GENERAL PURPOSE TYPE PNEUMATIC CYLINDER DC7 SERIES (Φ40 ~ by nle13756

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									                                                                        07-T098




          INSTRUCTION MANUAL
GENERAL PURPOSE TYPE PNEUMATIC CYLINDER
              DC7 SERIES (Φ40 ~ Φ150)




                      <<For safe use of product>>
       Wrong operation of the product may result in unavailability
      of exhibition of full performance of the product or lead to a
      serious accident. To prevent occurrence of an accident, be
      sure to read the Instruction Manual of the product carefully to
      completely understand the contents given therein before
      operating the product.
       Those described as precautions are items to which your
      careful attention has to be paid. Operators or products may
      be injured or damaged, unless these precautions are strictly
      observed. Accordingly, be sure to operate the product in strict
      conformance with the instructions given therein.
      If you find any unclear point, contact us.




                               TAIYO, LTD.
                 1-1-1 Kitaeguchi, Higashiyodogawa-ku
                        Osaka 533-0002 JAPAN
                   URL: http://www.taiyo-ltd.co.jp/eg/
                                                      LIST OF CONTENT


1.      FOR SAFE USE...................................................................................................................................... 3

2.      PRECAUTIONS FOR OPERATION OF PNEUMATIC CYLINDERS ...................................................... 4

     PRECAUTIONS ON RELATED LEGISLATION ........................................................................................................... 4
     PRECAUTIONS ON RELATED DESIGN ................................................................................................................... 4
     PRECAUTIONS ON SELECTION ........................................................................................................................... 5
     PRECAUTIONS ON AIR PRESSURE SOURCE ......................................................................................................... 6
     PRECAUTIONS ON OPERATING ENVIRONMENT ..................................................................................................... 6
     PRECAUTIONS ON INSTALLATION ........................................................................................................................ 6
     PRECAUTIONS ON PIPING .................................................................................................................................. 7
     PRECAUTIONS ON LUBRICATION......................................................................................................................... 7
     PRECAUTIONS ON ADJUSTMENT ........................................................................................................................ 7
     PRECAUTIONS ON MAINTENANCE AND INSPECTION ............................................................................................. 8
     PRECAUTIONS ON STORAGE .............................................................................................................................. 8
     PRECAUTIONS ON SCRAPING ............................................................................................................................. 8

3.      PRECAUTIONS FOR OPERATION OF SWITCHES .............................................................................. 9

     PRECAUTIONS ON DESIGN AND SELECTION ......................................................................................................... 9
     PRECAUTIONS ON MOUNTING AND ADJUSTMENT ................................................................................................. 9
     PRECAUTIONS ON WIRING ................................................................................................................................. 9
     PRECAUTIONS ON OPERATING ENVIRONMENT ................................................................................................... 10
     PRECAUTIONS ON MAINTENANCE ..................................................................................................................... 10
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                                           1. FOR SAFE USE
Cautionary descriptions given here are for correct use of the products and for prevention of hazard on
you and other people in vicinity and damage with equipment. These descriptions are divided into three
items of “DANGER”, “WARNING” and “CAUTION” depending on the severity of hazard or damage and
level of imminence. All bear important descriptions pertaining to safety. Strictly observe the instructions
in addition to those of ISO4414*1), JISB8370*2) and other safety rules.

                                       Indicates an imminently hazardous situation which, if not avoided, will
         DANGER :                      result in death or serious injury.
                                       Indicates a potentially hazardous situation which could result in death
         WARNING :                     or serious injury, if the equipment is operated wrongly.
                                       Indicates a potentially hazardous situation which may result in injury
         CAUTION :                     and machine damage, if the equipment is operated wrongly.
*1) ISO4414: Pneumatic Fluid Power - Recommendations for the application of equipment to transmission control
                                     systems.
*2) JISB8370: General Rules of Pneumatic System.



                                                   WARNING
   For decision of conformity of pneumatic equipment, the designer of a pneumatic system or a
    person deciding the specifications is requested to render judgment.
    Since pneumatic equipment is used in many kind of situation, the decision for adaptability of system
    is depended on the designer or a person deciding the specifications to judge by the result of analysis
    and testing report if necessary. The guarantee of the performance and security which expected is up
    to the responsibility of the person who decides the adaptability of system. Construct the system with
    consideration of the possibility of machinery trouble by checking up the details specifications through
    latest product catalog and others documents.

   Operators with sufficient knowledge and experiences should operate the equipment.
    Compressed air, if handled wrongly, will cause a hazard. Personnel with sufficient knowledge and
    experiences only are requested to assemble, operate or maintain machines and devices which use
    pneumatic equipment.

   Do not handle the machines and devices or remove the equipment until safety is confirmed.
    1) Inspect or service the machines and devices after making sure of measures taken securely for
       prevention of drop of driven bodies and out-of-control run of them.
    2) Remove the equipment after making sure of the safety measures mentioned above duly taken
       and exhausting compressed air in the system.
    3) When restarting the machines and devices, make sure of a measure taken for prevention of
       protrusion in advance.

   Use the product in environment conforming to the specifications.
    You are requested to be sure to inform us in advance, when you intend to use the product outdoors
    or for applications likely to have large effects on people and properties and requiring safety in
    particular such as atomic energy, railways, aircraft, rolling stocks, medical equipment, equipment to
    be in touch with beverage and foodstuff, amusement equipment, emergency shut-off devices, press
    safety devices, brake circuits and safety equipment.
                                                                                                  4/10
                                     2. Precautions for Operation of Pneumatic Cylinders
                                                 Precautions on related legislation

  WARNING
When using a compressor that the rated discharge pressure is over 5Mpa, or an air pressure that is
supplied from an air tank over 1Mpa are covered in High Pressure Gas Safety Law.
When using a single gas such as Nitrogen, using a container of over 1Mpa as an air pressure source
is also covered in High Pressure Gas Safety Law.

                                                   Precautions on related design

  DANGER
The built-in cushion at the stroke end of cylinder is limited in energy absorption. If energy allowable
absorbed range exceeded, it will cause a huge impact and vibration to the machine. And, this major
shock will also cause damage to the cylinder and other peripheral devices. Do not use the cylinder in
a load that exceeded the maximum energy that can be absorbed by cushioning mechanism. Be sure
to install an external shock absorber when the cylinder is used in a heavy workload. The allowable
absorbed range of the cushion is shown at Fig 1 as below.


                                            Fig.1 Allowable Absorbed Range of Cushioning
    maximum working pressure to
    The ratio of actual weight and

         cylinder thrust force




                                                Average speed of piston (mm/sec)




  WARNING
General purpose pneumatic cylinder DC7 series is designed to be used in an air system only. If
working with fluid other than air, an accident or trouble may be caused.
An air cylinder may jump out at a speed higher than expected, if its mechanical sliding area is
disordered. Design the cylinder so that the machine may operate smoothly and the cylinder may not
damage persons or machines.
Fit a protective cover when the cylinder or driven body is likely to cause a hazard to persons.
When required frequency of operation is high or the cylinder is mounted on a place exposed too
much vibration, adopt a fastening method not to allow the fixed area or connection of the cylinder to
loosen.
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Take safety measures with power failure and possible trouble with the power source taken into
consideration.
Conduct design so the motions of the cylinder may not cause damages to persons and machines and
devices at the occasion of emergency stop, systems error or restarting.

                                   Precautions on selection

  WARNING
This cylinder is designed to be used in an industrial compressed air system only. Confirm the
specifications and do not use out of the range of specifications.
Use the cylinder in a proper working pressure within the pressure range. Do not apply exceeded
pressure that over the upper limit of working pressure range.

         Cylinder type             Working pressure range

         Single-rod                0.05 to 1.0Mpa
         Double-rod                0.10 to 0.7Mpa


Use the cylinder in a proper temperature environment within the working temperature range. Confirm
the temperature is within this range even when the cylinder is heated by radiant heat or heat transfer.

         Cylinder type             Working temperature range

         Standard                  -10 to +70ºC (but do not use when frozen)



  CAUTION
Supply an air pressure to the cylinder that commensurate with the loads. If the supply pressure is
minimized, it may cause instable operation.
In the case of an air cylinder, accurate interim stopping accuracy such as that of a hydraulic cylinder
 cannot be obtained because of compressibility of air.
“Zero leak” of an air cylinder and air valve is not guaranteed. Do not use the cylinder in environments
 or for applications where leak of air from a cylinder or valve poses a problem.
Be sure to calculate the cylinder buckling. The strength in the case that the piston rod is regarded as
a long column, the buckling strength, cannot be enhanced by adopting highly tension-proof steel or
heat treatment. When buckling occurs to a cylinder, the cylinder rod may be bent, causing
malfunctions or serious accidents.
If cylinders are used in the places under unfavorable conditions, where are subjected to wind, rain,
 and dusts, the piston rod especially needs to be protected. When selecting the boots, consider the
 environment conditions and temperature.
If the boots are provided, the length of extended cylinder rod is changed. Be sure to check the
 dimension drawing.
The volume of boots will change by move of piston rod, and therefore there is a window for air flow
(with filter) in the boots, through which small foreign matters of liquid and particle might be entered
with air flow. In such a case the boots does not work.
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Boots type and resistible temperature

       Code            Name                            Material                   Resistible temperature

      J           Nylon tarpaulin      Vinyl-coated nylon cloth                     80ºC
      JN          Chloroprene          Nylon cloth coated with chloroprene          100ºC
      JK          Conex                Silicon-coated Conex cloth                   200ºC
    Note 1. Remember that the resistible temperatures in the table above are for the boots, not for the cylinder.
           2. Conex is the registered trademark of Teijin Ltd.
           3. Neoprene, the older name of chloroprene, is the registered trademark of DuPont-Showa Denko Co., Ltd.
             Thus, we have adopted general name, chloroprene.



                                Precautions on air pressure source

   CAUTION
Use clean compressed air. Air containing chemicals or corrosive gas will cause break or malfunction
of the cylinder.
Mount an air filter to remove foreign matter in compressed air.
Set an after-cooler, air dryer or air filter to remove drain in compressed air.

                              Precautions on operating environment

   WARNING
Do not use the cylinder in environment under corrosive gas or a place exposed to splash of corrosive
chemicals or solutions. For cylinder material, see the catalog.


   CAUTION
Attach a cover to the piston rod in a much dusty place or a place exposed to water drops or oil drops.
It is dangerous that the strength of material may be decreased by corrosive in a salty atmosphere. Be
 sure to use a cylinder with corrosion proof or corrosion resistant material in such kind environment.
In the case of use in the places where splashed with solvent, cutting oil and coolant may deteriorate
 the quality of seal parts and may cause air leakage at the early stage. Be sure to check the
 adaptability of packing material.

                                       Precautions on installation

   CAUTION
Be sure to couple the rod with the rod axial center adjusted to the rod moving direction. Otherwise,
the bush and rod surfaces, tube inner surface and packing will be worn out or broken. When a
cylinder is mounted with fixed (Foot type or Flange type), we recommend using the floating joint with
self-aligning function.
Do not bump things against the cylinder tube, piston rod, etc. to scratch them. Scratched sliding area
will cause wear of packing.
For the mounting of cylinders, use bolts of the specified size, and fix with the bolts of the strength
                                                                                                  7/10
class. And, be sure to fix the bolt by using a tool that can get an adequate clamping torque.
Install an external stopper to the mounting base when using foot type mounting to prevent direct
 application of impact.
Apply grease to rotary areas of trunnion accessories and clevis accessories to prevent seizure.
If the boots are provided, conduct mounting with care not to twist the boots

                                     Precautions on piping

  CAUTION
Flush the piping sufficiently to remove foreign matters.
Be careful so that no seal tape or sealing material may enter the pipe.
When wrapping a seal tape around threaded area of the piping or joint,
wrap the tape leaving 1 to 2 threads at the end as untapped.
Conduct the piping work in conformance with the regulations of the
applicable country.
Proper torque for piping

      When fastening a joint, tighten the joint to the torque shown below.
        Connecting      Proper tightening torque      Connecting   Proper tightening torque
          thread                   (Nm)                  thread              (Nm)
            M5                   1.2 to 1.5              Rc 1/2            28 to 30
           Rc 1/8                 7 to 9               Rc 3/4              60 to 65
           Rc 1/4                12 to 14                  Rc 1            70 to 75
           Rc 3/8                22 to 24


                                  Precautions on lubrication

  CAUTION
Use the lubricating oil of “Turbine Oil Class 1 ISO VG32” or equivalent. Do not use a spindle oil or
machine oil, since they will shorten the life of seals to cause malfunction of the equipment.
Be sure to continue lubrication to the last, once started. Stop of lubrication on the way will cause
malfunction of the equipment due to loss of initial lubrication.

                                 Precautions on adjustment

  CAUTION
When starting up a device, increase the supply pressure from a low pressure gradually to check that
the device operates smoothly.
Be sure to attach a speed controller on the cylinder to adjust setting speed from the low speed side
gradually.
The cylinder with pneumatic cushion is adjusted to the intermediate speed position before shipment.
Adjust the cushion needle position from the low speed side gradually according to the operating
condition. If energy higher than the capacity of the pneumatic cushion should apply, collision of the
cover with the piston will take place in some cases, resulting in damage with the machine or device.
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Check whether there is any abnormal motion, noise or friction heating during the trial run of cylinder.
If any abnormality is found, do not use the equipment until specified countermeasures are taken.

                     Precautions on maintenance and inspection

  WARNING
To remove or disassemble equipment, take measures for prevention of drop of components and run
out of control of the equipment, exhaust compressed air in the system, and make sure of safety in
advance. There still may be residual pressure even when the supply pressure is exhausted
depending on the working circuit. Remember to exhaust the compressed air completely before
removing the cylinder for disassembling.


  CAUTION
Drain the pneumatic system periodically.
Check the pneumatic equipment periodically. If any abnormality is found, do not use the equipment
until specified countermeasures are taken.
Before disassembling a cylinder, the operator has to completely understanding the inner structure by
structural drawing or assembly drawing.

                                    Precautions on storage

  CAUTION
Consider following points under storage of product.
     1. Become rusty
     2. Permanent stress of packing
Store the product as followings.
     1. Store the product in a cold and dark place (37ºC max.) protected from direct sunlight and
        moisture in position 30cm above the floor level.
     2. Transportation causes a hazard, if collapse of cargo should take place due to excessive
        vibration. Further, parts may be damaged due to excessive vibration.

                                   Precautions on scraping

  CAUTION
Disassemble cylinders, sort the disassembled components by material (iron, copper, aluminum, resin,
rubber, waste oil, etc.), and then, dispose them.
Piston rods are hard chrome plated. When disposing them, consult with a disposal company.
Dispose resin base and rubber base components as nonflammable wastes.
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                   3. Precautions for Operation of Switches
                           Precautions on design and selection

  WARNING
Use the cylinder within the specified operating ranges. Use at load current, voltage, temperature,
impact and others in excess of specifications will cause rupture or malfunction of the cylinder.
When inductive load such as relay and solenoids is connected, be sure to set a contact protective
circuit, since surge voltage is generated.
When switch wiring extends over a long distance, switch contact may be broken by inrush current. Be
sure to set a contact protective circuit.
Series connection of switches with indicating lamps will cause voltage drop due to indicating lamp
internal resistance. Further, load may not operate, even if the switch operates.
In the case of 2-wire type non-contact switch, current (leak current) to actuate the internal circuit is
 flowing into the load, even if the switch is in the OFF position. In the case of parallel connection in
 particular, check the load working current.
The switch is actuated by the magnet incorporated in the cylinder. In the case of excessive access,
magnetic forces on both sides interfere with each other to cause malfunction of the switch. Further,
do not use the switch in an environment of strong magnetic field, since the switch may malfunction in
such an environment.
When the switch is used in an interlock circuit requiring high reliability, set a mechanical protective
function to provide for a possible trouble, or adopt the double interlock system such as installation of
a sensor in addition to the cylinder switch.


  CAUTION
As to detection on the way of piston stroke, be careful of responsibility of the load. When the piston
speed is high, it is possible that the load cannot follow operation of the piston.
Work out design with space required for maintenance and inspection taken into consideration.

                        Precautions on mounting and adjustment

  CAUTION
Do not drop or throw a switch. The inside of a switch may be damaged.
Do not hold the switch lead wire to carry the cylinder. The inside of a lead wire may be broken.
Fix the switch securely while strictly observing the specified tightening torque for screws. Application
of excessive tightening torque may break the switch.
Set the switch at the center of the working range. If the switch is used at the end of the working range,
detection may be unstable.

                                     Precautions on wiring

  WARNING
Do not connect the switch directly to a power source. All switches must have the required load (relay,
sequencer, etc.) installed between them and the power source.
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Check the wiring for insulation properties. If there is a short, the switch may break instantaneously
due to over current.
Avoid use of wiring commonly for the motive power sources or high-voltage cable. The switch may
malfunction due to noises.


  CAUTION
Be careful so that repetitive bending or pulling force may not apply to the lead wire. Otherwise, the
lead wire will be broken.
Be careful of wrong wiring. Connect according to the color of a lead wire.

                         Precautions on operating environment

  DANGER
Never use the switch in an ambience of explosive gas. The switch is not explosion-proof. When
the switch is used in an ambience of explosive gas, the switch may cause an explosion hazard. Be
fully careful never to use the switch in an ambience of explosive gas.


  WARNING
Do not use the switch where a magnetic field is generated. Malfunction of the switch or
demagnetization of the magnet in the cylinder may be caused.
Do not use the switch in an environment where it is exposed to splashing of water at all times. The
switch conforms to IEC Standard IP67, but imperfect insulation may be caused in some cases, if it is
exposed to continuous splashing of water.
Do not use the switch in an environment where it is exposed to oil such as cutting oil or chemicals.
Do not use the switch in an environment where it is exposed to excessive impact. In the case of a
contact switch, the contact may malfunction, resulting in instantaneous output of a signal.
Do not use the switch in an environment where there is a noise generation source. If there is a large
noise generating equipment (such as electromagnetic lifter, high frequency induction furnace and
motor) in vicinity of the non-contact switch, deterioration or break of the switch internal circuit
element may be caused. Take counter-measures against noise at the generation source. Also, be
careful not mix or touch the line with other lines.
Avoid accumulation or access of magnetic substances. Much deposit of chips or weld spatters
around the switch deprives the magnetic force from the cylinder in some cases, resulting in
malfunction of the switch.
Even if the operating temperature is within the specified range, the switch internal parts may be
affected adversely, if abrupt temperature change should take place.

                                Precautions on maintenance

  WARNING
Retightening the switch mounting screws as needed. At that time, check and switch mounting
position and conduct readjustment, if necessary.
Check the lead wire for damage. If the lead wire cover is damaged, imperfect insulation or break in
wiring may result. In such a case, replace the switch or the lead wire promptly.

								
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