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User Guide: Air/Oil Hydraulic Cylinders

1. I Ceo de dh ut OX 4 ut x LX i d elata LA NM 4 E ox ECL CM SS LAMNIFLEX DIE SPRINGS ud L In many applications the forward travel of the cylinder during high pressure is limited by the application itself such as resistance wedling staking etc However for punching and piercing applications the forward travel of the cylinder must be limited after punching through the material If external resistance is not provided the cylinder rod will continue to travel causing a potential vacuum in the high pressure reservoir sections of the cylinder adversely affecting performance If a single point punch is used on the application a single spring may be located around the punch which will also act as a stripper spring We recommend use of LamniFlex Polyurethane Die Springs Please contact BTM for additional information BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 8 0 CONTROL SYSTEMS BTM Air Oil Cylinders are similar to two 2 typical air cylinders with one cylinder extending before the other and both retracting at the same time see the illustration to the right Each BTM Air Oil Cylinder requires two 2 pneumatic directional control valves for operation Pneumatic directional control valves can be e
2. HIGH PRESSURE POWER STROKE PISTON EXTEND PORT 1 CYLINDER EXTEND PORT HIGH PRESSURE SEPARATOR 82 POWER STROKE RESERVOIR FILL BLOCK RETRACT PORT COUPLING RESERVOIR PISTON RESERVOIR TUBE HIGH PRESSURE ROD HYDRAULIC VALVE BLOCK GAGE COUPLING Bi CYLINDER WORK PISTON RETRACT PORT WORK TUBE BEARING CYLINDER HEAD WORK ROD Fig 3 1 3 2 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com BTM AIR OIL CYLINDERS 0 4 0 FUNCTIONAL DESCRIPTION Note During the Approach and Retract stroke air 6 must be directed to port B2 Failure to do so may cause the high pressure rod to extend into the valve 4 1 In Line Series block therefore stopping the cylinder work rod p rry CE A1 1 Cylinder Retracted In this view air is directed to Ports B1 and B2 fully retracting the Reservoir Working and High Pressure Pistons ODD LY 2 Approach Stroke Air is directed to Port A1 The Reservoir piston advances displacing the reservoir oil through the Valve Block to the back of the Working Piston advancing the cylinder rod at low force until meeting resistance work surface or part contact 3 Power Stroke Regulated air pressure is applied to Port A2 High Pressure Piston and Rod advance until contacting the Valve Block seal isolating the reservoir oil from the oil co
3. emergency stop or output signal if a certain pressure is not reached quality control e activation of functions external to the cylinder 60 1 Gage Kit GA 1 Gage Adapter PHA Hose Assembly PB 1 Pressure Block Module SW Pressure Switch BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 13 AIR OIL CYLINDERS CONTROL CIRCUITRY DIAGRAM WY 30 LOVYLSY ONY QN3 X3 LYOd au aouanbas pasn si jeuGis jndjno eu au Buunp paddojs sey wes sapujo ON jndjno ue uondo Yoo ambas 102 jo sseoxe ut JO 1nus JJo peuunj si yup sjosues saues sapuyAo pue 175 O Z ALON SANA HOVOMddV 0 Z ALON 335 HOSN3S 035070 A TIVINHON 101043201 NIYIN HLM LIN 33OHIS 1 HOlVIn938 43113 3ATVA 37 5 H3MOd _ 4 5 HO ANN tI AVIA SSATVA 1 1VNOLLO3MIO 3LON OL 38 LSNW ILON NO 200 100 105 SHOYLS 832MOd 200 30S 100 105 NOLLWNO
4. ________ ____ a 13 Control Circuitry Diagrams oeuseeesaiVeaawxF exu Fia RUE CR E SA FR OR BOR m ERU c c rA ara 14 15 Pressure Switch wiring Schematics 114444 eese eee eii ie eee ness ses u aua a aaa aa aaa aaa Rau 16 RA RERUM p IERI E 17 In Line amp Satellite Series Cylinders 1111 17 VONNE siete 8 PA 17 Venne _______ 18 Air Pressure Hydraulic Pressure Output Force Table 19 Approach Retract Table rc 19 Problems Causes SOLUTIONS w orsa ru ELarKES VWRRRVECFAFRA RV Vn FERFEEI ARENA VES E UE FD a ad KNEE 20 Cylinder Seal Replacement 2 220 21 560 A uae E E E A eee es 21 Satellite Series Seal Location vestenacwecserqenendagaiis 22 IN LINS LOCOTION _______ 23 FOCON a SUPPONE o __ _____________ ___ __ 24 EE EA 25 SOP NOS EAEE 26 27 Disclaimer BTM Reserves the right to ammend the contents of this manual without notice Contact BTM to verify the latest revision BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com CAUTION Always disconnect air and electr
5. options provide full adjustment of the complete cylinder stroke i e 000 to 4 000 for a 4 000 stroke cylinder 1 Loosen the allen head set screw on the locking ring 2 Loosen the allen head set screw on the adjustment barrel 3 Rotate the adjustment barrel in a clock wise direction to decrease the amount of power stroke 4 Rotate the adjustment barrel in a counter clock wise direction to increase the power stroke 5 Rotate the locking ring until contacting the adjustment barrel Tighten both locking ring and adjustment barrel set screws BTM air oil cylinders ordered with the TSL option are shipped from the factory with the locking ring and adjustment barrel in a fully clock wise postiion 000 power stroke Please adjust to application requirements before use Note During the Approach and Retract stroke air must be directed to port B2 Failure to do so may cause the high pressure rod to extend into the valve block therefore stopping the cylinder work rod BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 9 10 BTM AIR OIL CYLINDERS EM 1 1 1 7 0 CYLINDER INSTALLATION 7 1 Attach the cylinder to the mounting surface with the integral head end mount Use only grade 8 bolts 7 2 Provide a way to reduce or eliminate side loading of the cylinder rod Failure to do so will cause excessive wear of the guide bearin
6. 4 00 50 FH Serial No Example 4055 It is important to provide both model In line Design serial numbers when ordering replacement 4 4 tons force 100 PSI cylinders and or seal kits 4 00 4 00 total cylinder stroke 50 50 power stroke FH mounting style BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com BTM AIR OIL CYLINDERS 2 0 GENERAL SAFETY BTM Cylinders are designed and built according to the state of the art utilizing CAD CAM techniques accepted industry standards Quality Assurance systems and trained personnel BTM Cylinders are designed and manufactured to be operationally safe However due to the nature of the product pressing there are areas of the product which cannot be protected at the factory For this reason good personal safety procedures and practices are required to protect the operator and maintenance personnel Risks may arise if the cylinder is used or maintained by untrained personnel or in any way which is inconsistent with it s intended use and or purpose 2 1 APPLICATION AND INTENDED USE BTM Cylinders may only be used for their intended purpose as a penumatic hydraulic power cylinder built exclusively for industrial applications in which pressing forces are required Any other applications are regarded as inconsistent with the inded use and the manufacturer and BTM Corporation is not liable for any
7. I S BTMCYL I S BTMCYL I S BTMCYL S BTMCYL S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S Pressure 1 Ton Series 2 Ton Series 4 Ton Series 10 Ton Series 15 Ton Series 20 Ton Series 30 Ton Series 40 Ton Series 50 Ton Series EE Hyd PSI Force Ib Hyd PSI Force Hyd PSI Force Ib Hyd PSI Force Ib Hyd PSI Force Ib Hyd PSI Force Ib Hyd PSI Force Ib Hyd PSI Force Ib Hyd PSI Force Ib 210 670 330 1636 316 2626 396 7785 480 9422 591 11601 651 19540 852 24086 630 31663 280 893 440 2181 422 3501 528 10380 644 12641 788 15468 921 26053 1136 32114 840 42218 350 1117 550 2727 528 4377 661 12975 805 15802 985 19335 1152 32567 1420 40143 1050 52773 EN 420 1340 660 3272 633 5252 793 15570 966 18962 1182 23202 1382 39080 1704 48172 1260 63327 490 1563 110 3817 139 6127 925 18165 1127 22123 1379 27069 1612 45593 1988 56200 1470 73882 560 1787 880 4363 844 7003 1057 20760 1288 25283 1576 30936 1843 52107 2272 64229 1680 84436 630 2010 990 4908 950 7878 1189 23355 1449 28443 1773 34803 2073 58620 2556 72258 1890 94991 700 2234 1100 5454 1056 8754 1322 25950 1600 31408 1970 38671 2304 65134 2840 80286 2100 105546 11 1 APPROACH RETRACT TABLE Tolerance for data 5 90 values in pounds Ib Air BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S Pressure 1 Ton Series 2 Ton Series 4 Ton Series 10 Ton Series 15 Ton Series 20 Ton Series 30 Ton Series 40 Ton Series 50 Ton Series Approac
8. PT or electrical ELT signal when the air exhausting from the B1 cylinder port has decayed to 6 PSI indicating the cylinder rod and customer tooling have made contact with the work surface see illustration to the right Please refer to pages 14 15 for detailed enlarged view of control circuitry drawing 12 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 8 2 OIL PRESSURE MONITORING BTM Air Oil Cylinders are equipped with an IC 1 gage port coupling refer to page 3 1 for location The IC 1 provides an easy to connect threaded coupling for attachment of e Oil Pressure Gage e Oil Pressure Switch e Pressure Electronic Transducer e Oil Pressure Hose Assembly When attaching any monitoring device to the cylinder make sure the device and connecting lines are filled with oil Failure to do so will impair the function of the monitoring device and allow air into the reservoir section of the cylinder Pressure monitoring devices such as switches and transducers are used to verify that the internal oil pressure of the cylinder has achieved a customer specified pressure As a result the following control functions can be obtained e changeover to retract stroke when a user specified oil pressure has been reached oil pressure is proportional to cylinder output force e dwell time for the retract stroke for applications such as embossing or riveting
9. extend Compressed air supply insufficient Increase air pressure Directional control valves not shifting Repair replace valve Sideloading of the cylinder rod Repair install alignment coupling misalignment of the rod and tooling Air is not applied to the B2 cylinder port Repair control circuit during the approach or retract stroke 12 2 Cylinder Rod Doesn t Retract PROBLEM SOLUTION Cylinder rod doesn t retract Compressed air supply insufficient Increase air pressure Directional control valves not shifting Repair replace valve Sideloading of the cylinder rod Repair install alignment coupling misalignment of the rod and tooling Air is not applied to the B2 cylinder port Repair control circuit during the approach or retract stroke 12 3 Cylinder Will Not Develop Power Stroke PROBLEM CAUSE SOLUTION Cylinder will not develop power Compressed air supply insufficient Increase air pressure stroke Directional control valves not shifting Repair replace valve Reservoir oil is low Refill reservoir Insufficient power stroke for application air has been allowed into the oil sections of Vent and or refill cylinder the cylinder 20 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 13 0 CYLINDER SEAL REPLACEMENT 1 Before disassembly of the cylinder ensure all air lines have been disconnected WARNING Disas
10. 040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 1 AIR OIL CYLINDERS 6 0 FUNCTIONAL DESCRIPTION 6 2 Power Stroke Limiter Option The Power Stroke Limiter option PSL limits the travel of the high pressure piston and rod assembly during the power stroke cycle of the cylinder The PSL option limits the power stroke only It does not limit the total stroke of the cylinder work rod 6 3 Adjusting the PSL Limiting the stroke of the high pressure piston and rod assembly after it comes into contact with the valve block seal permits control of the amount of oil displaced by the high pressure rod during the power stroke cycle The amount of travel is determined by adjusting the locking ring and barrel assembly located on the cap end of the cylinder Rotation of the adjustment barrel in a clock wise direction decreases the amount of power stroke Rotation of the adjustment barrel in a counter clock wise direction increases the power stroke The PSL option provides full adjustment of the complete power stroke i e 000 to 500 for a 500 power stroke cylinder 1 Loosen the allen head set screw on the locking ring 2 Loosen the allen head set screw on the adjustment barrel 3 Rotate the adjustment barrel in a clock wise direction to decrease the amount of power stroke 4 Rotate the adjustment barrel in a counter clock wise direction to increase the power stroke 5 Rotate the locking ring until cont
11. 734281 User Guide Air Oil Hydraulic Cylinders Air Powered Hydraulic Cylinders for Forming and Assembly Eleven standard sizes available from 1 to 100 tons Two standard design configurations available Ideal for a wide variety of applications CORPORATION www B IMcorp com 810 364 4567 2 BTM AIR OIL CYLINDERS TABLE OF CONTENTS Patents and Registered Trademarks 3 Product spss a _____ ___ ____ 3 General 4 Application and Intended Use 22 4 aa ET dd E AE EA ee ear eee E Eroguot WSS CHI a Dior __ ____ _ i aS 4 Cylinder Port Locations saci M 5 Cylinder COUDIIDnE LOCATIONS 5 Cylinder Components 5 Functional DOSCKIDUION ___ _ 6 9 6 cuc 7 LIMI OT 8 orbe 9 Cylinder InstallatlOl ___ _ _ _ _ 10 CONTO ____ _ 6 ______ dE 11 Sequence from Approach Stroke to Power Stroke 12 Pressure 0 _____
12. IS3a 1909 H3ONI1AO O319VH13H 105 100 200 jojid 0 ILON MO138 01 ILON 338 1019 dl SATWA TOS LO Wd WNOILdO BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 14 CONTROL CIRCUITRY DIAGRAM SEQUENCE OF OPERATION CYL RETRACTED SOL 001 003 ON SOL 002 004 CYLINDER PORT OFF DESIGNATION EXT RAM SOL 002 003 ON SOL 001 004 OFF PWR STROKE SOL 002 004 ON SOL 001 003 OFF NOTE AIR MUST BE APPLIED TO THE B2 CYLINDER NOTE DIRECTIONAL CONTROL VALVES MAY BE 4 PORT 4 WAY OR 5 PORT 4 WAY OPTIONAL FLOW CONTROL p POWER STROKE PILOT SOL soL 001 S0L 003 OPERATED CHECK AE aN li sOL 004 VALVE VAEVE ELT PAR Ub KFA FILTER REGULATOR LUBRICATOR UNIT WITH MAIN AIR LOCK OUT STROKE SEQUENCE SENSOR IF AIR PILOT SEE NOTE 1 0 BELOW APPROACH VALVE NOTE 1 0 Air pilot operated 1 check valve will require use of a shuttle valve Inputs to shuttle valve are A1 and B1 cylinder ports DWG NO 2 Output from the shuttle valve to pilot port on air operated check valve PORT DURING EXTEND AND RETRACT OF THE RAM 15 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fa
13. acting the adjustment barrel Tighten both locking ring and adjustment barrel set screws BTM air oil cylinders ordered with the PSL option are shipped from the factory with the locking ring and adjustment barrel in a fully clock wise postiion 000 power stroke Please adjust to application requirements before use 8 Note During the Approach and Retract stroke air must be directed to port B2 Failure to do so may cause the high pressure rod to extend into the valve block therefore stopping the cylinder work rod Locking Ring Adjustment Barrel BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 6 0 FUNCTIONAL DESCRIPTION 6 3 Total Stroke Limiter Option The Total Stroke Limiter option TSL limits the travel of the working piston and rod assembly during the operation of the cylinder The TSL option limits the total stroke of the cylinder work rod 6 4 Adjusting the TSL Limiting the stroke of the working piston and rod assembly by a mechanical link to the adjustment barrel permits control of the amount of total cylinder travel The amount of travel is determined by adjusting the locking ring and barrel assembly located on the cap end of the cylinder Rotation of the adjustment barrel in a clock wise direction decreases the amount of power stroke Rotation of the adjustment barrel in a counter clock wise direction increases the power stroke TSL
14. are expressly excluded In addition BTM shall not be held liable for consequential damages such as loss of profit delays expense or breach of any contract or injury resulting from inadequate guarding BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 25 BTM AIR OIL CYLINDERS NOTES 26 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 5 CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 21 has wide range of products to meet your needs including but definitely not limited to PNEUMATIC CLAMPS amp GRIPPERS SHEET METAL JOINING Light amp Heavy Duty Clamps Tog L Loc Clamps range from light duty BTM s Tog LLoc sheet metal omni directional head clamps to joining system is a cold forming heavy duty precision sealed power process that quickly joins pre clamps 13 painted galvanized coated and dissimilar metals 6 6 6 6 6 BIM s Gripper line ranges from BTM s Lance N Loc Joining compact light duty models to System produces clean strong locking amp non lo
15. cking heavy duty and consistent joints in most models coated or uncoated metals PIN PRODUCTS Ways to Tog L Loc Precision Shot Pin cylinders BTM s Precision Part Locators are used whenever your production needs require locating precise holes in a workpiece Press Brakes Handheld Units Pin Locator Clamps 5 Pin Locator Clamps and Single Finger clamps are used in stationary part nests welding fixtures transfer systems robot end effectors and numerous other clamping applications These clamps locate and hold the work while other operations are performed Die Sets Universal Presses Standard pin sizes range from 12 5mm 40mm Specialized Units For more information or to see our full line of products please visit WWW B I McoRP coM
16. container of suitable size 3 Depress and hold the manual overide on the fast approach directional control valve until all oil and air have been vented from the cylinder Disconnect the fill coupling Release manual overide 4 Reattach the fill unit coupling and line to the fill unit Refill cylinder with oil refer to 9 1 10 1 2 Satellite Series 1 Position the booster reservoir unit and working cylinder vertically as shown in the illustration below The Vent Port Fitting located on the cap end of the work cylinder must be at a greater or equal height then the booster reservoir unit 2 Fill the HFP 2 fill unit with ISO 32 oil or equivalent 3 Depress the inner ring on the fill unit coupling opening coupling and depress the fill unit handle until all air has been vented from the fill unit tubing Close coupling 4 Remove the black rubber dust cover from the cylinder fill coupling Connect fill unit to cylinder 5 Loosen the vent port fitting located on the cap end of the work cylinder Repeatedly depress the fill unit handle until all air has been vented from the vent port fitting Disconnect fill unit from cylinder Procedure complete Vent Port Fitting BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 11 0 AIR PRESSURE HYDRAULIC PRESSURE OUTPUT FORCE Tolerance for data 5 90 values in pounds Ib Air BTMCYL
17. damage resulting therefrom the risk being assumed in this case by the user Arbitrary changes or modifications to the cylinder mechanical hydraulic or pneumatic exempt Aries Engineering Co Inc the manufacturer and BTM Corporation from any liability for any damage resulting therefrom 2 2 OPERATING SAFETY Work on power driven equipment should only be entrusted to persons who a are confidently able to carry out the work on their own b are under the supervision of someone familiar with this work after previous training or are accordingly authorized to perform the work 3 0 PRODUCT DESCRIPTION BTM Cylinders are purely pneumatically driven cylinders with an integral pneumatic hydraulic power stroke Power stroke initiation is user preference of either distance time delay or part contact opposing force Cylinder construction is of modular sandwich design joined together with depending upon the model four or eight tie rods All other parts are inserted into the cylinder BTM cylinders operate with compressed air from 30 to 100 PSI approx 2 to 7 bar maximum Output forces in Power Stroke range from 670 to 142 900 Ib 1 5 kN to 1750 kN depending on the model 4 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 3 1 CYLINDER PORT LOCATIONS IN LINE SERIES 3 2 CYLINDER COUPLING LOCATIONS 3 3 CYLINDER COMPONENTS IDENTIFICATION TAG
18. g seals and wear strip Cylinders returned for repair with indications of side loading will not be covered under warranty 7 3 cylinders are provided with a high pressure gage coupling and reservoir fill coupling Allow room to access for future options and cylinder service 7 4 Punching and piercing applications must provide and external resistance to the cylinder rod and tooling prior to break through see the illustration below Failure to do so may cause a vacuum inside the cylinder adversely effecting performance 7 5 Air directional control valves should be mounted within five 5 feet of the cylinder Use of suitable diameter tubing tube I D equal to the cylinder port size is recommended 7 6 Install an air lock out valve on the main air supply line upstream to the directional control valves If the air supply is to be shut off for an extended period of time and tooling weight exceeds 2596 of the cylinder approach force mechanically block tooling in the retracted position 7 7 Do not exceed 100 PSI air pressure to the cylinder 7 8 Use of clean filtered air 4O micron minimum is mandatory Light lubrication of the supply air will extend cylinder service life tatur OC M T E ma atate ta tutatus 0 e te z gt rE Putus ww at rere CX X J yu
19. h Retract Hyd PSI Force Hyd PSI Force Ib Hyd PSI Force Ib Hyd PSI Force Hyd PSI Force Ib Hyd PSI Force Ib Hyd PSI Force Ib Hyd PSI Force 94 70 147 123 248 204 588 494 588 494 588 494 848 701 848 701 1507 1296 125 94 196 164 331 272 785 659 785 659 785 659 1130 934 1130 934 2010 1728 50 157 117 245 205 414 340 981 824 981 824 981 824 1413 1168 1413 1168 2513 2160 188 141 294 246 497 408 1177 989 1177 989 1177 989 1696 1402 1696 1402 3015 2592 219 164 343 287 580 476 1374 1154 1374 1154 1374 1154 1978 1635 1978 1635 3518 3024 251 188 392 328 663 544 1570 1319 1570 1319 1570 1319 2261 1869 2261 1869 4020 3456 9 282 211 441 369 746 612 1766 1484 1766 1484 1766 1484 2544 2103 2544 2103 4523 3888 314 235 490 411 829 681 1963 1649 1963 1649 1963 1649 2827 2337 2827 2337 5026 4320 11 1 1 Cylinder Break away Forces New Air Oil Cylinders may require 35 PSI of air pressure for the fast approach and retract stroke Typically 50 PSI of air pressure is recommended for reliable operation until the cylinder seals have seated Please refer to the Quality Assurance certification bulletin attached to the cylinder for specific minimum break away air pressures BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 19 AIR OIL CYLINDERS 12 0 PROBLEMS CAUSES SOLUTIONS 12 1 Cylinder Rod Doesn t Extend Cylinder rod doesn t
20. ical supply lines before working on or around Air Oil Cylinders BTM s Air Oil Cylinders are precision devices designed to produce very high output forces utilizing a compressed air supply Appropriate safeguards to protect both the operator and maintenance personnel are the responsibility of the end user Please read this user guide before proceeding with the installation or maintenance of a BTM Air Oil Cylinder WARNING Dissassembling the cylinder prior to the expiration of the warranty will void the warranty Do not modify the working components of the cylinder without written authorization 1 2 PATENTS AND REGISTERED TRADEMARKS The BTM Air Oil Cylinders featured in this User Guide are patented products which are licensed under agreement by BTM Corporation Rights Reserved This user guide is copyrighted and may not be copied reproduced or distributed without expresed written permission of BTM Corporation BTM reserves the right to change product specification and related support materials without notice This manual covers standard BTM Air Oil Cylinders Special cylinders may not be covered Contact BTM for more information 1 3 PRODUCT IDENTIFICATION BTM Air Oil Cylinders are shipped from the factory with an identification plate attached to the cap end of the cylinder The identification plate contains the cylinder model number and serial number MOD NO SERIAL NO Model No Example BTMCYL 1 4
21. ither mechanical solenoid or remote air piloted Valve size must be of suitable flow to permit proper cylinder function refer to catalog for cylinder air consumption Pneumatic flow control valves may be customer installed metered out at cylinder ports B1 and B2 to control the speed of the cylinder and speed of the power stroke Please ensure the main air supply is dry clean 40 micron and if possible lightly lubricated Unique to the BTM Air Oil Cylinder design is the ability to regulate the Approach Stroke force independently from the Power Stroke Force through use of separate air regulators Stacking regulators installed on the valve manifold are recommended for best performance Please refer to pages 14 15 for detailed enlarged view of control circuitry drawing BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 11 BTM AIR OIL CYLINDERS 8 1 SEQUENCE FROM APPROACH STROKE TO POWER STROKE BTM Air Oil Cylinders may be sequenced into the power stroke anywhere within the total stroke of the cylinder Sequencing into the power stroke is customer defined Recommended suggestions are Time Delay External Proximity Switch Threshold Sensor The BTM Air Oil Cylinders PT and ELT series threshold sensors are a threshold not sensor installed directly into the cylinder B1 port Both sensors provide either a pneumatic
22. llite Series Work Cylinder Fig 15 1 1 15 2 Satellite Series Reservoir Booster Unit Fig 15 2 1 Fig 15 1 1 wow ww 1 4 T An state sts Lx X te es es e ode dede de E M x x x x Lx t ata L AU nhe 08 11 12 13 Fig 15 2 1 Reservoir Piston O D Seperator Block O Ring Teflon Wear Ring High Pressure Piston O Ring 2 eio 22 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 16 0 IN LINE SERIES SEAL LOCATION 17 1 In Line Series Cylinder Fig 17 1 1 04 14 13 10 09 11 087 07 06 05 04 02 03 01 Fig 17 1 1 aie 6 moms 41 Work Piston U Cup Hyd LIENNNLL NN Rod Wiper Description 14 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 23 AIR OIL CYLINDERS SSE ee 17 0 TECHNICAL SUPPORT application engineers are available during normal business hours to provide technical support You can reach an application engineer through one of the following contact methods Phone 810 364 4567 Fax 810 364 6178 Email sales btmcorp com Normal business hours are from 8 00a
23. m to 4 30pm EST Please have the cylinder model number and serial number when inquiring about a specific cylinder or replacement parts If you have an emergency outside of normal business hours please call 810 364 4567 and follow the instructions 24 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com Warranty Information Corporation warrants its Air Oil Cylinders to be free from defects in material or workmanship for a period of thirty six 36 months from the date of shipment to the Distributor or Customer provided any defect escaping our detection be reported in writing within thirty six 36 months from the date of shipment to the Distributor or Customer The warranty is limited to repairing or replacing at BTM s option F O B BTM s factory any part which upon inspection is found to be defective This warranty shall not apply a to product which has been repaired or altered by parties other than BTM b to product which has been subjected to negligence accident or damage by circumstances beyond the control of AEC or to improper installation operation maintenance storage or normal wear The above warranty comprises the company s sole and entire warranty obligation and liability in connection with BTM products All other warranties expressed or implied including without limitation warranties or merchantability and fitness for a particular purpose
24. ntained in the working section Continued movement intensifies and displaces the trapped oil developing the Power Stroke Step 1 returns all three pistons and oil to the retracted position BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 5 0 FUNCTIONAL DESCRIPTION 5 1 Satellite Series 1 Cylinder Retracted In this view air is directed to Ports B1 and B2 fully retracting the Reservoir Working and High Pressure Pistons 2 Approach Stroke Air is directed to Port A1 The Reservoir piston advances displacing the reservoir oil through the Valve Block to the back of the Working Piston advancing the cylinder rod at low force until meeting resistance work surface or part contact 3 Power Stroke Regulated air pressure is applied to Port A2 High Pressure Piston and Rod advance until contacting the Valve Block seal isolating the reservoir oil from the oil contained in the work ing section Continued movement intensifies and displaces the trapped oil developing the Power Stroke Step 1 returns all three pistons and oil to the retracted position Note During the Approach and Retract stroke air must be directed to port B2 Failure to do so may cause the high pressure rod to extend into the valve block therefore stopping the cylinder work rod T E d ree Ie LIES EE CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48
25. r rod 3 Depress the inner ring on the fill unit coupling opening coupling and depress the fill unit handle until all air has been vented from the fill unit tubing Close coupling 4 Remove the black rubber dust cover from the cylinder fill coupling Connect fill unit to cylinder 5 Repeatedly depress the fill unit handle until the handle becomes difficult to depress cylinder is full 6 Disconnect the fill unit from the cylinder Replace rubber dust cover Push in indicator pin Procedure complete 10 0 VENTING BTM Air Oil Cylinders utilize a patented total air oil separation system which under normal operating conditions eliminates the possibility of air entering into the working and reservoir sections of the cylinder Improper installation of oil pressure monitoring devices and or removal of either gage or fill couplings will permit air to enter both oil sections of the cylinder Air intrained in the oil will adversely effect cylinder performance BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 17 BTM AIR OIL CYLINDERS I 10 1 VENTING PROCEDURE 10 1 1 In Line Series 1 Remove the fill line and coupling from the HFP 2 fill unit Retract cylinder and block in retracted position 2 Remove the black rubber dust cover from the cylinder fill coupling Connect the fill coupling to the cylinder Place the opposite end of the fill line into a
26. sembly of this device while under air pressure may cause the components to suddenly come apart 2 Drain oil from cylinder reservoir by connecting the HFP 2 fill unit to the cylinder fill coupling Depress the manual override on the directional control valve until oil has stopped flowing from the cylinder 3 Loosen cylinder tie rods evenly Remove tie rods Disassemble components 4 Remove seals and clean parts carefully Replace seals noting seal direction and location suggestion remove clean and replace seals one component at a time 5 Assemble device 6 Tighten tie rods evenly to specified torque value see chart below f Refill cylinder with oil section 9 1 on page 17 BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S BTMCYL I S 1 Ton Series 2 Ton Series 4 Ton Series 10 Ton Series 15 Ton Series 20 Ton Series 30 Ton Series 40 Ton Series 50 Ton Series 18 ft Ib 20 110 ft Ib 110 ft Ib 110 ft Ib 350 ft Ib 350 ft Ib 470 ft Ib 14 0 SEAL KIT PART NUMBERS 14 1 Cylinder model number and serial number must be supplied when ordering replacement seal kits Refer to the chart below for part numbers Model Series Part No 66 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 21 AIR OIL CYLINDERS 15 0 SATELLITE SERIES SEAL LOCATION 15 1 Sate
27. x 810 364 6178 www BTMcorp com BTM AIR OIL CYLINDERS PRESSURE SWITCH WIRING SCHEMATICS SWA 01 50 1000 PSI SWA 02 250 5000 PSI 48 30 VDC PNP Output Micro DC Connection Normally Open Normally Closed SWA 03 50 1000 PSI SWA 04 250 5000 PSI 102 132 VAC Solid state Relay Output Mini AC Connection SWD 01 50 1000 PSI SWD 02 250 5000 PSI Analog 4 20 ma Output and Switching Output 20 30VDC Supply Micro DC Connection SW 01 150 2300 PSI ACIDC Supply Contact Output 3 Pin DIN Connector 16 BTM CORPORATION 300 DAVIS ROAD MARYSVILLE MI 48040 Tel 810 364 4567 Fax 810 364 6178 www BTMcorp com 9 0 REFILLING CYLINDERS All BTM Air Oil Cylinders are pre filled and tested at the factory The internal oil reservoir contains sufficient excess oil 3096 that with normal operation will operate for millions of trouble free cycles All units are supplied with a reservoir fill coupling identified as F on the cylinder The fill coupling is protected by a black rubber dust cap Cylinders are also equipped with a low oil level indicator pin 4 Ton and larger which will extend outward approximately 3 16 when the cylinder requires refilling To refill the cylinder please use only the unit part number HFP 2 Fill with an ISO 32 hydraulic oil 9 1 IN LINE amp SATELLITE SERIES CYLINDERS 9 2 Filling Procedure 1 Fill the HFP 2 fill unit with ISO 32 oil or equivalent 2 Retract cylinde

User Guide: Air/Oil Hydraulic Cylinders

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