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Vortex® manufactures slide gates, diverters, and iris valves for handling dry bulk solids.
USA EUROPE
Version 09.18.2008
Manufacturer's Declaration
Vortex hereby declares that the design of DVC series pneumatic cylinder components supplied
by us are intended for installation in a machine of the design supplied and that commissioning
thereof is prohibited until it has been established that the machine into which the above is to be
installed meet the EC directives for machinery and the amendment directives below.
USA EUROPE
Section One
Preface 1
Safety 1
Prior to Installation 1
Hazard Labels 1
Explanation of Symbols 2
Section Two
Function 3
ATEX Environments 3
Intended Use 3
Section Three
Warranty 4
Section Four
General Maintenance 5
Suggested Routine Maintenance and Inspection (ATEX Applications) 5
Cleaning and Wash-down Procedures 5
External cleaning 5
Section Five
Technical Data 6
Section Six
Troubleshooting 8
Section One
Preface
Detailed product specifications, intended use, general operating instructions and the conformity declaration
are contained within this document.
Safety
The installation, operating and maintenance instructions contain safety information to:
Prior to Installation
Do not energize this product until installation has been completed and all safety/precautionary steps have been
taken.
Remove all transport safety measures such caps, plugs, or protective film.
Salina Vortex Corporation strongly recommends that a vented ball valve be installed within 12” of the air
cylinder to block the compressed air from reaching the air cylinder, and vent the residual compressed air in the
air cylinder during shut-down and servicing. Such ball valve should be equipped with a lock out device for the
“off” position. Proper lock-out and tag-out procedures should be followed when using the ball valve to perform
service on the cylinder. Refer to specific lock-out and tag-out procedures for each piece of equipment.
Hazard labels
The safety alert symbol is used to identify safety information about hazards that can result in personal injury.
Page 1 Copyright 2008 – Salina Vortex Corporation
A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the
potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.
DANGER indicates a hazard that, if not avoided, will result in death or serious injury.
WARNING indicates a hazard that, if not avoided, could result in death or serious
injury.
CAUTION indicates a hazard that, if not avoided, might result in minor or moderate
injury.
Explanation of symbols
These symbols are provided to highlight information regarding proper use of equipment and operator safety.
Please ensure all personnel have read and understand this information.
Caution: Explosive
Safety Alert
Atmosphere
Caution: Amputation
Information
Hazard
Caution: Laceration
CE Mark
Hazard
ATEX Environments
Detailed product specifications and technical data contained within this document must be adhered to in
whole in order for the product to meet ATEX requirements. The Conformity Declaration must also be
observed. Always observe the maximum permitted limits contained in this manual.
Intended Use
The cylinder has been designed for use in explosive environments in accordance with the regulations
specified by the ATEX directive 94/9/EC. Operational safety can only be guaranteed if the cylinder is used
as intended.
The cylinders intended use is to;
• Move loads
• Apply force in the linear direction of the piston rod
• Be driven with compressed air
• Be used under the specified conditions in zones 1 and 2 of potentially gas atmospheres and zones
21 and 22 of potentially explosive dust atmospheres.
• Be used in its original and unmodified condition without any modifications. The right of use will be
withdrawn if modifications are made by the user.
If the cylinder is used in a manner other then “intended use”, this classifies as “inappropriate use” and
could result in injury to persons or damage to property.
→ The device must be operated only with compressed air of quality class 5 to DIN ISO 8573-1.
→ The device is not intended for use with fluids or gases (compressed air only).
→ Usage as a spring or cushioning element is not part of intended use as unacceptable loading may
occur.
→ The system integrator is responsible to ensure the cylinder is installed by qualified personnel who
work in accordance with the explosion protection regulations.
The discharge of electrostatically charged parts can lead to sparks which can cause an explosion.
Prevent electrostatic discharge by means of suitable installation and appropriate cleaning measures
Include the device in the grounding of the system / equipment
A. THE BUYER’S EXCLUSIVE REMEDY AND SVC’S ENTIRE LIABILITY IN CONTRACT, TORT, OR
OTHERWISE IS STRICTLY LIMITED TO REPAIR, REFUND OF PURCHASE PRICE PAID FOR, OR
REPLACEMENT IN KIND OF ANY NONCONF ORMING ITEMS, PROVIDED THOSE PRODUCTS ARE
RETURNED TO SVC PREPAID. SVC RESERVES THE RIGHT TO DECIDE WHICH OF THESE
EXCLUSIVE REMEDIES SHALL BE EXERCISED.
C. An “Instruction and Operating Manual” (referred to herein as “IOM”) will be included with each
shipment. Buyer assumes responsibility to read and understand the IOM prior to installation and
operation of the products. Additional copies of the IOM are available upon request.
WHEN PLACING A SLIDE GATE OR DIVERTER VALVE IN A CORROSIVE ENVIRONMENT, CARE MUST BE TAKEN TO
ENSURE ALL COMPONENTS ARE COMPATIBLE WITH THE ENVIRONMENT AND CONTACT MATERIAL. CORROSION
OF COMPONENTS MAY CAUSE EXCESSIVE HEAT BUILD UP WHEN ACTUATING THE CYLINDER.
INADEQUATE CLEANING OF THE VALVE COULD CAUSE CORROSION, RESULTING IN FRICTION, EXCESSIVE HEAT
GENERATION, OR ERRATIC PISTON ROD MOVEMENT.
OPERATING THE CYLINDER WITHOUT DOING REGULARLY SCHEDULED MAINTENANCE COULD CAUSE THE
MECHANISM TO BECOME PITTED AND DAMAGED AND CAUSE FRICTION AND HEAT GENERATION. SCHEDULED
MAINTENANCE IS DETERMINED BY THE APPLICATION AND USE OF THE CYLINDER.
The following maintenance work can be carried out by the integrator / operator
If any other cylinder service / repair work is required, remove the cylinder and return it to Salina Vortex
Corporation for evaluation and repair.
Check the compressed air connections; tighten to proper torque specification if required (See DVC Series
Pneumatic Cylinder Rebuild Instructions).
Visual inspection of the piston rod (see troubleshooting).
Lubricate the cylinder after every 100,000 actuations.
(see technical data for information on grease and lubricants)
Clean exterior surfaces
Check the device regularly to ensure proper function. The inspection interval should be after one million
cycles or every six months, whichever comes first.
If the device is in a dusty environment the service life will be diminished due to increased wear on the piston
rod and guide bearing.
When using actuators in an ATEX environment, periodic cleaning must be performed. Cleaning is to be
done either with a vacuum cleaner approved for use in explosive zones, or with a damp cloth. Solvents or
dry wool cloths must never be used for cleaning purposes.
REMOVE ALL COMPRESSED AIR POWER SOURCES, INCLUDING ANY STORED OR RESIDUAL
ENERGY BEFORE PERFORMING CLEANING OR WASHDOWN PROCEDURES ON ANY CYLINDER.
SEE SPECIFIC LOCK-OUT OR TAG-OUT PROCEDURES BEFORE CONTINUING.
External cleaning
All standard cylinders are designed to accommodate low pressure water washdown.
DVCM 5 x 12 -MG
Bore *Max
Size Standard Stroke (in) Stroke
(in) (in)
2.5 Specify stroke in inches 45
3 Specify stroke in inches 55
3.5 Specify stroke in inches 60
4.5 Specify stroke in inches 60
5 Specify stroke in inches 60
6 Specify stroke in inches 41
8 Specify stroke in inches 23
*For ATEX applications only, the stroke (cylinder volume) is limited to less than 20 Liters @ 10 bar pressure.
Figures in the body of this chart are not physical volume of the cylinder. They show the cubic feet of free
(uncompressed) air at normal atmospheric conditions (STP) that would be contained in a 1 inch column length of
cylinder barrel if that air were compressed to the gauge pressure shown at the top of the column.
Cylinder
70 PSI 80 PSI 90 PSI 100 PSI 110 PSI 120 PSI
Bore
2.5 0.0163 0.0183 0.0204 0.0223 0.0240 0.0260
3.0 0.0235 0.0267 0.0291 0.0319 0.0408 0.0372
3.5 0.0319 0.0357 0.0395 0.0433 0.0471 0.0508
4.5 0.0563 0.0467 0.0656 0.0730 0.0790 0.0840
5.0 0.0655 0.0735 0.0810 0.0890 0.0970 0.1030
6.0 0.0942 0.1050 0.1170 0.1250 0.1390 0.1500
8.0 0.1640 0.1830 0.2060 0.2220 0.2400 0.2600
Most problems in fluid power circuits result in a gradual or sudden loss of power in the cylinder, which may cause
them to stall or move slower than required.
This chart assumes all other components in the pneumatic circuit have been checked and the problem has been
isolated to the cylinder. Properly installed and maintained cylinders should function for millions of cycles.
Premature cylinder failures are usually caused by system or environment problems that can be prevented. The
purpose of this chart is to aid in identifying and correcting the most common causes of premature cylinder failure.
* For ATEX environments only, repairs of this nature can only be undertaken by qualified personnel.
Please contact Salina Vortex Corporation for more information.
Warning
Before removing or repairing cylinder, remove any power
sources, relieve any residual pressure, and apply all applicable
lockout / tag out procedures.
Required Tools:
Snap Ring Pliers
Pick Tool
Barrel Nut Tool
o Snap on Part# SW32E – 0.31 Tie Rod
o Snap on Part# A26A – 0.50 Tie Rod
o Snap on Part# A-17 – 0.63 Tie Rod
Socket
o 1-1/8 for 3/4-10 Hex Nut
o 1-1/2 for 1-8 Hex Nut
Torque Wrench
Ring compressor sleeve tool (optional)
Recommended Lubricant:
Jet Lube
Semi-synthetic multi purpose lubricant w/ PTFE
0˚F (-18˚) to 400˚F (204˚C)
1. Once the cylinder is removed from service, fully bar). *Removal of Front Head Flange (01) is
retract the Piston Rod (04) and remove any port required when corroded or worn parts do not allow
connections. The Rod Bushing assembly allows for extraction of the Cylinder Bushing using the
for easy removal and replacement without method prescribed above. In this case, the
disturbing the Tie Rods (06). Cylinder Bushing will need to be extracted from the
back side of the Front Head Flange using a socket
2. Remove any burrs from the Piston Rod shaft and or round bar of appropriate diameter. Use caution
wrench flats as these will cause premature seal not to damage or gouge the bushing cavity as this
failure. Secure the cylinder, rod end up if possible, will require replacing the Front Head Flange.
and remove the Bushing Retaining Ring (08) from
the Front Head Flange (01). 4. Lightly lubricate the new seals, bushing and rod
wiper. Replace onto Piston Rod (04) in reverse
3. Remove the Bushing Retaining Washer (09), Rod order being careful not to damage them as they
Wiper (10), Cylinder Bushing (11), and U-cup Seal are gently depressed into the cavity from which
(20) from the Front Head Flange (01). To remove they were removed.
the Rod Bushing Seals on smaller cylinders place
your thumb over the rod end port connection and 5. Replace the Bushing Retaining Washer (09) and
give a quick pull on the piston rod. For larger install the Bushing Retaining Ring (08). Stroke the
cylinders use low pressure air below 15 psig (1
3. Remove the Cylinder Tube (05) and Piston Rod 12. Install High Collar Lock washers into recess in
Assembly. Remove the green Tube Gaskets (13) Front Head Flange and thread Barrel Nuts (07)
from the groove of the Front and Rear Head onto Tie Rods until snug. Place cylinder
Flanges (01, 02). Clean groove and remove any horizontally onto work surface to align Front and
debris. It is not necessary to remove the Tie Rods Rear Head Flanges.
(06) from the Rear Head Flange (02) for servicing,
unless they are damaged. The Piston (03) does 13. Tighten Barrel Nuts (07) in a cross sequence
not have to be removed to facilitate replacement of pattern to proper torque using the Barrel Nut tool
U-cup Seals (16). listed above. Check each Barrel Nut a second
time after reaching recommended Torque.
4. To remove the Piston (03) from the Piston Rod
(04), place Piston Rod in a vice using the wrench Rec Rec
flats to restrict rotational movement while removing Tie Rod
Bore Torque ft- Torque N-
the Piston Rod Nut (18). The Piston Rod Nut is Dia.
lb. m
dimpled and may require an impact wrench to
2.5 5/16-24 16 22
remove. If Piston is removed from Piston Rod,
replace Piston Rod O-ring (15) 3.0 5/16-24 16 22
3.5 1/2-20 64 87
5. After removing all seals from Piston Rod assembly, 4.5 1/2-20 64 87
thoroughly clean all surfaces with non-petroleum 5.0 1/2-20 64 87
based cleaner. Repeat the same procedure for the
6.0 1/2-20 64 87
Cylinder Tube inspecting it for marks or gouges
which will cause premature cylinder failure. 8.0 5/8-18 125 170
Replace if necessary.
14. Perform steps 4 and 5 as listed in “Replacing the
6. Lubricate new U-cup Seals (16) thoroughly and Rod Bearing Assembly”.
replace onto Piston (03) making sure of proper
orientation (cup portion of seals oppose each 15. Install port connections and actuate, testing
other). cylinder for leaks at normal operating pressure in
both extend and retract positions. Soapy water or
7. Reinstall the Magnetic Strip (21) (if required). window cleaner works well as a means to “bubble
Lightly lubricate the White Teflon Strip (17) and test” the connections between the Cylinder Tube
place in center groove of the Piston (03). (05) and the Front and Rear Head Flanges (01,
02). Also spray the area around the Piston Rod
8. Apply a thin coat of lubricant to inner wall of where it protrudes from the Front Head flange (01).
Cylinder Tube (05) making sure to cover all If leakage occurs, the cylinder will need to be dis-
surfaces completely. assembled to address the area of leakage.
9. Place Rear Head Flange (02) on smooth even 16. The cylinder is now repaired and ready to be
surface with Tie Rods (06) extending vertically. installed into service. Make sure all safety
Install Tube Gasket (13) into recess in Rear Head procedures are followed when commissioning the
Flange making sure it fits completely into groove. cylinder. Be sure to start at a low pressure and
Next, assemble Cylinder Tube (05) between Tie increase slowly with compressed air regulator until
Rods and into groove in Rear Head Flange. full working pressure is reached. This will ensure
no shock loading will occur and all equipment will
be brought up to working pressure slowly.
Copyright2008 Salina Vortex® Corporation. All Rights Reserved. RevA:0809 -2-