Hyson Products XP Manifold Systems Associated Spring ... PROGRAMMA STAMPI LAMIERA... · 10-99 Hyson ™ Products Associated Spring ® Nitro-Dyne® XP Manifold Systems Design/Layout

10-99

Hyson™ ProductsAssociated Spring

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Component Description .............................................................................................. 10.02.01

Manifold Design/Layout ............................................................................................... 10.03.01

General Design Rules .................................................................................................. 10.04.01

Manifold Work Sheet .................................................................................................... 10.05.01

Volume Hole Charts ..................................................................................................... 10.06.01

Port Plug Chart ............................................................................................................. 10. 07.01

Cylinder Location Chart .............................................................................................. 10.08.01

Cylinder ChoicesMOR, MORD, TSB, SB, BCQ........................................................................................ 10.09.01

Control Panel ChoicesCP-1555, CPM-1555-M, CPM-1555-E ........................................................................... 10.10.01

Hoses, Fittings, Assemblies, Use ............................................................................... 10.11.01

Compression Tanks ..................................................................................................... 10.12.01

Safety Features ............................................................................................................ 10.1 3.01

Charging and Discharging Nitro-Dyne XP Systems ................................................. 10.14.01

10.01.01

Nitro-Dyne® XP Manifold Systems(Section 10) Index

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10.02.01

Nitro-Dyne® XP Manifold SystemsComponent Description

2

3

1

3. Control PanelHyson Products control panels contain all of the necessarycontrols for charging, exhausting and reading pressure ina nitrogen cylinder system. A control panel may be sealeddirectly to the manifold plate or may be attached remotelywith a hose. Control panels are available in several styles,depending on the application. See page 10.10.01 fordetailed control panel information.

1. Manifold PlateA manifold plate is machined to customer specificationsand finished top and bottom. It serves two purposes: tohold cylinders in the proper location and to act as areservoir for nitrogen gas. See page 10.03.01 for propermanifold designs.

2. CylindersNitrogen cylinders are threaded into a manifold plate andsealed by an O-ring. Cylinders are available in a widevariety of sizes and tonnages. See Page 10.09.01 for acomplete listing of cylinder choices with dimensions.

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Nitro-Dyne® XP Manifold SystemsDesign/Layout

10.03.01

Die DesignNitrogen manifold design begins with the design of the die.The following information should be available prior tomanifold design:

1. Pad or draw ring size in die2. Pad and shoe thickness3. Shut height available4. Pad travel requirements5. Pressure needed on pad or draw ring6. Does pad bottom on the shoe7. Shoe size8. Where in the stroke pressure is needed

Manifold Design FollowsThese Simple StepsStep 1: Determine Force NeededEstablish how much force is required to form, hold, strip,or draw the part.

Example:For this example we will use 30,000 lb./15 tons of force ona rectangular draw pad. This tonnage is needed to pro-duce a good draw.

Step 2: Determine Cylinder QuantityDetermine how many pressure points are necessary todistribute the pressure evenly across the pad. This isdetermined, in part, by the force calculated in Step 1.When making force calculations, it is best to build into thecalculation a factor for variance in part thickness, tensilestrength, and die wear. This is accomplished by buildingmore force into the design than is originally calculated.

Example:The nitrogen design has the capability of 20 tons of force.If 15 tons is accurate, this nitrogen system will operate at86 bar/1250 psi.

Cylinder Choices Quantity Needed1/4 ton 801/2 ton 401 ton 202.5 tons 84 tons 56 tons 4

Eight 2.5 ton cylinders give a good pressure point distribu-tion with the tonnage needed.

Step 3: Determine Cylinder StrokePad travel will dictate stroke length; standard strokes onmost cylinder types are in one half-inch increments. Selectthe stroke length that will not be exceeded by the actualworking stroke.

Example:The actual travel of the pad is 44 mm (1.75 in. ). Theproper cylinder stroke for this application is 51 mm (2 in.).

Step 4: Determine Cylinder ProfileMeasurement from the bottom of the shoe to the bottom ofthe pad in the die-open position is known as the “X”dimension. It is important to choose a cylinder that closelymatches the “X” dimension. Remember, the cylindershould be protected from overstroking.

Example:

44mm1.75 in.

51mm2 in.

X

PAD

MANIFOLD

DIE SHOE

93 mm3.66 in.

Note: All dimensions are nominal unless tolerance is stated. Data shown are typical. Actual data for any particular unit may vary from those shown here.

Cylinder choice:MORD 2.5 x 2 in. stroke

Step 5: Determine Volume Drilling in ManifoldAfter cylinder locations have been plotted, draw in anymounting holes, handling holes, or other holes that may benecessary for the manifold. After plotting, drilling patternscan be established. The amount of drilling in a manifoldplate is determined by the amount of pressure rise thatcan be allowed in an application during a given cylinderstroke.

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The total volume should then be converted into linearinches of drilling.

From the Volume Hole Drilling Chart (page 10.06.01),establish the largest volume hole for a plate thickness.The chart will give the volume of that hole per linear inch.

To calculate total linear inches of drilling:

Linear inches Volume requireddrilling required

=Volume per inch of the drilled hole

Conversion Factors

1 in. = 25.4 mm = 2.54 cm1 in2 = 645 mm2 = 6.45 cm2

1 in3 = 16,400 mm3 = 16.4 cm3

1 cm = 0.394 in. = 10 mm1 mm = 0.0394 in. = 0.1 cm

Pressure Rise GuidelinesControlled material flow is needed in conventional drawdies. The cylinders in this type of die require a nearlyconstant force throughout the stroke. This type of nitrogensystem is generally designed with a 10-20% pressure rise.Other applications can use a higher pressure rise in themanifold system.

Volume requirements can be achieved in many ways.Drilled holes in a variety of lengths and diameters can beconsidered in determining system design. The first step isto find the Swept Volume (S.V.) of the nitrogen cylinders.Swept Volume is the amount of nitrogen displaced fromthe cylinders during the stroke.

(S.V.) Swept Volume = number of cylinders x workstrokeof cylinders x effective piston area of the cylinder.

Example:Swept Volume = 8 x 1.75 in. x 3.44 in.2Swept Volume = 48.16 in.3

To calculate total manifold volume, the Swept Volumemust be multiplied by a pressure rise factor.

Desired Pressure Pressure RiseRise Factor (PF)10% S.V. x 1015% S.V. x 6.6620% S.V. x 530% S.V. x 3.3340% S.V. x 2.5

Our example is a conventional draw with a desiredpressure rise of 10%.

Total Volume = S.V. x PFTotal Volume = 48.16 in.3 x 10 = 481.6 in.3

When shut height allows, design a system with a thickermanifold plate and reduce the number and length of drilledholes. This will reduce the cost of the manifold system.

Example:The example plate is 2.5 in. x 80 in. x 48 in. The largestdiameter volume hole that can be used is 1.5 in. Volumeper linear inch of drilling is 1.767 in.3

481 in.3 272 total linear inches

1.767 in.2=

of drilling using a 1.5 in. Ø hole

4 holes 45 in. long 180 linear inches3 holes 25 in. long 75 linear inches1 hole 30 in. long 30 linear inches

285 linear inches

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10.03.03

The chart gives the force of a cylinder at a specificcharging pressure.

Net Force = Effective Piston Area x Charging Pressure.

To obtain total manifold system force, locate the cylindermodel and charging pressure on the chart. Then multiplynet force per cylinder by the number of cylinders in themanifold.

Effective Charging Pressure

Piston Cylinder 17 bar 34 bar 52 bar 69 bar 86 bar 103 barArea Models 250 psi 500 psi 750 psi 1000 psi 1250 psi 1500 psi

2.97 cm2

BCQkN .51 1.02 1.53 2.04 2.56 3.07

.460 in.2 lbs. 115 230 345 460 575 689

5.02 cm2 MOR .5 kN .87 1.75 2.62 3.49 4.37 5.24

.785 in.2MORD .5

lbs. 196 393 589 785 982 1178TSB .5

11.40 cm2 MOR 1 kN 1.97 3.93 5.90 7.86 9.83 11.79MORD 1

1.767 in.2TSB 1 lbs. 442 884 1325 1767 2209 2651SB 1

22.26 cm2 MOR 2.5 kN 3.84 7.67 11.51 15.35 19.19 23.02MORD 2.5

3.450 in.2TSB 2.5

lbs. 863 1725 2588 3450 4313 5176SB 2.5

34.92 cm2 MOR 4

5.412 in.2

MORD 4kN 6.02 12.04 18.05 24.07 30.09 36.11

TSB 4lbs. 1353 2706 4059 5412 6765 8118SB 4

51.50 cm2 MOR 6 kN 8.88 17.75 26.63 35.51 44.38 53.26

7.982 in.2

MORD 6lbs. 1996 3991 5987 7982 9978 11973SB 6


Note: Net force shown is die-open force and does notNote: include any pressure rise that occurs during theNote: cylinder’s stroke.

NetForcePerCylinder

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10.04.01

Nitro-Dyne® XP Manifold SystemsRecommended Design Rules


1. Design with Die Open Clearance.Proper manifold design requires clearance in the die toallow nitrogen cylinders to come to a full, open position.In an upper application, the clearance would be betweenthe end of the rod and the pad. In a lower application,the clearance would be between the pad and its retainersystem. This clearance should be a minimum of .254 mm(.010 in.). The purpose of this clearance is to allow thepiston rods to come to a full die-open position.

PAD

DIE SHOECYLINDER

KISS BLOCK

Upper Application

Lower Application

2. Avoid Special Length Piston Rods.If the height of a standard nitrogen cylinder does notmatch the distance to the back of the pad, kiss blocksare recommended to make up the height difference.The cylinders can also be counterbored into the manifold.A cylinder with a special length piston rod is a customproduct and requires a longer delivery time than astandard cylinder.

Note: Kiss blocks should be hardened to at least 25 Note :Rockwell C.

Note: The weight of the pad is not enough to preload the Note :cylinders.

3. Make Sure the Piston Rod Contact Surface is Flat.It is very important that the piston rod of the nitrogencylinder contacts a flat surface. Never put the piston rodagainst a counterbored hole, rough casting, or bolt.

PAD

DIE SHOECYLINDER

INCORRECT

KISS BLOCK

KISS BLOCK

PAD

DIE SHOECYLINDER

CORRECT

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4. Use Stop Blocks.It is very important to have stop blocks in the design ofthe die to prevent cylinder damage should the pad beoverstroked. The stop block should be equivalent to orgreater than the A dimension of the cylinder.

5. Install Drain Slots.In most designs, the cylinders are placed through a pocketin the die shoe or subplate in the die. This pocket can fillup very easily with draw lubricants, metal chips, and/orcleaning solvents that submerge the cylinders. This canshorten the life of a nitrogen system.

STOPBLOCKS

AMANIFOLD

DIE SHOE

DRAIN SLOTIN MANIFOLD

MANIFOLD

DIE SHOE

DRAIN SLOTIN DIE SHOE

Drainage slots should be installed in each cylinder pocketto prevent build-up around the cylinders. Drain slotsshould be of sufficient size to prevent blockage. HysonProducts recommends a minimum slot width of 19-25 mm(.75-1.0 in.). If drain slot is in manifold, slot should start attop face and extend down to within .4-.8 mm (.015 - .030in.) above cylinder mounting surface. If drain slot is in dieshoe, slot depth should be 19-25 mm (.75-1.0 in.) deep.

If cylinder is counterbored 44 mm (1.75 in.) or greaterbelow manifold surface, drain holes should be usedinstead of drain slots. Drain hole should not be closerthan 1.6 mm (.06 in.) above cylinder mounting surface.Minimum diameter of drain hole is 19 mm (.75 in.).

6. Install Handling Holes.Each manifold should have handling holes so the manifoldsystem can be installed, turned, and worked on withoutdamaging the nitrogen cylinders.

Size of drain slots and drain holes also depends onnumber of cylinders connected by one slot/hole. Fordesign help, contact Hyson Products Customer Service orEngineering departments at 1-800-876-4976.

Illustrates drain slot machined into the manifold plate.This is used when cylinders are counterbored down inthe manifold block.

Illustrates drain slot machined into the bottom of thedie shoe.

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10.04.03

B. Always use the largest diameter volume hole forsuggested plate thickness.This allows for the fewest linear inches of drilling to obtainthe desired nitrogen volume. See Volume Chart, page10.06.01.

C. Minimize port plugs.Drilling and tapping for a port plug are expensive.Use as few plugs as possible without sacrificing theneeded volume.

INCORRECT

INCORRECT

CORRECT

CORRECT

Suggestions For Volume Hole Drillingin Manifold SystemsA. Do not use blind drilled holes.A drilled volume hole must go to the edge of the plate,dead-end into a cross drilled hole, or dead-end into acylinder cavity. This enables the manifold to be cleanedof all metal chips.

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10.04.04


D. Check the material thickness aroundnitrogen holes.There are minimum wall thicknesses of material requiredaround nitrogen volume holes. See Nitrogen Volume HoleChart, page 10.06.01.

E. Make certain there are sufficient threadsfor cylinder cavities.It is best not to put nitrogen volume holes directly under-neath the cylinder cavity. By putting the volume hole to theside, more thread engagement of the cylinder is allowed.

INCORRECT

CORRECT

CORRECT

INCORRECT

F. Allow sufficient material between cylinder cavities.When cylinders are positioned on close centers, there islittle material between them. A single large cross-drilledhole through the center area beneath the cylinders maycreate an unsupported web of metal between the cylin-ders. Since nitrogen pressure is underneath, this areamust be supported to safely contain the pressure. For astronger die design, use two smaller holes outside thecenter of the cylinders and leave the web with support.

For design help, contact Hyson ProductsCustomer Service or Engineering departmentsat 1-800-876-4976.

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Nitro-Dyne® XP Manifold SystemsWorksheet


10.05.01

Use this worksheet to compile datafor proper manifold design.

Die/Job number: ________________________________

Quantity of plates: _______________________________

1. Finish plate size: ______ x ______ x ______

2. Describe the shape of the plate by choosing one of the

following: ________________

A. Burned to template (includes control panel recess)B. No special burn

3. What is the finished thickness tolerance? ± ________ .

4. Describe the deep hole drilling

Diameter Length Quantity________ ________ ________

________ ________ ________

________ ________ ________

________ ________ ________

5. How many edges should be finish milled? ________(minimum 2 required)

6. Advise quantity and type of cylinders:

Quantity Model Stroke “Y” Dimension(If Special)

_______ ______ ______ ____________

_______ ______ ______ ____________

7. Advise quantity and type of plugs:

Quantity Size Quantity Size_______ ____ _______ ____

_______ ____ _______ ____

_______ ____ _______ ____

8. What style of control panel?

___ CPM-1555-M ___ CPM-1555-E ___ CP-1555

9. Is the control panel recessed or flush mounted?

____Recessed ___ Flush Mounted

10. Advise quantity of mounting holes (drill and C-Bore)and size:

Quantity __________ Size ____________

11. Advise quantity of handling holes and size:

Quantity __________ Size ____________

Plate Weights Handling Holekg lbs. (Min. 2 req’d)

0-910 0-2,000 M16 x 2.0 5/8 - 11

911-1,590 2,001-3,500 M20 x 2.5 3/4 - 10

1,591-2,270 3,501-5,000 M24 x 3.0 1 - 8

2,271-3,400 5,001-7,500 M30 x 3.5 1-1/4 - 7

3,401-5,670 7,501-12,500 M36 x 4.0 1-1/2 - 6

12. Advise quantity and size of any other holes (tapped,clearance, dowel pin, etc.)

Quantity Size Quantity Size_______ ____ _______ ____

_______ ____ _______ ____

_______ ____ _______ ____

13. Advise quantity and description of any other specialmachining (milled pockets, milled flanges, keyways,chamfers, drain slots, etc.)

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

14. List quantity and description of any other components(hose, fittings, tanks, etc.)

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

_____________________________________________

Return to:10367 Brecksville Road • Brecksville, OH 44141(440) 526-5900 • FAX: (440) 838-7684

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Nitro-Dyne® XP Manifold SystemsVolume Hole Drilling Chart

for 1500 psi System


10.06.01

AB

AA

A

Hole Suggested Plate Max. DrillingPlugs Used Area/Linear Inch Diameter A B Thickness* Depth (1 Way)

NF-771-4.71 cm2 mm 9.5 10 19 51 152

.110 in.2 in. .375 .375 .738 2 6

NF-771-5.97 cm2 mm 11.1 10 22 51 152

.151 in.2 in. .438 .406 .875 2 6

NF-771-82.18 cm2 mm 16.7 14 31 51 203

.338 in.2 in. .656 .563 1.219 2 8

NF-771-102.85 cm2 mm 19.1 16 35 51 203

.442 in.2 in. .750 .625 1.375 2 8

NF-771-124.46 cm2 mm 23.8 19 42 51 203

.691 in.2 in. .938 .750 1.656 2 8

NF-771-145.71 cm2 mm 27.0 22 46 51 533

.886 in.2 in. 1.062 .884 1.813 2 21

NF-771-167.15 cm2 mm 30.2 24 51 57 533

1.108 in.2 in. 1.188 .938 2.00 2.25 21

NF-771-2011.40 cm2 mm 38.1 27 59 64 1219

1.767 in.2 in. 1.500 1.062 2.313 2.50 48

NF-771-24 15.52 cm2 mm 44.5 32 60 70 1219 andNF-771-M47 2.405 in.2 in. 1.750 1.250 2.375 2.75 48

NF-771-M6327.75 cm2 mm 59.4 40 76 89 1524

4.301 in.2 in. 2.340 1.563 3.00 3.50

NF-771-3228.58 cm2 mm 60.3 40 76 89 1524

4.430 in.2 in. 2.375 1.563 3.00 3.50 60

NF-771-8248.51 cm2 mm 78.6 54 95 114 1524

7.518 in.2 in. 3.094 2.125 3.75 4.50 60

NF-771-10071.26 cm2 mm 95.5 64 111 133 1524

11.045 in.2 in. 3.750 2.500 4.38 5.25 60

*Drilling patterns may affect plate thickness.

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Nitro-Dyne® XP Manifold SystemsPort Plugs

10.07.01


D

For -4 through -16 plugs For -20 through -100 plugs

LT LT

D S

InternalSquareDrive

H

InternalHex

Part Thread ToolNumber Size H D T L S Needed

NF-771-4 7/16-20mm 5 14 3 9 —

3/16 Hex Head Allen Wrenchin. 0.19 0.56 0.11 0.36 —

NF-771-5 1/2-20mm 5 16 3 9 —


NF-771-8 3/4-16mm 8 22 4 11 —


NF-771-10 7/8-14mm 10 25 4 13 —


NF-771-12 1 1/16-12mm 14 32 5 15 —


NF-771-14 1 3/16-12mm 14 35 5 15 —


NF-771-16 1 5/16-12mm 16 38 5 15 —


NF-771-20 1 5/8-12mm 48 4 15 12.7

1/2 Sq. Drive Wrenchin. — 1.88 0.16 0.59 0.50

NF-771-24 1 7/8-12 mm 54 4 15 12.71/2 Sq. Drive Wrench

NF-771-M47 M47 x 2 in. — 2.12 0.16 0.59 0.50

NF-771-32 2 1/2-12 mm 70 4 15 12.71/2 Sq. Drive Wrench

NF-771-M63 M63 x 2 in. — 2.75 0.16 0.59 0.50

NF-771-82 M82 x 2mm 89 6 19 19.1


NF-771-100 M100 x 2mm 108 6 19 19.1


Standard Plugs

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Part Number D T L S Tool Needed

NF-771-20 RDmm 48 4 15 25

FS-418 Spanner Wrenchin. 1.88 0.16 0.59 1.00

NF-771-24 RDmm 54 4 15 32


NF-771-32 RDmm 70 4 15 44


NF-771-82 RDmm 89 6 19 57


NF-771-100 RDmm 108 6 19 57


Nitro-Dyne® XP Manifold SystemsPort Plugs

10.07.02

Plugs with a Rupture Discfor 1500 psi System

Plugs with Internal Ports for 1/2-20 SAEHose Connection to the Manifold through the Plug

S

S


Part Number D T L S Tool Needed

NF-771-20-5mm 48 4 15 25


NF-771-24-5mm 54 4 15 32


NF-771-32-5mm 70 4 15 44


NF-771-82-5mm 89 6 19 57


NF-771-100-5mm 108 6 19 57


Rupture DiscPart Number Thread Size H T L Tool Needed

RD-2150 7/16-20

mm 14.3 6.9 10.59/16 Wrench

in. 0.562 0.274 0.415

RD2150

H T L

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Nitro-Dyne® XP Manifold SystemsCylinder Location Chartfor 1500 psi System

10.08.01

DD

CE

The following chart shows minimum distance between cylinders and minimum edge plate distance.

Cylinder Minimum MinimumCylinder Diameter Center Distance Edge DistanceTonnage D C E

1/4 Tonmm 33 42 19

in. 1.31 1.66 0.75

1/2 Tonmm 41 51 24

in. 1.60 2.00 0.94

1 Tonmm 54 60 32

in. 2.12 2.38 1.25

2.5 Tonmm 70 76 40

in. 2.75 3.00 1.56

4 Tonmm 90 95 54

in. 3.56 3.75 2.13

6 Tonmm 109 114 64

in. 4.31 4.50 2.50


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Choosing the Correct CylinderHyson Products cylinders are available in a wide variety ofdiameters, tonnages, profiles, strokes and heights to meetthe requirements of each application.

The cylinders are sized:

Small: Diameter of 1.31 in.; BCQ model

Short: Height of .69 in.; SB model

Large: Force of 6 tons; MOR 6 & MORD 6 models

Nitro-Dyne® XP Manifold SystemsCylinder Choices

10.09.01


MOR 1 x1.0 MORD 1 x1.0 TSB 1 x 1.0

SB 1 x 1.0 BCQ x 1.0

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Nitro-Dyne® XP Manifold SystemsMOR Cartridge Cylinders

Y

K

RCD

A

P

B

Rod FullyExtended

10.09.02

Force and Fixed Dimensions

Max. Force Effective Rod ClearanceSize at Piston K P Diameter BModel 103 bar/1500 psi Area RCD

MOR .5 5.24 kN 5.07 cm2 41mm 21.6 mm 22 mm

1/2 Ton 1178 lbs. .785 in.2 1.60 in.1-5/16-12

.85 in. .88 in.

MOR 1 11.79 kN 11.40 cm2 54 mm 1-7/8-12 27 mm 18 mm

1 Ton 2651 lbs. 1.767 in.2 2.12 in. M47 x 2 1.08 in. .72 in.

MOR 2.5 23.02 kN 22.26 cm2 70 mm 2-1/2-12 35 mm 25 mm

2.5 Ton 5176 lbs. 3.450 in.2 2.75 in. M63 x 2 1.38 in. 1.0 in.

MOR 4 36.11 kN 34.92 cm2 90 mm 47 mm 32 mm

4 Ton 8118 lbs. 5.412 in.2 3.56 in.M82 x 2*

1.86 in. 1.25 in.

MOR 6 53.26 kN 51.50 cm2 109 mm 64 mm 32 mm

6 Ton 11973 lbs. 7.982 in.2 4.31 in.M100 x 2**

2.51 in. 1.25 in.

**Also available in 3-1/4-12 thread.**Also available in 4-12 thread.


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Nitro-Dyne® XP Manifold SystemsMOR Cartridge Cylinders

10.09.03

Variable Dimensions with Stroke

MOR 1, MOR 2.5MOR .5 MOR 4, MOR 6

Stroke Y A Y A

6 mm 29 23

0.25 in. 1.16 0.91

13 mm 42 29 48 36

0.50 in. 1.66 1.16 1.91 1.41

19 mm 55 36 61 42

0.75 in. 2.16 1.41 2.41 1.66

25 mm 68 42 74 49

1.00 in. 2.66 1.66 2.91 1.91

38 mm 93 55 99 61

1.50 in. 3.66 2.16 3.91 2.41

51 mm 118 68 125 74

2.00 in. 4.66 2.66 4.91 2.91

64 mm 144 80 150 87

2.50 in. 5.66 3.16 5.91 3.41

76 mm 169 93 176 99

3.00 in. 6.66 3.66 6.91 3.91

89 mm 195 106 201 112

3.50 in. 7.66 4.16 7.91 4.41

102 mm 220 118 226 125

4.00 in. 8.66 4.66 8.91 4.91

114 mm 252 137

4.50 in. 9.91 5.41

127 mm 277 150

5.00 in. 10.91 5.91

140 mm 303 163

5.50 in. 11.91 6.41

152 mm 328 176

6.00 in. 12.91 6.91

165 mm 353 188

6.50 in. 13.91 7.41

178 mm 379 201

7.00 in. 14.91 7.91

191 mm 404 214

7.50 in. 15.91 8.41

203 mm 430 226

8.00 in. 16.91 8.91

Minimum Plate Thickness

Model Min. Plate Thickness

MOR .544 mm

1.75 in.

MOR 144 mm

1.75 in.

MOR 2.551 mm

2.00 in.

MOR 451 mm

2.00 in.

MOR 664 mm

2.50 in.

StandardStroke Lengths Available

Model Max. Stroke

MOR .5102 mm

4 in.

MOR 1127 mm

5 in.

MOR 2.5152 mm

6 in.

MOR 4178 mm

7 in.

MOR 6203 mm

8 in.


Additional Stroke LengthsAvailable on Request

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Nitro-Dyne® XP Manifold SystemsMORD Cartridge Cylinder

10.09.04


Max. Force Effective Rod ClearanceSize at Piston K P Diameter AModel 103 bar/1500 psi Area RCD

MORD .5 5.24 kN 5.07 cm2 41 mm 22 mm 42 mm

1/2 Ton 1178 lbs. .785 in.2 1.60 in.1-5/16-12

.85 in. 1.66 in.

MORD1 11.79 kN 11.40 cm2 54 mm 1-7/8-12 27 mm 42 mm

1 Ton 2651 lbs. 1.767 in.2 2.12 in. M47 x 2 1.08 in. 1.66 in.

MORD 2.5 23.02 kN 22.26 cm2 70 mm 2-1/2-12 35 mm 42 mm

2.5 Ton 5176 lbs. 3.450 in.2 2.75 in. M63 x 2 1.38 in. 1.66 in.

MORD 4 36.11 kN 34.92 cm2 90 mm 47 mm 42 mm

4 Ton 8118 lbs. 5.412 in.2 3.56 in.M82 x 2*

1.86 in. 1.66 in.

MORD 6 53.26 kN 51.50 cm2 109 mm 64 mm 42 mm

6 Ton 11973 lbs. 7.982 in.2 4.31 in.M100 x 2**

2.51 in. 1.66 in.

**Also available in 3-1/4-12 thread.**Also available in 4-12 thread.

K

RCD

Y Rod FullyExtended

A

B

P


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Nitro-Dyne® XP Manifold SystemsDeep Cavity Cylinders

10.09.05

MORD .5 MORD 1 MORD 2.5 MORD 4 MORD 6

Min. Plate Min. Plate Min. Plate Min. Plate Min. PlateStroke Y B Thickness Y B Thickness Y B Thickness Y B Thickness Y B Thickness

6 mm 48 15 44

0.25 in. 1.91 0.59 1.75

13 mm 55 15 44

0.5 in. 2.16 0.59 1.75

19 mm 61 16 44

0.75 in. 2.41 0.63 1.75

25 mm 68 22 44 68 25 44 68 32 51 68 38 64 68 38 64

1.00 in. 2.66 0.88 1.75 2.66 0.97 1.75 2.66 1.25 2.00 2.66 1.50 2.50 2.66 1.50 2.50

38 mm 80 35 46 80 37 48 80 44 57 80 51 69 80 51 69

1.50 in. 3.16 1.38 1.81 3.16 1.47 1.88 3.16 1.75 2.25 3.16 2.00 2.73 3.16 2.00 2.73

51 mm 93 48 59 93 50 60 93 57 70 93 64 82 93 64 82

2.00 in. 3.66 1.88 2.31 3.66 1.97 2.38 3.66 2.25 2.75 3.66 2.50 3.23 3.66 2.50 3.23

64 mm 106 60 71 106 63 73 106 70 83 106 76 95 106 76 95

2.50 in. 4.16 2.38 2.81 4.16 2.47 2.88 4.16 2.75 3.25 4.16 3.00 3.73 4.16 3.00 3.73

76 mm 118 73 84 118 75 86 118 83 95 118 89 107 118 89 107

3.00 in. 4.66 2.88 3.31 4.66 2.97 3.38 4.66 3.25 3.75 4.66 3.50 4.23 4.66 3.50 4.23

89 mm 131 86 97 131 88 98 131 95 108 131 102 120 131 102 120

3.50 in. 5.16 3.38 3.81 5.16 3.47 3.88 5.16 3.75 4.25 5.16 4.00 4.73 5.16 4.00 4.73

102 mm 144 98 109 144 101 111 144 108 120 144 114 133 144 114 133

4.00 in. 5.66 3.88 4.31 5.66 3.97 4.38 5.66 4.25 4.75 5.66 4.50 5.23 5.66 4.50 5.23

114 mm 156 113.5 124 156 121 133 156 127 146 156 127 146

4.50 in. 6.16 4.47 4.88 6.16 4.75 5.25 6.16 5.00 5.73 6.16 5.00 5.73

127mm 169 126 137 169 133 146 169 140 158 169 140 158

5.00 in. 6.66 4.97 5.38 6.66 5.25 5.75 6.66 5.50 6.23 6.66 5.50 6.23

140 mm 182 146 159 182 152 171 182 152 171

5.50 in. 7.16 5.75 6.25 7.16 6.00 6.73 7.16 6.00 6.73

152 mm 195 159 171 195 165 184 195 165 184

6.00 in. 7.66 6.25 6.75 7.66 6.50 7.23 7.66 6.50 7.23

165 mm 207 178 196 207 178 196

6.50 in. 8.16 7.00 7.73 8.16 7.00 7.73

178 mm 220 191 209 220 191 209

7.00 in. 8.66 7.50 8.23 8.66 7.50 8.23

191 mm 233 203 222

7.50 in. 9.16 8.00 8.73

203 mm 245 216 234

8.00 in. 9.66 8.50 9.23


Standard Stroke Lengths Available

Model Stroke

MORD 4 178 mm7 in.

MORD 6 203 mm8 in.

Model Stroke

MORD .5 102 mm4 in.

MORD 1 127 mm5 in.

MORD 2.5 152 mm6 in.



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Nitro-Dyne® XP Manifold SystemsTSB Cartridge Cylinders

10.09.06


Max. Force Effective Rod ClearanceSize at Piston K P Diameter AModel 103 bar/1500 psi Area RCD

TSB .5 5.24 kN 5.07 cm2 41mm 22 mm 17 mm1/2 Ton 1178 lbs. .785 in.2 1.60 in. 1-5/16-12 .85 in. .66 in.TSB 1 11.79 kN 11.40 cm2 54 mm 27 mm 17 mm1 Ton 2651 lbs. 1.767 in.2 2.12 in. 1-7/8-12 1.08 in. .66 in.TSB 2.5 23.02 kN 22.26 cm2 70 mm 35 mm 17 mm2.5 Ton 5176 lbs. 3.450 in.2 2.75 in. 2-1/2-12 1.37 in. .66 in.TSB 4 36.11 kN 34.92 cm2 90 mm 47 mm 17 mm4 Ton 8118 lbs. 5.412 in.2 3.56 in. M82 x 2 1.86 in. .66 in.

Y Rod FullyExtended

K

RCD

A

B

P


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Nitro-Dyne® XP Manifold SystemsTSB Cartridge Cylinders

10.09.07


TSB .5 TSB 1 TSB 2.5 TSB 4

Min. Plate Min. Plate Min. Plate Min. PlateStroke Y B Thickness Y B Thickness Y B Thickness Y B Thickness

6 mm 23 29 440.25 in. 0.91 1.13 1.7513 mm 29 35 46 29 36 39 29 44 57 29 51 690.50 in. 1.16 1.38 1.81 1.16 1.41 1.84 1.16 1.75 2.26 1.16 2.00 2.7019 mm 36 41 52 36 42 45 36 51 64 36 57 750.75 in. 1.41 1.63 2.06 1.41 1.66 2.09 1.41 2.00 2.51 1.41 2.25 2.9525 mm 42 48 59 42 49 59 42 57 70 42 64 811.00 in 1.66 1.88 2.31 1.66 1.91 2.34 1.66 2.25 2.76 1.66 2.50 3.2038 mm 55 60 71 55 61 72 55 70 83 55 76 941.50 in. 2.16 2.38 2.81 2.16 2.41 2.84 2.16 2.75 3.26 2.16 3.00 3.7051 mm 68 73 84 68 74 85 68 83 96 68 89 1072.00 in. 2.66 2.88 3.31 2.66 2.91 3.34 2.66 3.25 3.76 2.66 3.50 4.2064 mm 80 86 97 80 87 98 80 95 108 80 102 1192.50 in. 3.16 3.38 3.81 3.16 3.41 3.84 3.16 3.75 4.26 3.16 4.00 4.7076 mm 93 99 109 93 99 110 93 108 121 93 114 1323.00 in. 3.66 3.88 4.31 3.66 3.91 4.34 3.66 4.25 4.76 3.66 4.50 5.2089 mm 106 111 112 106 112 123 106 121 134 106 127 1453.50 in. 4.16 4.38 4.81 4.16 4.41 4.84 4.16 4.75 5.26 4.16 5.00 5.70102 mm 118 124 135 118 125 136 118 133 146 118 139 1574.00 in. 4.66 4.88 5.31 4.66 4.91 5.34 4.66 5.25 5.76 4.66 5.50 6.20114 mm 131 137 148 131 146 159 131 152 1704.50 in. 5.16 5.41 5.84 5.16 5.75 6.26 5.16 6.00 6.70127 mm 144 150 161 144 159 172 144 165 1835.00 in. 5.66 5.91 6.34 5.66 6.25 6.76 5.66 6.50 7.20140 mm 156 171 184 156 178 1965.50 in. 6.16 6.75 7.26 6.16 7.00 7.70152 mm 169 184 197 169 191 2086.00 in. 6.66 7.25 7.76 6.66 7.50 8.20165 mm 182 203 2216.50 in 7.16 8.00 8.70178 mm 195 216 2347.00 in. 7.66 8.50 9.20

Model Stroke

TSB 2.5 152 mm

6 in.

TSB 4 178 mm

7 in.

Model Stroke

TSB .5 102 mm

4 in.

TSB 1 127 mm

5 in.

Standard Stroke Length Available



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Nitro-Dyne® XP Manifold SystemsSB – Short Stroke Cylinders

B

A

Y

K

P

R

Rod FullyExtended

10.09.08


SB 1, SB 2.5 SB 4, SB 6

Min. Plate Min. PlateStroke B Y Thickness B Y Thickness

6 mm 30 17 43 37 22 550.25 in. 1.19 0.69 1.69 1.47 0.87 2.1610 mm 34 21 46 40 25 580.38 in. 1.32 0.81 1.82 1.59 1.00 2.2813 mm 37 24 49 44 29 610.50 in. 1.44 0.94 1.94 1.72 1.12 2.4116 mm 40 27 53 47 32 640.62 in. 1.56 1.06 2.07 1.84 1.25 2.5319 mm 43 30 56 50 35 670.75 in. 1.69 1.19 2.19 1.97 1.37 2.6625 mm 49 37 62 56 41 731.00 in. 1.93 1.44 2.44 2.22 1.62 2.91



Max. Force Effective Actual RodSize at Piston K P Diameter AModel 103 bar/1500 psi Area R

SB 1 11.79 kN 11.40 cm2 54 mm 19 mm 11 mm1 ton 2651 lbs. 1.767 in.2 2.12

1 7/8-12.75 in. .44 in.

SB 2.5 23.02 kN 22.26 cm2 70 mm 19 mm 11 mm2.5 ton 5176 lbs. 3.450 in.2 2.75

2 1/2-12.75 in .44 in.


M82 x 21.50 in. .63 in.


M100 x 21.87 in. .63 in

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Nitro-Dyne® XP Manifold SystemsBCQ – Small Diameter Cylinder

10.09.09

Variable Dimensionswith Stroke

BCQ

Stroke A Y

13 mm 29 42.50 in. 1.16 1.6619 mm 36 17.75 in. 1.41 2.1625 mm 42 681 in. 1.66 2.6638 mm 55 931.5 in. 2.16 3.6651 mm 68 1182.0 in. 2.66 4.6664 mm 80 1442.5 in. 3.16 5.6676 mm 93 1693.0 in. 3.66 6.66


Max. Force Effectiveat Piston K P R B

Size/Model 103 bar/1500 psi Area

BCQ 3.07 kN 2.97 mm 33 mm 12 mm 15 mm1/4 ton 689 lbs. .460 in.2 1.31 in.

1 1/16-12.46 in. .59 in.

Y

A

B

P

KR

Rod FullyExtended


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®

Nitro-Dyne® XP Manifold SystemsControl Panels

10.10.01

Hyson Products control panels contain all of thenecessary controls for charging, exhausting, andreading nitrogen pressure in a nitrogen cylinder system.Control panels should be mounted in an accessiblelocation where the pressure gauge can be observed.Each control panel is equipped with an RD-2150 SafetyRupture Disc to protect the nitrogen system frombecoming overpressurized.

Styles

CP-1555The CP-1555 control panel is used for remote connectionto a manifold plate. An NH-250 Hose is used to attach thecontrol panel to the manifold plate.

Note: When using this control panel, an RD-2150 safetyNote: rupture disc must be installed in the manifold.

CPM-1555-MThe CPM-1555-M control panel is directly mountedby means of an O-ring seal to a finished manifold platesurface. This type of installation eliminates the need fora hose connection. The manifold thickness must be aminimum of 76 mm/3 in. to use this control panel.

127 mm5 in.

approx.

76 mm3 in.

approx.

84 mm3 5/16 in.approx.

EXHAUSTVALVE

RD-2150 SAFETYRUPTURE DISC

HEAVY-DUTYLIQUID FILLED

GAUGE

QUICK-CHECKINLET VALVE

Tap 3/8-16 X 3/4 in. deep*9.53 mm/3/8 in.Drill to Connect

O-Ring CounterboreMachined

9.53 mm/3/8 in. Drill to Connect12.57 mm/.620 in.12.83 mm/.625 in. C’bore x 1.27 mm/.050 in.

1.32 mm/.052 in.

41.27 mm1-5/8 in.

20.65 mm13/16 in.

17.46 mm11/16 in.

47.62 mm1-7/8 in.

max.

31.75 mm1-1/4 in.

15.87 mm5/8 in.

41.27 mm1-5/8 in.

47.62 mm1-7/8 in.

max.

17.46 mm11/16 in.

31.75 mm1-1/4 in.

2-MTG Screws3/8-16 S.H.C.S.M10-1.5 S.H.C.S.

1/2-20 JIC ST. THD.O-Ring Port

12.7 mm1/2 in.

38.1 mm1-1/2 in.


* Also available with M10 x 1.5 screws. Add suffix -M10 to part number.

1/8 IN. INLETCONNECTOR

HOSECONNECTION

PORT

REMOTE CONTROL PANEL

DIRECT MOUNT FOR PLATESGREATER THAN 3 IN. THICK

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Nitro-Dyne® XP Manifold SystemsControl Panels

10.10.02

CPM-1555-EThe CPM-1555-E control panel is directly mounted bymeans of an O-ring seal to a finished manifold surface.This type of installation eliminates the need for a hoseconnection. This control panel is recommended for usewith manifold plate thicknesses below 76 mm/3 in.

9.53 mm/3/8 in. Drill to Connect12.57 mm/.620 in.12.83 mm/.625 in.

C’bore x 1.27 mm/.050 in. 1.32 mm/.052 in.

31.75 mm1-1/4 in.

19.05 mm3/4 in.

Tap 3/8-16 X 3/4 in. deep*

47.62 mm1-7/8 in.approx.

47.62 mm1-7/8 in. 1.58 mm

1/16 in.

34.92 mm1-3/8 in.Min. Plate Thickness


1/8 IN. INLETCONNECTOR

DIRECT MOUNT FOR PLATESLESS THAN 3 IN. THICK

* Also available with M10 x 1.5 screws.* Add suffix -M10 to part number.

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Nitro-Dyne® XP Manifold SystemsHose Use

10.11.01

Hose assemblies are an option when using manifoldsystems. They may be used to connect manifolds to eachother, to a remote control panel, or to an additional volumetank. See examples below.

Hose to connect manifold plates(Consult factory for proper hose size.)

Hose to connect a remote control panel(Consult factory for proper hose size.)

Hose to connect additional volume tank(Consult factory for proper hose size.)


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Nitro-Dyne® XP Manifold SystemsHoses and Fittings

10.11.02

Hose Hose Hose Min. BendNumber I.D. O.D. Radius

NH-2506 mm 12 mm 64 mm.25 in. .47 in. 2.50 in.

NH-37510 mm 16 mm 102 mm.38 in. .63 in. 4.00 in.

NH-50013 mm 21 mm 140 mm.50 in. .81 in. 5.50 in.

Hose Swivel Fitting Female 37 ° J.I.C. FlareThis fitting mounts to end of each hose.

Hose GuardThe hose guard provides protection where hose lines aresubjected to abrasion, kinking, or accidental damage.

Hose Guard Hose GuardNumber

Hose SizeI.D.

HG-5 NH-25015 mm.570 in.

HG-8 NH-37519 mm.750 in.

HG-10 NH-50022 mm.875 in.

Hose ClampsHose Clamps are used tohold the hose in place to:• prevent damage to hose• avoid twisting of hose• minimize hose chafing• provide hose support where• long lengths are used

Hose Clamp Hose Hole A BNumber Size Diameter Approx.

HC-5 NH-2505.1 mm 13 mm.20 in. .50 in.

HC-8 NH-3755.1 mm 16 mm.20 in. .62 in.

HC-10 NH-5005.1 mm 21 mm.20 in. .81 in.

Fitting No. Hose No. A B (Thd) C (Hex) D

NF-10000-5 NH-25022 mm 15.7 mm 31 mm.87 in.

1/2-20.62 in. 1.23 in.

NF-1000-8 NH-37526 mm 22.4 mm 38 mm1.04 in.

3/4-16.88 in. 1.48 in.

NF-1000-10 NH-50030 mm 25.4 mm 43 mm1.20 in.

7/8-141.0 in. 1.70 in.

Straight Fittings Male 37 ° J.I.C. Flare

HoseThe Hyson Products thermoplastic hosehas an abrasion resistant cover withfiber braid reinforcement for strength.This hose is designed for factorypre-assembled or reusable fittings.Maximum working pressure is103 bar/1500 psi.

B = the distance from the center of the hoseto the center of the hole.

Min.Bend Radius

B

D

A

B

A C

D B

B

Hose Swivel Hose HexNumber Number

A (Thd) BD

NHF-5 NH-250 1/2-2057 mm 15.7 mm2.24 in. .62 in.

NHF-8 NH-375 3/4-1673 mm 20.6 mm2.88 in. .87 in.

NHF-10 NH-500 7/8-1486 mm 25.4 mm3.37 in. 1.00 in.


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Nitro-Dyne® XP Manifold SystemsHoses and Fittings

10.11.03

Fitting No. Hose Size A B (Hex) C D

SN-3300-5 NH-250 1/2-20 5/8 in.24 mm 27 mm

.95 in. 1.06 in.

SN-3300-8 NH-375 3/4-16 7/8 in. 32 mm 35 mm

1.25 in. 1.38 in.

SN-3300-10 NH-500 7/8-14 1 in.37 mm 41 mm

1.45 in. 1.62 in.

BA

C

DC

B A

C

D

C

BA D

C

A

BA

D

C

A

A

A

45° ElbowSwivel Nut

90° ElbowSwivel Nut


SN-4500-F NH-250 1/2-20 5/8 in.20 mm 25 mm

.77 in. 1.00 in.

SN-4500-8 NH-375 3/4-16 7/8 in.25 mm 33 mm

.98 in. 1.28 in.

SN-4500-10 NH-500 7/8-14 1 in.28 mm 37 mm

1.11 in. 1.44 in.


SN-2000-5 NH-250 1/2-20 5/8 in.24 mm 27 mm

.95 in. 1.06 in.

SN-2000-8 NH-375 3/4-16 7/8 in. 32 mm 35 mm

1.25 in. 1.38 in.

SN-2000-10 NH-500 7/8-14 1 in.37 mm 41 mm

1.45 in. 1.62 in.

Branch TeeSwivel Nut


SN-3000-5 NH-250 1/2-20 5/8 in.24 mm 27 mm

.95 in. 1.06 in.

SN-3000-8 NH-375 3/4-16 7/8 in.32 mm 35 mm

1.25 in. 1.38 in.

SN-3000-10 NH-500 7/8-14 1 in.37 mm 41 mm

1.45 in. 1.62 in.

Run TeeSwivel Nut


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Nitro-Dyne® XP Manifold SystemsHose Assembly

10.11.04

Proper hose assembly is essential to ensure a leak-freesystem. Following the seven easy steps below will providea long-lasting, leak-free hose assembly.

4. Put hex portion of socket in vise.

2. Remove all burrs from inside and outside diameter ofhose end and lubricate inside and outside of hose witha light machine oil.

Critical areas:The surfaces shown are the actual sealing areas andmust be free from all dirt and scratches to produce aproper seal. After observation, should one of thesesurfaces be scratched, discard and replace with newswivel assembly.

3. Place hose end in the J-810 clamp extending past theclamp, the length of the swivel socket. Screw the socketcounterclockwise until it seats on the hose. Important:after seating socket on hose, back socket out 1 to1-1/4 turn.

Hose Assembly Instructions1. Measure accurately. Then cut hose, leaving a sharp

square end.

5. Lubricate nipple liberally with a light machine oil.

The J-810 hose clamp will act as a fixture to properly holdthe hose during assembly. This hose clamp may bepurchased from Hyson Products.

SOCKET NIPPLE


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Nitro-Dyne® XP Manifold SystemsHose Assembly

10.11.05

6. Screw nipple clockwise into socket until metal to metalcontact is made.

7. The complete assembly should be charged to69 bar/1000 psi and all fitting areas should be checkedfor leaks. This can be accomplished by applying a lightmachine oil or soapy water on each fitting. Bubbles willform where there are any leaks.


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Nitro-Dyne® XP Manifold SystemsCompression Tanks

10.12.01

PurposeThe compression tank serves as the reservoir for the“Swept Volume” of nitrogen forced from the cylinderswhen they are stroked.

Standard compression tanks are available in four sizes:50 in.3, 160 in.3, 320 in.3 and 730 in.3 The length is a factorof the volume required. The specifics of the application willdetermine proper tank length. Multiple tanks can beconnected together in series if space restrictions prohibitthe use of one larger tank.

How to Determine Compression Tank SizeThe volume of nitrogen necessary should be establishedbefore the system is built. The pressure increase causedby the stroking of the cylinders can affect the success ofthe operation

The first step in determining the required volume is to findthe “Swept Volume” (S.V.) of the nitrogen pushed from thecylinder during its working stroke. The following formula isused in that determination:

S.V. = Effective piston area x working strokex No. of cylinders

From this the tank volume is determined as follows:

Required 100% Totaltank = of desired x Swept

volume pressure rise Volume

General Points to RememberPressure increase or rise is generally recommended:

• 15 to 20% for draw dies• 30 to 40% for cam returns, strippers and form pads• Systems under 50 in.3 not recommended

System pressure with the die closed should never exceedrecommended pressure limits of the system. Example: Asystem designed with a compression tank allowing a 33%pressure rise as the die closes, should not be chargedabove 77 bar/1125 psi in the die open position so it will notexceed 103 bar/1500 psi in the die closed position.

Example of Tank Size Determination10 tons of force is needed with a 38 mm (1.5 in.) workingstroke. Allowable pressure rise is 10% and a minimum of 4cylinders are required to distribute the force.

Cylinders are:4 - MORB 2.5 x 2 in. (50 mm stroke)Piston Area = 3.44 in.2Total Swept Volume (S.V.) = 3.44 in.2 x 1.5 in.x 4 = 20.64 in.3Compression tank volume =100 x 20.64 in.3 = 206 in.3 10

You can choose one of the four standard tanks available,provided your required volume is near that of one of thestandard tanks, or you can specify a special tank using thechart on the following page.

Our example shows a required volume of 206 in.3 We maychoose the SCT-320 or specify special compression tankSCT-5, F (overall length) = 11.5 in. or other combinationsof tube size and length as required. Extra volume in asystem is generally not a problem; often the next largeststandard tank can be used. When this is not the case, youcan specify a special tank as described on the next page.

Piston Areas

Cylinder BCQ MOR .5 MOR 1 MOR 2.5 MOR 4 MOR 6

Effective 2.97 cm2 5.07 11.40 22.26 33.92 51.50Piston Area .460 in.2 .785 1.767 3.450 5.412 7.982

Standard Tank ModelsStandard tanks come in 4 sizes with port locations asspecified in the chart. Where special tank or port require-ments are necessary, see the following page.

3 mm1/8 in.

6 mm1/4 in.

FACE 5

E = Dia. Holes

FACE 1

25 mm1 in.

DOverall Length

C

A

B

Standard Tanks

Overall No. of Port SizeModel Volume Length Ports Face 1 & 5 A B C D E

SCT-50820 cm3 305 mm mm 108 114 13 13 11

50 in.3 12 in.3 each 3/4-16

in. 4-1/4 4-1/2 1/2 1/2 7/16

SCT-1602622 cm3 610 mm mm 108 114 13 13 11

160 in.3 24 in.3 each 3/4-16

in. 4-1/4 4-1/2 1/2 1/2 7/16

SCT-3205244 cm3 610 mm mm 149 152 13 13 11

320 in.3 24 in.4 each 3/4-16

in. 5-7/8 6 1/2 1/2 7/16

SCT-73011963 cm3 610 mm mm 225 254 19 19 17

730 in.3 24 in.5 each 3/4-16

in. 8-7/8 10 3/4 3/4 11/16

All ports come with 3/4-16 SAE O-ring ports with 1/2-20 reducers.


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Nitro-Dyne® XP Manifold SystemsSpecial Compression Tanks

10.12.02

Special Compression Tanks can be manufactured to suit special volume or length requirements.

1

2

3

6 7

5

8

4

I.D.

3 mm1/8 in.

6 mm1/4 in.

K

A

C

B

D

O-Ring Port End

N = Dia. HolesG = No. Req’dG – Each Foot

25 mm1 in.

D

Tube Length =Volume Required ÷ J

M

F = T + Tube Length

H = O.D.

All compressiontanks come withan RD-2150 SafetyRupture Disc.

Specify Port LocationsThe compression tank head is used as the base in whichfittings/O-ring ports are located for those connections to thecylinders and/or control panel. The application will dictate theport size and location for easy hose attachment.

To Order Special Tanks SpecifyExample:

1. Model SCT-52. Overall length (F) 292 mm

(11.5 in.)

3. Number of ports 2 portsdesired eachwhich face Face 1 & 5

4. Size of ports1/2-20

desired

Tanks do not have to be round.Special tanks can be made in variousshapes or configurations to meet yourspecific requirements.

Tanks with less than 50cubic inches of volume arenot recommended.

Compression TanksT J

Base Length A B C D E G H K L M N TubeModel Zero Volume Area

SCT 3.5mm 152 108 54 114 57 40 102 13 13 25 11 5721 mm2

in. 6 4-1/4 2-1/8 4-1/2 2-1/4 1-9/162

4 1/2 1/2 1 7/16 8.87 in.2

SCT 5mm 165 149 75 152 76 46 141 13 13 25 11 11723 mm2

in. 6-1/2 5-7/8 2-15/16 6 3 1-13/162

5-9/16 1/2 1/2 1 7/16 18.17 in.2

SCT 8mm 203 225 113 254 127 51 219 19 19 38 17 29422 mm2

in. 8 8-7/8 4-7/16 10 5 23

8-5/8 3/4 3/4 1-1/2 11/16 45.6 in.2

SCT 10mm 203 286 143 305 152 51 279 19 19 38 17 50671 mm2

in. 8 11-1/4 5-5/8 12 6 24

11 3/4 3/4 1-1/2 11/16 78.5 in.2

The recommendations for maximumports per face are made to permit theuse of elbow fittings.

Maximum Ports Per FaceTube Faces Faces

Model I.D. 1 & 5 2, 3, 4, 6, 7, 8

SCT 3.585 mm

2 each 2 each3.36 in.

SCT 5122 mm


SCT 8194 mm


SCT 10254 mm


Note: The remote attachment of a control panelNote: always requires a -5, 1/2-20 port


10-99


®

Nitro-Dyne® XP Manifold SystemsSafety Features

10.13.01


All our nitrogen systems and components are designed and tested to ensure an adequate structural factor of safety.As with all nitrogen systems, read and follow all operating and maintenance instructions.

Safety Features:1. Pressure Relief Groove

The threads of nitrogen gas cylinders contain pressurerelief grooves through which nitrogen will escape ifanyone attempts to remove a nitrogen gas cylinder fromthe manifold while the cylinder is pressurized. Thesound of escaping gas warns that the system is stillunder pressure and no further service should be doneuntil the manifold is completely discharged.

RD2150

Pressure ReliefGroove

Rupture Discin Control Panel

Rupture Discin Plug if remote

Control Panel

If a rupture disc bursts, the sound of escaping gas warnsof an overpressurizing condition in the manifold system.Always replace the rupture disc with an identical new one.Never use a plug or higher-rated rupture disc in place ofthe supplied rupture disc. Always correct the overpressurecondition in the manifold before recharging.

2. Rupture DiscAll Nitro-Dyne XP manifold systems contain rupturediscs.

When the control panel is bolted to the manifold plate,the rupture disc is located on the control panel. Whenthe control panel is mounted remotely, rupture discs areinstalled in both the control panel and the manifold.

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10.14.01

WARNING: Put on safety glasses before charging any nitrogen gas system. Prior to pressurizing any manifold,inspect for damage or factory-unauthorized modifications such as welding, grinding or gouges. Do not pressur-ize if damage or improper modifications are noted.

WARNING: Prior to pressurizing any manifold, inspect for proper assembly of manifold cylinders and compo-nents. Manifold cylinders and plugs are available in both English and metric threaded versions and may appearto be very similar in size. Never mix thread types! If there is any doubt about thread type, contact HysonProducts, Customer Service department at 1-800-876-4976.

!

!

Nitro-Dyne XP Charging Instructions:

11. Attach Nitrogen Charging Assembly (NCA) tonitrogen gas bottle.

12. Set NCA regulator to zero pressure.13. Close shut-off valve on NCA hose.14. Close bleed down valve on control panel.15. Attach NCA quick disconnect to quick check inlet

valve on control panel.16. Open valve on nitrogen gas bottle.17. Set desired pressure on NCA regulator.

WARNING: To prevent damage to the manifoldsystem and possible personal injury, chargemanifold to a maximum of 103 bar/1500 psi.

!

!

Nitrogen Charging Assembly (NCA)

ControlPanel

Shut-OffValve

Quick Disconnect

Quick CheckInlet Valve

Regulator

Valve

NitrogenGas

Bottle

Nitro-Dyne® XP Manifold SystemsCharging Nitro-Dyne® XP Systems

18. Slowly open shut-off valve on NCA hose.

WARNING: To prevent damage to nitrogen gascylinders with depressed piston rods, slowly applypressure until piston rods are fully extended.

19. When correct pressure is obtained, close valve onNCA hose.

10. Disconnect NCA from control panel.11. Replace protective cap on quick check inlet valve.12. Close valve on nitrogen gas bottle.13. Open shut-off valve on NCA hose to vent charging

assembly.14. When gas flow stops, close NCA shut-off valve.

Bleed Down Valve Quick Check Inlet Valve

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Nitro-Dyne® XP Manifold SystemsDischarging Nitro-Dyne® XP Systems

10.14.02

Nitro-Dyne XP Discharging Instructions:

WARNING: Put on safety glasses and hearingprotection before discharging any nitrogen gassystem.

11. Slowly open bleed down valve on control panel.12. When gauge reaches zero and the gas flow stops,

depress piston rods.

CAUTION: Do not depress piston rods with yourhand directly. Place a block of wood between therod and your hand. The piston rod may pop upafter being manually depressed.

13. Close bleed down valve on control panel.

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Bleed Down Valve Quick Check Inlet Valve

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Hyson Products XP Manifold Systems Associated Spring ... PROGRAMMA STAMPI LAMIERA... · 10-99 Hyson ™ Products Associated Spring ® Nitro-Dyne® XP Manifold Systems Design/Layout