Technical Specifications and Product Overview

This document details block hydraulic cylinders designed for high-pressure die casting applications, featuring integrated cooling systems and end-of-stroke switches. It provides comprehensive technical data, configurations, and ordering information to ensure optimal performance and reliability.

1. Product Description and Applications

The cylinders are engineered for demanding die casting environments, incorporating integrated cooling options to maintain temperature and enhance durability. End-of-stroke switches enable precise piston position control.

2. Technical Specifications

• Pressure Ratings: Up to 450 bar (45 MPa) depending on bore size.
• Nominal Delivery Flow: 7 to 45 l/min, varying with bore diameter.
• Bore Sizes: Available in 40, 50, 63, 80, and 100 mm diameters.
• Maximum Piston Speed: Specified per bore size with corresponding maximum applicable mass.
• Operating Temperature: Up to 160°C (320°F), dependent on seal type and fluid compatibility.
• Seal Compatibility: Options for oil-compatible and water-glycol compatible seals.

3. Cooling Options

• No cooling
• Cartridge cooling integrated into cylinder housing
• Rod cooling for direct piston rod temperature control

4. Mounting and Oil Port Configurations

Multiple clamping styles and oil delivery port options are offered:

• Threaded body clamping with BSP (gas) or NPT threaded oil ports on left, right, or both sides.
• Longitudinal through holes with BSP or NPT threaded oil ports, configurable on left, right, or both sides.

Dimensional data includes bore diameter, rod diameter, stroke length, and thread sizes, adhering to DIN 7168-m tolerances where applicable.

5. Stroke Lengths and Tolerances

• Standard stroke lengths with tolerance of -0/+0.5 mm.
• Intermediate strokes require selection of next longer standard stroke with a minimum 8 mm stroke reducer.
• Special stroke lengths available upon request.

6. Force and Load Data

Tables provide push and pull forces (in daN) for various bore and rod sizes at different pressures, facilitating precise load-based selection.

7. Dimensional Details and Warnings

• Caps may protrude up to 5 mm; maximum eccentricity 0.5 mm.
• O-rings included with cylinders.
• Detailed dimensional tables cover bore, rod diameters, thread sizes, mounting holes, and oil port dimensions.

Critical Information and Best Practices

• Select seal type based on fluid compatibility (oil or water-glycol).
• Choose cooling option according to operating temperature and application needs.
• Adhere to stroke length guidelines; use stroke reducers for intermediate lengths.
• Follow DIN 7168-m for unspecified tolerances.
• Observe maximum piston speed and mass limits for safe operation.
• Verify oil port threading and position to match hydraulic system requirements.

Clamping Styles and Oil Delivery Options

• Key-way Clamping with Threaded Oil Delivery: BSP or NPT threads on left, right, or both sides.
• Longitudinal Through Holes: Threaded NPT or BSP ports on left, right, or rear side (rear side not for versions P, V, Z).
• Threaded Body Clamping: Threaded oil ports on rear side (not for versions P, V, Z).

Note: For oil pressure above 160 bar, use holding bracket or key-way to prevent cylinder torsion.

Rod End Styles and Thread Standards

• Standard rod ends include female and male metric threads and female/male UNF-UNEF threads (U.S. standard).
• Alternative rod ends available as special orders.

Fluid Types and Seal Compatibility

• Seals compatible with water-glycol mixtures or mineral-based hydraulic fluids.
• Cooling circuit designed exclusively for water-glycol or mineral oils; other fluids require technical consultation.

Cooling System Details

• Options: no cooling, cartridge cooling, rod cooling.
• Maximum cooling circuit fluid pressure: 10 bar.
• Cooling "rod" option not available with clamping style E or port position R.
• Switches unavailable for clamping E combined with cooling R.

Installation and Operational Recommendations

• For pressures above 160 bar, provide additional mechanical support to prevent torsion.
• Custom cylinder lengths available on request.
• Observe warnings on unavailable sensor options for certain clamping and cooling combinations.

Switch Versions and Compatibility

• Mechanical and inductive PNP switches rated for 70 °C, 80 °C, and 180 °C.
• Switches not available for clamping style "E" combined with cooling type "R".
• Maximum stroke lengths: 80 mm for bores Ø40, 50, 63, 80 mm; 50 mm for Ø100 mm bore.
• Switch versions include front side, rear side, and connector-equipped types with control shaft joining brackets.

Switch Technical Features

• Mechanical switches (MS5, MS6, MS7) and inductive switch (MSI) with PNP output.
• Electrical ratings: 1-250 VAC (mechanical), 10-30 VDC (inductive).
• Max current: 2.5 A (mechanical), 130 mA (inductive).
• Mechanical life: 10 million cycles (80 °C), 5 million cycles (180 °C).
• Protection: IP67 (DIN 40050).
• Switch position adjustment: rear -5 mm, front minimum 5 mm.

Wiring and Connector Details

• Standard wire color coding: Brown (+24 V), Blue (0 V), Black (PNP output), White, Yellow.
• Cable diameters ~6 mm; lengths 3000-5000 mm depending on switch type.

Rod End and Threaded Accessories

• Rod ends available with metric male threads, floating joints, female threads, made from high-performance steel.
• Thread standards include metric and UNF/UNEF with detailed dimensions.

Spare Parts and Maintenance Kits

• Rod cartridges (with/without seals), rod seal kits, piston seal kits, piston rods with female metric or UNF threads.
• Special rod cartridges for cooling applications with seals.

Mounting Accessories

• Flanges for clamping style "B" with 4 metric screws and detailed dimensions.

Mechanical and Inductive Switch Components

• Components include cylinder body, control shaft joining bracket, switch control shaft, guide supports, mechanical switches, and protection covers.
• Versions grouped as Q, T, W, I and separately P, V, Z, corresponding to mechanical or inductive switch kits.

Temperature Ratings and Versions

• Mechanical switches rated at 80 °C and 180 °C, with versions including connectors.
• Inductive switches with PNP output rated at 70 °C.

Spare Parts and Accessories

• Complete mechanical switch kits identified by part numbers.
• Extension cables (4-pole, 5 m length) available.

Key Recommendations and Critical Notes

• Ensure piston-rod ends match required thread standards (metric or UNF-UNEF).
• Select seals based on fluid compatibility.
• Verify cylinder bore and stroke dimensions per application.
• Confirm cylinder bodies have pre-drilled holes before installing mechanical switches.
• Choose appropriate clamping and BSP/NPT port configurations.
• Observe maximum stroke limits for switch functionality and mechanical integrity.
• Use additional mechanical support for high-pressure applications to prevent torsion.

Summary

This document comprehensively covers the selection, configuration, installation, and maintenance of block hydraulic cylinders with integrated cooling and end-of-stroke switches for die casting. It includes detailed mechanical dimensions, pressure and flow ratings, cooling and clamping options, fluid and seal compatibility, switch types and wiring, as well as spare parts and accessories. Adherence to specified tolerances, operational limits, and installation guidelines ensures safe and reliable cylinder performance in demanding industrial environments.