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Operating instruction
Pneumatic cylinder
AC.100 AC.320

AB STAFSJ BRUK, SE-618 95 STAVSJ, SWEDEN TEL:+46 (0)11-39 31 00 FAX: +46 (0)11-39 30 67
DECLARATION of CONFORMITY
The Manufacturer AB Stafsj Bruk, SE-618 95 STAVSJ, SWEDEN, hereby certify that the products in the
scope

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 1987
RN 1978

Stavsj, March 3, 2003

AB STAFSJ 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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Operating instruction
Pneumatic cylinder
AC.100 AC.320

AB STAFSJ BRUK, SE-618 95 STAVSJ, SWEDEN TEL:+46 (0)11-39 31 00 FAX: +46 (0)11-39 30 67
Operating instruction
The Operating instruction describes how the pneumatic cylinders of Stafsj shall be installed and operated to
ensure the products function and safety during its lifetime.

The Operating instruction shall be made available to the personnel responsible for the installation, operating
and service of the Stafsj pneumatic cylinders.

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

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

A - Pneumatic cylinder
The Stafsj pneumatic cylinder consists of two
cast end cups and a cylinder tube in aluminium.
The piston and rod seal are made of nitrile and
the piston rod is made of stainless steel.

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

The pneumatic cylinder can be equipped with
different accessories, such as solenoid valve, a
magnetic piston and magnetic limit switches.






B - Technical information
The technical data of the pneumatic cylinder is described in its data sheet. All data sheets are available on
www.stafsjo.com. If you have any questions regarding the products, please contact AB Stafsj Bruk or your
local representative.
C - Storage
The Stafsj pneumatic cylinder shall be stored in a clean and dry environment. It shall be protected against
dirt, dust and other pollutants and should not be exposed to direct sunlight.
D - Transportation and handling
The Stafsj 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 important
to make a visual inspection of the valve at arrival. If transport damages are detected a report shall be written
to the transportation company.

When mounting the Stafsj 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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Operating instruction
Pneumatic cylinder
AC.100 AC.320

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


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 - Installation
The Stafsj pneumatic cylinder is delivered ready for installation on a Stafsj knife gate valve.

To mount a pneumatic cylinder on a Stafsj 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 pneumatic
cylinder is connected. The pipe line must be free from pressure and empty and the pneumatic
cylinder must be disconnected before work begins.

Before installing the Stafsj 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 Stafsj 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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Operating instruction
Pneumatic cylinder
AC.100 AC.320

AB STAFSJ BRUK, SE-618 95 STAVSJ, SWEDEN TEL:+46 (0)11-39 31 00 FAX: +46 (0)11-39 30 67
o Check that the knife gate valve is closed and that the gate clevis and clevis pin are placed under the
hole 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 100
M12 DN 200-300 DN 200-250 DN 150-250
M16 DN 350-400 DN 300-350 DN 300-350
M20 DN 450 DN 400-450 DN 400
M22 DN 500-600
M24 DN 700-1000 DN 500-800

For more information on the installation of a pneumatic cylinder, please see Service instructions on
www.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 rod
to the gate by gently operating the cylinder. Fasten the gate clevis to the gate with the clevis pin and split
pins.

Open the valve by gently operating the cylinder. The piston must be in its top position in the cylinder. In this
position, 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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Operating instruction
Pneumatic cylinder
AC.100 AC.320

AB STAFSJ BRUK, SE-618 95 STAVSJ, SWEDEN TEL:+46 (0)11-39 31 00 FAX: +46 (0)11-39 30 67
Carefully close the knife gate valve. Dismount the split pins and clevis pin to release the gate clevis from the
gate. Adjust the gate clevis on the piston rod the same distance Y and lock it with the locking nut. Connect
the 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 a
completely open valve. The seat might be damaged at closing if the gate is too far into the valve and if the
gate 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 to
be able to close respectively open the knife gate valve. The connections are pipe threads according to ISO
228-1:

Air pipe
dimension
(mm)
AC 100 G 6
AC 160-200 G 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 the
cylinder 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 does
not 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 Stafsj pneumatic cylinder should be dust free and dry. Too high or low
temperatures or fast temperature swings may affect the cylinder and its accessories.

The recommended working temperature for the pneumatic cylinder is limited to -20 - +100C based on the
material 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 the
surrounding environment. The gas and liquids may affect the material and the function of the cylinder and its
accessories.
Support
The Stafsj knife gate valve should be mounted in a horizontal pipe line with the pneumatic cylinder in a
vertical upright position. If a knife gate valve is mounted in any other direction, the dead weight of a long gate
or a large pneumatic cylinder may cause tensions in the valve which might affect the valve tightness and
ability to manoeuvre.

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

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Operating instruction
Pneumatic cylinder
AC.100 AC.320

AB STAFSJ BRUK, SE-618 95 STAVSJ, SWEDEN TEL:+46 (0)11-39 31 00 FAX: +46 (0)11-39 30 67
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 a
fastened 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 can
be received from AB Stafsj Bruk by stating the article and serial number with which the knife gate valve is
marked.

AB Stafsj Bruk accepts no responsibility for the product if accessories are mounted on the knife gate valve
in such a way that it essentially affects the pneumatic cylinder design or function.
F - Operation
Before 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 to
prevent personal injuries before the valve is put into operation.

The surrounding environment and the system in which the valve is installed shall have normal operating
conditions to obtain the optimal function and lifetime of the valve and its pneumatic cylinder. The following
must be checked regularly when operating the valve:
o Check that the environment around the knife gate valve and its pneumatic cylinder does not imply
any risks to the valve, actuator or accessories.
o Avoid powerful pressure and temperature swings and vibrations in the system
o 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 the
pneumatic 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 might
involve 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 pneumatic
cylinder functions correctly.

If a fault or problem is detected at an inspection or manoeuvre test, the knife gate valve and its pneumatic
cylinder should go through service and maintenance as soon as possible. Information on spare parts and
instructions for service and maintenance are available on www.stafsjo.com.
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Operating instruction
Pneumatic cylinder
AC.100 AC.320

AB STAFSJ BRUK, SE-618 95 STAVSJ, SWEDEN TEL:+46 (0)11-39 31 00 FAX: +46 (0)11-39 30 67
Troubleshooting
Faults or problems that are detected on the pneumatic cylinder may have several reasons. The most
common problems and their reasons are listed in the table below. To remove the problem, the pneumatic
cylinder should undergo service and maintenance. How to perform the service, maintenance and available
spare 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 Stafsj Bruk or your local
representative.

Problem Reason Measure
Leakage in rod sealing Worn-out rod sealing See Service instructions
www.stafsjo.com
Leakage in cylinder end cup Unsufficient seal between cylinder
tube and cylinder end cups
See Service instructions
www.stafsjo.com
Gate does not open/close
completely
Unsufficient air supply to cylinder
Wrongly adjusted cylinder stroke
Fault in limit switches
Clogged valve
Damaged seat/gate
See Operating instruction
See instruction for limit switches
See Service instructions
www.stafsjo.com
Gate does not open/close in
a soft movement
Unsufficient air supply to cylinder
Clogged valve
Damaged seat/gate
See Operating instruction
Se Service instructions
www.stafsjo.com


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

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

AB Stafsj Bruk accepts no responsibility for the product if wear parts not tested and approved by AB Stafsj
Bruk are installed in the pneumatic cylinder. Nor does AB Stafsj Bruk accept responsibility for the product if
the Service instructions are not followed when maintaining the pneumatic cylinder.
H - Spare parts
Spare parts and instructions for service and maintenance are available on www.stafsjo.com or please
contact AB Stafsj Bruk or your local representative.









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