2 betriebsanleitung ac100-ac320e

7/27/2019 2 Betriebsanleitung AC100-AC320e

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Operating instruction

Pneumatic cylinder AC.100 – AC.320

AB STAFSJÖ BRUK, SE-618 95 STAVSJÖ, SWEDEN TEL:+46 (0)11-39 31 00 FAX: +46 (0)11-39 30 67

DECLARATION of CONFORMITYThe Manufacturer AB Stafsjö Bruk, SE-618 95 STAVSJÖ, SWEDEN, hereby certify that the products in thescope

PNEUMATIC CYLINDER type AC

have been designed and manufactured according to the Swedish standards of design and manufacture of pressure equipment and pipe lines:

TKN K 1987RN 1978

Stavsjö, March 3, 2003

AB STAFSJÖ BRUK

Magnus Westher Managing Director

Table of contents

OPERATING INSTRUCTION.....................................2

A - PNEUMATIC CYLINDER ..........................................2 B - TECHNICAL INFORMATION......................................2 C - STORAGE.............................................................2 D - TRANSPORTATION AND HANDLING .........................2 E - INSTALLATION.......................................................3

Mounting the pneumatic cylinder......................... 3 Adjusting the cylinder stroke................................4 Air connection ......................................................5 Tightness .............................................................5 Surrounding environment ....................................5 Support ................................................................5 Accessories..........................................................6

F - OPERATION ..........................................................6 G - SERVICE AND MAINTENANCE.................................6

Maintenance ........................................................6 Troubleshooting...................................................7

H - SPARE PARTS ......................................................7



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The Operating instruction describes how the pneumatic cylinders of Stafsjö shall be installed and operated toensure the products function and safety during its lifetime.

The Operating instruction shall be made available to the personnel responsible for the installation, operatingand service of the Stafsjö pneumatic cylinders.

More detailed information on the pneumatic cylinder is available in data sheets and Service instructions onwww.stafsjo.com or please contact AB Stafsjö Bruk or your local representative.

AB Stafsjö Bruk accepts no responsibility for the product if this Operating instruction is not followed wheninstalling, operating and maintaining the Stafsjö pneumatic cylinder. Nor does AB Stafsjö Bruk acceptresponsibility for the product if any essential change has been done to the product.

A - Pneumatic cylinder The Stafsjö pneumatic cylinder consists of twocast end cups and a cylinder tube in aluminium.The piston and rod seal are made of nitrile andthe piston rod is made of stainless steel.

The cylinder is operated by dry or oil mist air witha maximum pressure of 10 bar.

The pneumatic cylinder can be equipped withdifferent accessories, such as solenoid valve, a

magnetic piston and magnetic limit switches.

B - Technical informationThe technical data of the pneumatic cylinder is described in its data sheet. All data sheets are available onwww.stafsjo.com. If you have any questions regarding the products, please contact AB Stafsjö Bruk or your local representative.

C - Storage

The Stafsjö pneumatic cylinder shall be stored in a clean and dry environment. It shall be protected againstdirt, dust and other pollutants and should not be exposed to direct sunlight.

D - Transportation and handling The Stafsjö pneumatic cylinder has been packed according to the conditions of the transport for the delivery.Unfortunately damage can occur to the product due to mishandling during the transportation. It is importantto make a visual inspection of the valve at arrival. If transport damages are detected a report shall be writtento the transportation company.

When mounting the Stafsjö pneumatic cylinder, all lifting and handling shall be carried out with soft straps.The soft straps shall be placed and fastened at the bottom end cup or all around the cylinder.



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Before lifting you must always check:o Check that the lifting equipment is safe and designed to hold the weight of the cylinder. (See data sheet

on www.stafsjo.com.)o Check that the soft straps are fastened and do not risk to slide along the cylinder.o Do not expose the cylinder or mounted accessories to blows or thrusts.o Do not exert the weight of the cylinder to mounted accessories.

Note!Never place lifting equipment in accessories or the cylinder tie rods.

E - InstallationThe Stafsjö pneumatic cylinder is delivered ready for installation on a Stafsjö knife gate valve.

To mount a pneumatic cylinder on a Stafsjö knife gate valve, the valve must be uninstalled from the pipe line.This is necessary to correctly adjust the cylinder stroke.

Note!No work is allowed on the knife gate valve when the pipe line is pressurized or the pneumaticcylinder is connected. The pipe line must be free from pressure and empty and the pneumaticcylinder must be disconnected before work begins.

Before installing the Stafsjö pneumatic cylinder, the following must be checked:o Check that the pneumatic cylinder is correct in size regarding the size and model of the knife gate

valve.o Check that the air supply to the cylinder is correct regarding, quality, pressure and flow.

Mounting the pneumatic cylinder

Mount the pneumatic cylinder on the knife gate valve with regards to the direction of the air connections.

Before mounting the pneumatic cylinder to a Stafsjö knife gate valve, the following must be checked:o Check that the locking nut and gate clevis are screwed on to half of the piston rod.

o Check that the aluminium beams have holes to be able to loosen/fasten the clevis pin.



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o Check that the knife gate valve is closed and that the gate clevis and clevis pin are placed under thehole in the beam.

o Check that you have the clevis pin, split pins and gate guards.o Check that the cylinder is parallel to the gate and at right angles to the beam top before fastening the

cylinder on the tie rods.

The pneumatic cylinder is fastened by four (4) nuts to the tie rods.

MV, BV HG RKO

M10 DN 50-150 DN 80-150 DN 100M12 DN 200-300 DN 200-250 DN 150-250M16 DN 350-400 DN 300-350 DN 300-350M20 DN 450 DN 400-450 DN 400M22 DN 500-600M24 DN 700-1000 DN 500-800

For more information on the installation of a pneumatic cylinder, please see Service instructions onwww.stafsjo.com.

Adjusting the cylinder stroke

Check that the locking nut and gate clevis are screwed on to half of the piston rod.

When the pneumatic cylinder has been mounted to the beam top of the knife gate valve, move the piston rodto the gate by gently operating the cylinder. Fasten the gate clevis to the gate with the clevis pin and splitpins.

Open the valve by gently operating the cylinder. The piston must be in its top position in the cylinder. In thisposition, the gate should not have left the valve bore completely. Measure the distance Y between the edges

of the retainer ring and the lowest part of the gate.

Y Y



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Carefully close the knife gate valve. Dismount the split pins and clevis pin to release the gate clevis from thegate. Adjust the gate clevis on the piston rod the same distance Y and lock it with the locking nut. Connectthe gate to the piston rod and repeat the procedure.

After adjusting, the lowest part of the gate shall be edge-to-edge with the retainer ring (Y=0 mm) for acompletely open valve. The seat might be damaged at closing if the gate is too far into the valve and if thegate is partly in the valve bore, it will throttle the media flow and might be exposed to erosion.

Air connection

There are air connections on the top and bottom end cup of the pneumatic cylinder. These are connected tobe able to close respectively open the knife gate valve. The connections are pipe threads according to ISO228-1:

Air pipedimension(mm)

AC 100 G ¼” 6 AC 160-200 G ½” 12 AC 250-320 G 1” 25

Use thread sealing when the air connections are screwed to the cylinder end cups.

The air pipe connected to the pneumatic cylinder must have at least the same size as the connection in thecylinder end cup. If the air pipe is too small it will throttle the air flow which could cause power reduction of the pneumatic cylinder. This might mean that the knife gate valve does not open/close completely or doesnot open/close in a smooth movement.

The air shall be dry or oil mist air with a maximum pressure of 10 bar.

Tightness

A pneumatic cylinder with or without a solenoid valve, should be completely tight when not operated. The air is evacuated when it is operated and a noise occurs.

Surrounding environment

The environment around the Stafsjö pneumatic cylinder should be dust free and dry. Too high or lowtemperatures or fast temperature swings may affect the cylinder and its accessories.

The recommended working temperature for the pneumatic cylinder is limited to -20 - +100°C based on thematerial in the piston and the grease in the cylinder.

The pneumatic cylinder and its accessories must be protected from leakage of gas and liquids in thesurrounding environment. The gas and liquids may affect the material and the function of the cylinder and itsaccessories.

Support

The Stafsjö knife gate valve should be mounted in a horizontal pipe line with the pneumatic cylinder in avertical upright position. If a knife gate valve is mounted in any other direction, the dead weight of a long gateor a large pneumatic cylinder may cause tensions in the valve which might affect the valve tightness andability to manoeuvre.

Also, valves that are exposed to vibrations or other mechanical stresses can be subject to forces that willaffect the valve tightness and ability to manoeuvre.



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The knife gate valve and its pneumatic cylinder should in these cases be supported to avoid function failure.Supporting can preferably be done by mounting a loop and suspension in a wire or supporting by using afastened rod. The wire or rod should be placed on the bottom end cup of the pneumatic cylinder.

Accessories

Accessories shall be installed, operated and serviced by qualified personnel. Instructions for accessories canbe received from AB Stafsjö Bruk by stating the article and serial number with which the knife gate valve ismarked.

AB Stafsjö Bruk accepts no responsibility for the product if accessories are mounted on the knife gate valvein such a way that it essentially affects the pneumatic cylinder design or function.

F - OperationBefore operating the pneumatic cylinder you must check the following:

o Check that the pneumatic cylinder is correctly mounted on the knife gate valve with adjusted cylinder

stroke. (See E above.)o Check that the air connected to the cylinder does not exceed maximum allowed pressure. (See E

above.)o Check that the air pipe connected to the cylinder has the right size and is correctly installed. (See E

above.)o Check that all accessories are correctly installed by competent personnel.o Check that the knife gate valve and pneumatic cylinder are supported to avoid tensions. (See E

above.)

Note!The gate guards must always be installed on the knife gate valve with a pneumatic cylinder toprevent personal injuries before the valve is put into operation.

The surrounding environment and the system in which the valve is installed shall have normal operatingconditions to obtain the optimal function and lifetime of the valve and its pneumatic cylinder. The followingmust be checked regularly when operating the valve:

o Check that the environment around the knife gate valve and its pneumatic cylinder does not implyany risks to the valve, actuator or accessories.

o Avoid powerful pressure and temperature swings and vibrations in the systemo Be observant to leakage from the pneumatic cylinder and take measures immediately.o Do not expose the pneumatic cylinder or its accessories to external loads or other strains, for

example by climbing on it.

G - Service and maintenance

Maintenance

Piston, piston rod guide and piston rod seal are wear parts that have to be replaced regularly to keep thepneumatic cylinder function. The interval for replacement depends on how often the cylinder is in operation.Other factors are the surrounding temperature and the quality, pressure and temperature of the air.

The pneumatic cylinder must be inspected every day for leakage and other external effects that mightinvolve risks for operating personnel, the valve and its accessories.

A full scale manoeuvre test shall be performed at least two times a month to verify that the pneumaticcylinder functions correctly.

If a fault or problem is detected at an inspection or manoeuvre test, the knife gate valve and its pneumaticcylinder should go through service and maintenance as soon as possible. Information on spare parts andinstructions for service and maintenance are available on www.stafsjo.com.



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Troubleshooting

Faults or problems that are detected on the pneumatic cylinder may have several reasons. The mostcommon problems and their reasons are listed in the table below. To remove the problem, the pneumaticcylinder should undergo service and maintenance. How to perform the service, maintenance and availablespare parts is described in Service instructions and spare part data sheets on www.stafsjo.com.

If you can not find the information you are seeking, please contact AB Stafsjö Bruk or your localrepresentative.

Problem Reason Measure

Leakage in rod sealing Worn-out rod sealing See Service instructionswww.stafsjo.com

Leakage in cylinder end cup Unsufficient seal between cylinder tube and cylinder end cups

See Service instructionswww.stafsjo.com

Gate does not open/close

completely

Unsufficient air supply to cylinder

Wrongly adjusted cylinder strokeFault in limit switchesClogged valveDamaged seat/gate

See Operating instruction

See instruction for limit switchesSee Service instructionswww.stafsjo.com

Gate does not open/close ina soft movement

Unsufficient air supply to cylinder Clogged valveDamaged seat/gate

See Operating instructionSe Service instructionswww.stafsjo.com

Note!No work is allowed on the Stafsjö knife gate valve or its pneumatic cylinder when the pipe lineis pressurized or the cylinder is connected. The system must be empty and free from pressurebefore work begins. The pneumatic cylinder and accessories must be disconnected beforework begins.

The gate guards must always be installed on the knife gate valve before the valve is put intooperation after completed work.

AB Stafsjö Bruk accepts no responsibility for the product if wear parts not tested and approved by AB StafsjöBruk are installed in the pneumatic cylinder. Nor does AB Stafsjö Bruk accept responsibility for the product if the Service instructions are not followed when maintaining the pneumatic cylinder.

H - Spare partsSpare parts and instructions for service and maintenance are available on www.stafsjo.com or pleasecontact AB Stafsjö Bruk or your local representative.

All specifications subject to change without notice. www.stafsjo.com

2 betriebsanleitung ac100-ac320e

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