable and rebuildable. All RLM Series Gas Springs meet all ISO piston rod, body and height standards, in addition to mounting specifications. RLM- and 18 gas springs are shipped at full charge unless otherwise specified. See adjacent page for ordering information. Better by Design... RLM gas springs are designed for easy service and safety RLM- 1mm (.4) 1 (.71) ø (.31) M6 x 1. coloured ring indicates force radius 1 mm (.4) diameter ø 1 (.67) 6 mm (.24) RLM-18 1mm (.4) 1 (.71) ø 1 M6 x 1. coloured ring indicates force radius 1 mm (.4) diameter ø 23 mm (.1) (.28) Contact Forces - RLM-, 18 RLM- x RLM-18 x CONTACT FORCE die contact force charged pressure die contact force charged pressure dan lbs bar psi dan lbs bar psi Mounting Styles - RLM-, 18 Yellow Red Blue Green Highly polished ø 1 mm (.75) ø 25 mm (.8) Shown are examples of some typical mounting configurations for the Micro line - designed to be interchangeable with standard micro gas spring mountings. Solid Bronze Top Cap Threaded bronze top cap construction creates a mechanical solid for greater strength and safety. Bronze top cap and bearing provide greater bearing area for improved support and guiding. Upper Groove RLM- Lengths Model x mm (inch) RLM- x RLM- x RLM- x RLM- x 15 mm (.5 inch) 25 mm (.8 inch) 3 (1.5 inch) 5 mm (1.7 inch) 57 (2.24) 67 (2.64) 8 (3.15) 2 (3.62) ed 72 (2.83) 2 (3.62) 118 (4.65) 2 (5.5) RLM-18 Lengths Model x mm (inch) RLM-18 x 15 mm (.5 inch) RLM-18 x 25 mm (.8 inch) RLM-18 x 3 (1.5 inch) RLM-18 x 5 mm (1.7 inch) 57 (2.24) 67 (2.64) 8 (3.15) 2 (3.62) 72 (2.83) 2 (3.62) 118 (4.65) 2 (5.5) TYPE A TYPE B Quickest to rebuild Easiest to maintain Inlet Valve, Fill Port RLM- x (3.15 inch) RLM- Force Chart DIE OPEN FORCE DaN lbs (4.3) yellow red blue green TRAVEL (% of stroke) 25 (8.7) DIE CLOSED FORCE DaN lbs RLM-18 x (3.15 inch) RLM-18 Force Chart 125 (4.2) 25 (8.7) DIE OPEN FORCE DaN lbs DIE CLOSED FORCE DaN lbs yellow red blue green TRAVEL (% of stroke) TYPE C TYPE D 12 Die closed force is based on longest stroke. Force increase is less with shorter stroke. All dimensions and forces are nominal unless otherwise stated. Die closed force is based on longest stroke. Force increase is less with shorter stroke. All dimensions and forces are nominal unless otherwise stated. 13

8 RLM-23 RLM-3 The Micro Line (RLM Series) Every DESIGN-TITE Micro 23 and 3 gas spring is adjustable, rechargeable and rebuildable. RLM-23 ø mm (.55) RLM-3 Better by Design... The RLM-3 is designed for easy service and safety All RLM Series Gas Springs meet all ISO piston rod, body and height standards, in addition to mounting specifications. RLM-23 and 3 gas springs are shipped charged at 15 bar (2175 psi). 1mm (.4) Hollow piston rod lowers pressure rise Highly polished Better by Design... The RLM-23 is designed for easy service and safety Hollow piston rod lowers pressure rise Highly polished Solid Bronze Top Cap Threaded bronze top cap construction creates a mechanical solid for greater strength and safety. Bronze top cap and bearing provide greater bearing area for improved support and guiding. Upper Clamping Groove For Type C Clamping Quickest to Rebuild Easiest to Maintain 1 (.71) M6 x 1. ø 17mm (.67) ø 32mm (1.26) RLM-23 Lengths Model x mm (inch) RLM-23 x 1 mm (.3 inch) RLM-23 x 15 mm (.5 inch) RLM-23 x 25 mm (.8 inch) radius 1 mm (.4) diameter ø 3 mm (1.18) M6 x 1. (2) 6 (2.36) 65 (2.56) 75 (2.5) 7 (2.76) 8 (3.15) RLM-3 Lengths Model x S (mm, inch) RLM-3 x 13 mm (.51 inch) RLM-3 x 16 mm (.63 inch) RLM-3 x 25 mm (.8 inch) 63 (2.48) 66 (2.6) 75 (2.6) 76 (2.) 82 (3.23) Solid Bronze Top Cap Threaded bronze top cap construction creates a mechanical solid for greater strength and safety. Bronze top cap and bearing provide greater bearing area for improved support and guiding. Upper Clamping Groove For Type C Clamping Quickest to Rebuild Easiest to Maintain Lower Clamping Groove ISO Standard Provides User Flexibility Inlet Valve, Fill Port Inlet Valve, Fill Port RLM-23 x 3 (1.5 inch) RLM-23 x 5 mm (1.7 inch) 88 (3.47) 126 (4.7) RLM-3 x 3 (1.5 inch) RLM-3 x 5 mm (1.7 inch) 88 (3.47) 126 (4.6) Here s How To Order The RLM-3: Here s How To Order The RLM-23: RLM-23 x 25 Model Size Length in mm RLM-23 x 63 mm (2.48 inch) RLM-23 x (3.15 inch) RLM-23 Die Force 13 (5.12) 232 dan (521 lbs) 33.2 dan (681 lbs) 21 (8.27) RLM-3 x 63 mm (2.48 inch) RLM-3 x (3.15 inch) RLM-3 Die Force 13 (5.12) 267 dan (58 lbs) dan (756 lbs) 21 (8.27) RLM-3 x 25 Model Size Length in mm Force is based on longest stroke. Force increase is less with shorter strokes. Force is based on longest stroke. Force increase is less with shorter strokes. 15

9 Pre-mounted Systems Operating Conditions Assembling Fittings Pre-mounted Systems Assembling Fittings to Gas Springs An affordable and flexible alternative to nitrogen manifold systems. All pre-mounted systems are assembled and supplied danly for installation in your die. All gas springs are pre-mounted, pre-hosed and pressure tested prior to shipping, saving both time and money. All RLS, RL, and RLP-75 & 1 gas springs can be made part of a pre-mounted system. We offer two distinctly different types of fittings. Both are available from stock, O-ring face style and 37 JIC Fitting Type: flared fittings. For use with all RLS, RL, and RLP-75, 1 gas springs. Hose swivel Torque Specifications: Nm Lbf/ft O-Ring Face 37 JIC BSPP Male 45 BSPP Elbow Branch tee swivel nut Run tee swivel nut Straight fitting Charge port plug O-Ring Face DANLY Part # RT1JC RT42V4ML-S RT42C4ML-S RT4S6MLO-S RT4R6MLO-S RT42F4OMLO-S RTVSTI-R 1 /8 ED socket cap 37 JIC DANLY Part # RT RT4V4MX-S RT4C4MX-S RT4S6X-S RT4R6X-S RT4F4OMX-S H2-XXXXX-XXX-13 slot style How To Order a Pre-mounted System: When specifying a pre-mounted system the following information is necessary to ensure proper application and fit: 1. The finished plate length, width, and plate thickness including specific tolerances. 2. The location, size and stroke, preferred mounting, and quantity of each DESIGN-TITE gas spring. 3. The location of the control panel in relation to the plate. If remote mounting is desired, please specify hose length. 4. Provide a plan drawing for nitrogen hose routings, and specify the style of fittings (O-ring face or 37 JIC). The plan drawing must include the hose routing to ensure proper fit in your application. 5. The size and exact location of all plate mounting holes must be specified. If counterbored holes are required, please detail. Important Steps When Hosing Gas Springs Together 1. Always discharge all nitrogen pressure before working on any gas spring. Follow service instructions. 2. Using a slot screw driver, slowly remove port plug found on base of spring. A small amount of gas pressure may be present behind installed plug and an audible wisp of gas may be heard. 3. Discharge all nitrogen pressure and then remove nitrogen inlet valve located within port. It is helpful to remove the valve while the gas spring is in an upside down or rod down position. This will keep the lubricating oil from oozing out of the spring. Metric socket cap port plug available upon request. Port Plug Inlet Valve steps 2 & 3 Gas Spring General Operating Conditions Pressure Medium: Nitrogen Gas Maximum Charged Pressure: 15 bar (2175 psi)... RLP, RLSC, RLS, RL and RLM Micro 23 & 3 18 bar (261 psi)... RLM Micro &18 Minimum Charged Pressure: 5 bar (725 psi)..... RLP, RLSC, RLS, RL and RLM Micro Gas Springs Maximum Operating Temperature: C (+176 F) Maximum Velocity: m/min. Maximum Utilized : % of the stroke (Design should not exceed %) 4. Install the appropriate straight or angle fitting, O-ring or 37 JIC face, using a mm (/16 ) open-end wrench. Please take care not to over-torque the fitting (refer to torque specification chart). 5. Attach the hose swivel nut fitting. We recommend that you wait to fully torque all fittings until the hose is in proper position. NOTE: For best results, minimize the number of fittings used in the system. Use only approved hose and fittings. Hose and Swivel Straight Fitting Swivel Nut Fitting 37 JIC fittings pictured steps 4, 5 & 6 Maximum Rod Misalignment: All dimensions and forces are nominal unless otherwise stated. 17

10 Control Panel, Assembly Hose O-Ring Face Seal Fittings O-Ring and 37 Fittings Control Panel Part # RT-2175-CP A control panel is mandatory with all hosed systems. The control panel is designed for remote mounting and is used to monitor and adjust nitrogen pressure. The panel is also equipped with a rupture plug for added safety. (1) Rupture plug (2) Inlet valve (3) Exhaust valve (4) Pressure gauge (5) Straight fitting (one supplied) G-1/8 BSSP inlet port 1 (.7 in.) 41.2 mm (1.6 in.) Bottom View Front View (4) 5 (2.47 in.) 12 (5. in.) (2) (3) 3 (1.26 in.) (1) 7 (3.3 in.) Suggested drilling pattern for customer to mount the NAAMS standard control panel. Side View (5) 1/2-2 inch 85 mm (3.35 in.) BSPP Male Straight Connector 4.5 G-1/8 Swivel Nut Elbow Part # RT42F4OMLO-S 26.5 Part # RT4C6MLO-S BSPP Male 45 Elbow Part # RT42V4OMLOS-S Swivel Nut Run Tee Part # RT4R6MLO-S G-1/ BSPP Male Elbow Swivel Nut Branch Tee Part # RT42C4OMLO-S Part # RT4S6MLO-S G-1/ Assembly Hose Important: The hose length should be a minimum of 5% longer than the actual measured length. The additional length provides for the contraction of the hose length when pressurized. Note: The inlet valve must be removed prior to hosing. O-Ring Face Seal Hose Part # RT5241JC55-(*) (*) = specify required hose length 37 JIC Hose Part # RT (* (*) = specify required hose length) 37 JIC Fittings BSPP Male Straight Connector BSPP Male 45 Elbow BSPP Male Elbow 6.3 G-1/ /16-2 G-1/8 Male Straight Connector Part # RT4F4MX-S Part # RT4V4MX-S 7/16-2 G-1/ /16-2 Part # RT4C4MX-S G-1/8 Part No. O-ring Face RT5241JC55 37 JIC RT mm inch mm inch Hose I.D Hose O.D Max. Operating Pressure MPa Burst Pressure MPa Min Bend Radius Thread Size 1/16-2 A H Hex W Hex B Swivel Nut Elbow / / /16-2 /16 Swivel Nut Run Tee / / /16-2 / /16-2 Swivel Nut Branch Tee 7/ / /16-2 7/16-2 / Part # RT4C6X-S Part # RT4R6X-S Part # RT4S6X-S 18 All dimensions and forces are nominal unless otherwise stated. All dimensions and forces are nominal unless otherwise stated. 1

11 Junction Block, General Notes Design Guide Junction Block Good Performance Begins With Good Design Model HR-2 HR-4 HR-6 mm inch mm inch mm inch General Notes We recommend that all gas springs are supported on the base at all times. No stock removal permitted from any surface of the gas springs. All hoses and fittings are available individually, as assemblies, or in bulk upon request. We reserve the right to change the design, specifications, dimensions, force and offering without notice. All dimensions and forces are nominal unless otherwise stated. HR-6 Model shown A G-1/8 BSPP outlet port supplied with fitting and/or plugs. Available in 2, 4 or 6 ports. B Rupture plug 35 bar (5, psi) C D Measurement Converter For conversion of metric and US measurements, use these conversion factors; Length: 1 inch = 25.4 millimeters 1 millimeter =.337 inches Pressure Ratings: PSI to BAR = PSI x = BAR E Volume: 1 cubic inch = cubic millimeters 1 cubic millimeter =.6123 cubic inches Liquid Capacities: 1 milliliter =.3381 fluid ounces (4) holes drilled and counterbored to accommodate M1 or 3/8 socket head cap screws. F G-1/8 BSPP inlet port supplied with O-ring face or 37 JIC straight fitting. G Area: 1 square inch = square millimeters 37 JIC fittings pictured H I J Weight: 1 pound = kilograms 1 ton = kilograms 1 kilogram = pounds 1 metric ton = 4.6 pounds 1 metric ton = tons Self-Contained: When placed in a die pocket, gas springs should always be secured with bolts. Unlike pre-loaded die springs, gas springs operate at less than maximum efficiency when inserted into a pocket, in either an upper or lower application. This is true because the clearance fit between the gas spring and the pocket provides space for the gas spring to move off center as the press cycles. Over time, this can damage the gas spring and ultimately shorten its life. By securing a gas spring with bolts, it remains perpendicular to the pad or kiss block, and can no longer shift inside the die pocket. In addition, this eliminates the accumulation of metal chips or other debris under the gas spring. When grit and grime build up under a self-contained gas spring, it can become tilted or overstroked. Hose Systems: Gas springs can be hosed together into a system. However, the gas spring s inlet valve must be removed and a fitting installed to permit the attachment of hoses. Note: Always secure gas springs with bolts. The benefits of this method: Gas springs are always balanced in force and pressure. A control panel connected to the system provides the flexibility to adjust the force from outside the tool. Pressure monitors can be connected to the system. They automatically alert the user and/or shut down the press should changes occur in the pressure level. Production can continue should a leak develop. A nitrogen bottle with a regulator can be connected to the control panel to feed a leak until the die is released from production. NOTE: For best results, minimize the number of fittings used in the system. Use only approved hose and fittings. Installation Guidelines: The pocket diameter for a DESIGN-TITE gas spring should be approximately (.8 in.) larger than the body diameter. For optimum performance, the gas spring must be secured in place with an appropriate fastener to ensure that it remains perpendicular to the contacting surface. This eliminates possible debris from building up around the gas spring, leading to side loading or overstroking. When possible, machine drain slots or holes to allow die lubricants to flow away from the gas spring. This prevents flooding of the spring pockets and will keep die lubricants from contaminating the gas spring. It is very important that the piston rod contact a flat, smooth surface. Never allow the top of a piston rod to contact a counter-bored hole, casting or bolt head. Use of a stop block is helpful in preventing the gas spring from being overstroked. The stop block should be equivalent to or greater than the () dimension. Maximum available travel is 1% of stroke. Design should not exceed % of available stroke. Charging & Discharging When a gas spring has been in service for a long period of time, it may begin to lose force. DESIGN-TITE gas springs have the additional feature allowing customers to recharge the pressure by using an optional quick disconnect. To adjust or exhaust pressure, use the optional service gauge assembly with DESIGN-TITE gas springs. 2 21

12 Accessories, Service Gauge Better by Design Accessories DESIGN-TITE Gas Springs Other Gas Springs To fill or recharge a DESIGN-TITE nitrogen gas spring quickly and easily, order the quick disconnects shown to the right. RLP-75 & 1, RLSC, RLS, RL: Part #RT-QDM-6251-A RLM-, 18, 23, 3 & RLP-5: Part #RT-QDM-6-A Hollow piston rod lowers pressure rise Dust Cover C-Style Retaining Ring Service Gauge Assembly Part # RTUAL-4.-QDM This assembly is multi-functional. Use it to fill, empty, or adjust pressure in the gas spring. Installation of this device will result in a nominal loss of pressure. The charge port fitting must be changed when working with the RLM-, 18, 23, 3 and RLP-5 gas springs. Part # RTUAL-G1/8 x M6: Fitting used with RTUAL-4.-QDM to fill RLM and RLP-5 gas springs Casing/Spool Pressure Adjusting Screw Body Threaded Plug Inlet Valve Outlet Valve Retainer Ring Circlips O-ring O-ring O-ring Gauge On Hose Line: Quick Disconnect Female Part #RTQDF-42 To adjust or exhaust pressure of a DESIGN-TITE gas spring, order the service gauge assembly shown above. Solid Bronze Top Cap With Patented Lubrication Chamber Designed with greater bearing area for Improved support and guiding creates a mechanical solid for greater structural strength and safety Lubrication chamber provides long, maintenancefree life ISO standard clamping on body Threaded Bottom Cap ISO standard clamping ISO standard mounting and charge port Multi-piece, Cartridge Assembly Rod Retainer Retainer Wear Ring Body Assembly Inlet Valve and Port Plug DESIGN-TITE Ease of Repair is Better by Design DESIGN-TITE provides for quick, safe and simple repairs with our single piece piston rod and threaded bronze top cap. With DESIGN-TITE, gas spring repair is as simple as 1, 2, Unthread the bronze top cap from the spring body and push the piston rod out the bottom of the top cap. Discard the top cap. 2. Lubricate the piston rod and the three seals contained in the replacement top cap with assembly lubrication. Install the piston rod into the bottom of the replacement top cap and push it up to the lubrication chamber. Add lubrication over the top of the piston rod, filling the chamber. Push the piston rod completely through the top cap. All dimensions and forces are nominal unless otherwise stated. 3. Thread the top cap to the spring body and tighten. With the piston rod fully extended, recharge the gas spring. That s all there is to it, and you re back in production! DESIGN-TITE makes repairs simple and safe. No more hammering out C-style retaining rings. No more fighting to keep the multi-piece cartridge assembly together during handling and installation. No more concerns about installing the cartridge assembly upside down. Most important of all, no more fears that the C-Style retaining ring was damaged or installed improperly. DESIGN-TITE is Better by Design Simple, Solid Construction, Safe, Made of Superior Materials 1. Simple. Our design replaces the many components found on other brands with a one-piece piston rod and a threaded one-piece bronze cap. Our design thus eliminates problems associated with stack-up tolerance affecting overall height and life of the spring. Assembly is simple. The top cap and bottom cap screw into the body, and both are held securely in place with high pressure SEA threads. 2. Solid Construction. By eliminating the retaining ring, our design provides not only structural stability in the upper portion of the gas spring, but precise concentricity and minimum misalignment between the piston rod, top cap and the spring body, all of which extend life. Our patented lubrication system located between the rod seal and rod wiper further extends life. This degree of stability, precision and seal lubrication is only available with DESIGN-TITE. 3. Safe. With a threaded one-piece bronze top cap, we eliminate the retaining ring altogether, and hence, any concern whether the retaining ring is set correctly. 4. Superior Materials. We only use the best and have spared no cost to provide the highest quality. Examine a DESIGN-TITE gas spring and see the difference for yourself. DESIGN-TITE a true advancement in the technology of nitrogen gas springs. With all these features and more, is this not the gas spring you ve always wanted? 23

13 The Innovator of Our Industry SM Our factories and offices: U.S.A. U.K. France Belgium Germany Sweden Netherlands Singapore DANLY UK LIMITED Unit 1, Mucklow Hill 1 Trading Estate, Mucklow Hill, Halesowen, West Midlands, B62 8DF Tel: Fax: sales@danlyuk.com Website: Q M S ISO 1 REGISTERED FIRM DANLY UK LIMITED 2 Aintree Road Perivale, Middlesex UB6 7LA Tel: Fax: