Table B900-0/E

Operating and maintenance information

for industrial cylinders & servocylinders
These operating and maintenance information are valid only for Atos hydraulic cylinders and are intended to provide useful guidelines
to avoid risks when hydraulic cylinders are installed in a machine or a system. Information and notes on the transport and storage of
hydraulic cylinders are also provided.
These norms must be strictly observed to avoid damages and ensure trouble-free operation. The respect of these operating and main-
tenance information ensures an increased working life and thus reduced repairing cost of the hydraulic cylinders and system.

1 SYMBOLS CONVENTIONS

This symbol refers to possible danger which can cause serious injuries

2 GENERAL NOTES
The cylinder operating and maintenance information are part of the operating instructions for the complete machine but they cannot replace them

Atos is not liable for damages resulting from an incorrect observance of these instructions.
All the hydraulic cylinders have 1 year warranty; the expiration of warranty results from the following operations:
- Unauthorised mechanical or electronic interventions
- The hydraulic cylinders are not used exclusively for their intended purpose as defined in these operating and maintenance instructions

3 HARMONIZED STANDARDS
Hydraulic cylinders are subject to PED directive 2014/68/UE, see sec. 6 for details. Machinery Directive 2006/42/CE does not apply to hydraulic cylinders.
For an overall view relevant to application of the European directive in electrohydraulics, see www.atos.com, catalog on line page, section P, tab. P004

Check the code in the nameplate to ensure that the hydraulic cylinder is suitable for the installation area

4 WORKING CONDITIONS

The operation of hydraulic cylinders is not permitted at different operating and environmental conditions than those specified below
Description CK, CK*, CH, CN CC
Ambient temperature -20 앦 +120°C -20 앦 +120°C
Fluid temperature -20 앦 +120°C -20 앦 +120°C
Max surface temperature - -
Max working pressure 16 MPa (160 bar) 25 MPa (160 bar)
Max pressure 25 MPa (250 bar) 32 MPa (320 bar)
Max frequency 5 Hz 5 Hz
Max speed 4 m/s
Recommended viscosity 15 앦 100 mm2/s
Max fluid contamination level ISO4406 20/18/15 NAS1638 class 9, see also filter section at www.atos.com or KTF catalog

5 NAMEPLATES

Nameplate - Standard Nameplate - Standard (1)

1 Pos. Description
1234567
y Delivery date
5 21/17 03685071 4
x Cylinder code
2 CK-80/36*1360-N041--B2X2 c Series number
3 -33
approved ISO 10100 and ISO 4406 20/18/15
v Customer code (only if requested)
made in Italy www.atos.com
b CE mark (see section 6 )

Notes: (1) The position of the nameplate on the rear or front heads can change due to the cylinder overall dimensions

B900
 6 CE MARKING
Hydraulic cylinders are considered as pressure vessels and thus they are subject to the PED directive (2014/68/UE), point 1 a) of article 4. Particularly
they are designed to be used with fluids of group 2 (oil hydraulic fluids) and they have to be marked if the product Pmax x V (Volume under pressure)
is higher than 10.000 bar x liter. Tables below show the minimum stroke over which the cylinders have to be CE marked. ATEX cylinders are CE
marked according to ATEX directive (2014/34/EU).
Cylinders CK, CH and CN - Pmax = 250 bar Cylinders CC - Pmax = 320 bar
Stroke min [mm] Stroke min [mm]
Bore [mm] Rod [mm] Bore [mm] Rod [mm]
single rod double rod single rod double rod
56 4075 100 70 3975 5000
125 70 3255 4745
90 5000 125 90 2545 5000
70 2460 140 90 2030 3455
160 90 1985 2910
110 3770 160 110 1550 2945
90 1595 180 110 1225 1960
200 1270
140 2495
200 140 990 1950
250 140 810 1185
250 180 635 1320
320 180 495 725
320 220 385 735
400 220 315 455 400 280 245 485

7 SAFETY NOTES
7.1 General
- The presence of cushioning can lead to a peak of pressure that can reduce the cylinder working life, ensure that the dissipated energy is less than the
max value reported in tab. B015
- Make sure that the maximum working conditions, shown in section 4 , are not exceeded
- Ensure to use hydraulic fluids compatible with the selected sealing system, see tab. B137, B140, B160, B180, B241 and B310
- The rod must be handled with care to prevent damages on the surface coating which can deteriorate the sealing system and lead to the corrosion of the
basic material
- The mounting screws must be free from shearing stress
- Transverse forces on the rods must always be avoided
- When the cylinder has to drive a rotating structure or where little alignment errors are expected, mounting style with spherical bearing should be used
- Contact surfaces, support elements in tolerance, elastic materials and labels must be covered before painting the cylinder

7.2 Proximity sensors

- Proximity sensors are supplied already adjusted, if other regulations are necessary see tab. B137 or contact our technical office
- Ensure not to remove the sensor while the cylinder is under pressure
- The connectors must never be plugged or unplugged when the power supply is switched-on

7.3 Position measuring system

- Position transducers must never be removed, if not otherwise specified in tab. B310, while the cylinder is under pressure
- Observe the information provided in tab. B310 for the electronic connections
- The connectors must never be plugged or unplugged when the power supply is switched-on

7.4 Installation
- Consult tab. P002 for installation, commissioning and maintenance of electrohydraulic system
- The piping have to be dimensioned according to the max pressure and max flow rate required
- All pipes and surfaces must be cleaned from dirt before mounting
- Remove all plug screws and covers before mounting
- Make sure that connections are sealed before giving pressure to the system
- Ensure to not exchange the pipe ports when connecting the cylinders
- Bleed-off the system or the hydraulic cylinder using the proper device, see the technical data sheet for details
- Ensure that the cylinder mounting allow easy of acces for the purpose of maintenance and the adjustment of cushioning

8 MAINTENANCE

Maintenance must be carried out only by qualified personnel with a specific knowledge of hydraulics and electrohydraulics

8.1 Preliminary check and ordinary maintenance

Atos hydraulic cylinders don’t require any maintenance after commissioning. Anyway it is recommended to take into account the following remarks:
- Results of maintenance and inspection must be planned and documented
- Check oil escaping from oil ports or leakages at the cylinder heads
- Check for damages of the chromeplated surface of the rod: damages may indicate oil contamination or the presence of excessive transverse load
- Determine lubricating intervals for spherical clevises, trunnion and all parts not self-lubricated
- The rod should always be retracted during long stop of the machine or system
- Remove any salt, machining residuals or other dirt cumulated on the rod surface
- Follow the maintenance instructions of the fluid manufacturer
8.2 Repairing
Before beginning any repairing observe the following guidelines:
- Unauthorized opening of the cylinder during the warranty period results in the warranty expiration
- Be sure to use only original spare parts manufactured or supplied by Atos
- Provide all the required tools to make the repair operations safely and not damage the components
- Read and follow all the safety notes given in section 7
- Ensure that the cylinder is well locked before beginning any operation
- Disassembly or assembly the cylinder with the right order as indicated in section 8.3
- When mounting rod or piston guides and seals observe the correct position as indicated in section 8.4. Any bad positioning can result in oil leakages
- It is strongly recommended the use of expanding sleeves to insert the seals in the proper groove
- Tighten all the screws or nuts as follow: lubricates the threads, insert the screw or the nut by hand for some turns, tighten the screw crosswise with the
tightening torque specified in the technical table (a pneumatic screw driver may be used)
- Rod bearing and piston must be locked respectively to the front head and to the rod by means of special pin to avoid unscrewing
- The replacement of wear parts such as seals, rod bearing and guide rings depends on the operating conditions, temperature and quality of the fluid
8.3 Cylinders exploded views

CK* servocylinder - For spare parts see tab. SP-B310 CK/CH - For spare parts see tab.SP-B137, SP-B140 and SP-B160

CN - For spare parts see tab. SP-B180 CC - For spare parts see tab. SP-B241

Note: this symbol means that a particular equipment is required for mounting, contact our technical office

8.4 Sealing system mounting

PISTON ROD BEARING

G1-G8 G2-G4 G6 G7 G1 G2-G4-G6-G7 G8

Single effect Single effect
pushing pulling

9 TRANSPORT AND STORAGE

9.1 Transport
Observe the following guidelines for transport of hydraulic cylinders:
- Cylinders have to be transported using a forklift truck or a lifting gear always ensuring a stable position of the cylinder
- Cylinders have to be transported in horizontal position in their original packaging
- Use soft lifting belts to move or lift the cylinders in order to avoid damages
- Before any movement check the cylinders weight (due to tolerances, the weight may be 10% greater than the values specified in the technical table)

Additional parts such as pipes, subplates and transducers must never be used for lifting

9.2 Storage
Corrosion protection is achieved with alkyd primer painting RAL 9007: the primer grants a storage period up to 12 months. Additionally all cylinders are
tested
with mineral oil OSO 46; the oil film, presents in the cylinder chambers after testing, ensures the internal corrosion protection.
Anyway be care to observe the following remarks:
- When a storage in the open air is foreseen ensure that cylinders are well protected against water
- The cylinders must be inspected at least once a year and rotated through 90° every six months to preserve the seals

In case of storage period longer than 12 months, contact our technical office

B900
10 CYLINDERS TROUBLESHOOTING

TROUBLE POSSIBLE CAUSES SOLUTIONS

a) Improve the precision of the machine alignment
High lateral loads involve a premature wear of the
b) Decrease lateral loads
bronze bushing, seals and wear rings
c) Install a pivoted mounting style C-D-G-H-S-L
Fluid contaminants produce scratch and score
Check the fluid contamination class is < 20/18/15
marks on the seals
Chemical attack cause the deterioration of seals
Check seals compatibility with operating fluid
compound
High temperatures (fluid/ambient) the seals dark and a) Decrease the fluid temperature
flaked b) Install G2 sealings for high temperatures
a) Move the cylinder in a higher temperature zone
Oil leakage Low temperature (ambient) make the seals brittle
b) Install G9 seals for low temperatures
High rod speed reduce the lubricant capacity of the
For rod speed > 0,5 m/s Install G2 – G4 seals
seals
High frequency reduce the lubricant capacity of the
For rod frequency > 5 hz Install G0 seals
seals
Check the rod speed ratio in/out complies with the minimum Rmin
Output rod speed higher than the input one
value, see tech.table B015
The pressurization of the mixture air/mineral oil may
involve self combustion dangerous for the seals Bleed off completely the air inside the hydraulic circuit
(Diesel effect)
a) Limit the pressure of the system
Overpressure
b) Install G2-G4-G8 seals if overpressure cannot be reduced
Wiper or seal extrusion
Rod seals leakages may involve overpressures a) See possible causes and solutions for oil leakage troubles
among wiper and rod seal, causing their extrusion b) Install draining option L

a) Check the cushioning adjustment is not fully open, regulate it if necessary

b) Replace “fast” cushioning 1-2-3, with “slow” cushioning 4-5-6 if
Rod speed too low at end stroke
the cushioning is not effective with cushioning adjustment fully clo-
sed
Lose of cushioning effect
Cushioning adjustment cartridge with improper regu- Close the cushioning adjustment screw till restoring the cushio-
lation ning effect
Fluid contaminants produce scratch and score
Check the fluid contamination class is < 20/18/15
marks on the cushioning piston
a) Replace “fixed” cushioning 7-9 with “adjustable” cushioning 1-3
b) For adjustable cushioning, open the cushioning adjustment to
Overpressure in the cushioning chamber could
decrease the max pressure inside the cushioning chamber
Rod locked or impossible involve the cushioning piston locking
c) Check the energy dissipated by the cushioning is lower than max
to move energy dissipable, see tech.table B015
Fluid contaminants may lock the piston because of
Check the fluid contamination class is < 20/18/15
its tight tolerances
a) Check the overpressure inside the cylinder and decrease it
Overload/overpressure involves ductile rod failure b) Check the compliance with the admitted operating pressure
according to the cylinder series
Rod failure
a) Check the expected rod fatigue working life proposed in tech.
High load/pressure coupled to high frequencies or
table B015
long life expectation involves fatigue rod failure
b) Decrease the operating pressure
Seals with excessive friction could involve rod vibra-
Install low friction PTFE seals G2-G4, see tech.table B015
tion and noise
Rod vibration
Air in the circuit may involve a jerky motion of the rod Bleed off completely the air inside the hydraulic circuit

a) Decrease the temperature variations in the oil

Variations in the fluid temperature involve the fluid
b) Change the fluid type to decrease the coefficient of thermal
Rod motion without oil expansion / compression thus the rod moving
expansion
pressure
Excessive oil leakage from the piston or rod seals See likely causes and solutions for oil leakage troubles

a) Decrease the rod speed

Impact of the piston with the heads caused by high
b) Install external or internal cushioning system 1-9, see tech.table
speed ( >0,05 m/s)
B015 for the max energy that can be dissipated
Noisy cylinder Fluid contaminants, foreign particles inside the cylin-
Check the fluid contamination class is < 20/18/15
der may generate unusual noise
a) Increase the piping diameters to reduce the oil flow speed
High oil flow speed > 6 m/s
b) Install oversized oil ports, options D-Y

11 SERVOCYLINDERS TROUBLESHOOTING

TROUBLE POSSIBLE CAUSES SOLUTIONS

Improper electronic connections may involve the

Check the electronic connections scheme in tech table B310
transducer malfunctioning

Transducer Not stabilized power supply may involve dangerous

Install a voltage stabilizer
malfunctioning / failure peak of voltage

Uncontrolled disconnection and connection of plug- Be carefull to switch off the power supply before connecting the
in connectors may damage the transducer position transducer

Note: for cylinders troubleshooting refer to section 10

07/19