Controllable Gas Springs - jiscco.com · Gauging hoses / gauging couplings / distributor box 38 -...

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Ord

er N

o. 2

.250

1.01

.090

5.01

000

03/2006 PATENTED

Controllable Gas Springs

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subject to alterations2

PageFIBRO – The latest technology – with a tradition of service 4 - 5

Introduction 6

Description of the main components 8Active gas springs (KF) 2489.14. 8Passive gas springs (KP) 2489.16. 9Valve block 2489.00.40/41 10

Description of the functions 11Controllable gas spring KF 11 - 12KF + KP system without spring back 13 - 14Heating - cooling 15

Selecting the components 17 - 19KF order form 20KF + KP order form 21

Dimensions and Order Numbers 23Active gas springs (KF) 2489.14. 24 - 25 Passive gas springs (KP) 2489.16. 26

Control system 27 - 28Compressed air connections for 6 mm hose 29 - 30Control valves 31Filling and emptying gas, KF 32 - 33Filling and emptying gas, KF + KP 34 - 35Valve block 36Control unit 37Gauging hoses / gauging couplings / distributor box 38 - 39Connecting hoses / direct connection / dimensions 40 - 42

Monitoring Process Safety 43Overheating protection 44Monitoring air pressure 45Mechanical control system 46Pressure sensor 47Pressure switch 48Rating plate 49

Cooling 51 - 53Cooling unit for controllable gas springs 54Hose and hose connectors, cooling system 55Distributor block, cooling system 56Connector block, cooling system 56Quick release connector, cooling system 56

Typical Applications 57Example of application with Gas Spring system KF+KP 58 - 61FAQs 62 - 64Matching the stroke length in KF Gas Springs 65 - 66Suggestion: conversion of existing systems 67

Contents

subject to alterations 3

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Weibertreu Castle at Weinsberg

The FIBRO plant Weinsberg

Indexing tables

The FIBRO of today started up in Weinsberg on a verysmall scale back in 1958. Situated below the historicWeibertreu Castle, the company made precision rotaryparts, the forerunners of today’s FIBRO Standard Partsrange for the toolmaking industry.Progress was rapid and soon FIBRO needed new production facilities. A new factory was built at Hassmersheim on the River Neckar. Once again it was a historic location, this time opposite Hornberg Castle.

Indexing tablesFrom 1962 onwards FIBRO at Weinsberg pioneered thedesign and manufacture of indexing tables and soon gained an enviable reputation.FIBROTAKT: indexing tables with face gear and ultra-high-precision indexing, combined with dependablerigidity. Drive options: pneumatic, hydraulic, electric.Rotation by rack and pinion or worm drive. Manual orNC control.FIBROPLAN: indexing tables with worm drive and NCindexing and drive, for circular milling and divisions ofany size.FIBROTOR: revolving tables or indexing tables withpositive-drive cam, offering very short cycle times evenwhen transporting heavy loads. Suitable for automationwith short cycle times. Thousands of FIBRO units are inuse world-wide as integral key components in high-output machinery.

Standard PartsToday the Standard Parts division operates from the Hassmersheim works which manufactures a comprehensive range of standard parts and maintainsstocks ready for immediate despatch world-wide.The machine tool, mechanical engineering and systemsengineering product range includes machine pillars,guide rails, oilless guide elements and precision partssuch as cutting dies and die bushes, special steel pressure springs, gas springs, forming materials, metalbonding agents and moulding resins, accessories forpressing and toolmaking, tool slides with cam or rollerdrives and independent hydraulic drives.FIBRO has become renowned world-wide for its comprehensive range of products kept in stock and itsreadiness to deliver.

FIBRO – The latest technology – with a tradition of service


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Hornberg castle on the opposite side ofthe river

The FIBRO Hassmersheim plant

Standard Parts Automation+Robotics

Automation+RoboticsFIBRO has been active in the field of automation androbotics since 1974 from the Hassmersheim works.Modular construction based on translation units, rotaryunits, grippers and guide gantries with trolleys make foreasy construction of individual machines and completesystems, ranging from simple pick & place units rightthrough to multi-axis robots. These series-manufactu-red modules are available in several sizes for loads upto 3,150 kg, traversing speeds up to 6.5 m/sec and travel of up to 30 m. Module series with electric-motor,hydraulic and pneumatic drive can be combined to suitthe specific requirements. The system has a trackrecord of success in many sectors of industry.

FIBRO is much in demand as a supplier to the mechanical engineering and metalworking sectors.This success is based largely on three factors: FIBRO’sin-depth knowledge of the market, its commitment toquality assurance in line with ISO 9001 and its flexibleand responsive organisational structure so typical ofmedium-sized German companies.

FIBRO: a company with a great history. FIBRO hasdeveloped at a rapid pace in these fast-moving timesand will continue to demonstrate its proactive philoso-phy in the future.

FIBRO – precision technology for the toughest tasks

More about FIBRO:• 900 staff• 80 representatives and service stations world-wide• branch offices in France, USA, Singapore and

Switzerland.

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2489.14.Controllable Gas Springs 2489.16.

IntroductionControllable gas springs (KF springs) are gas springswhich can be locked in their bottom position.The timing of the return stroke can be controlled tosuit the application.

Controllable gas springs are available in 15 kN, 30 kN,50 kN and 75 kN versions.

For best results the stroke length must always beused to the full with a tolerance of ± 0.5 mm.

For this reason the springs are available with anystroke length from 4 to 167 mm in 1 mm increments.

The gas spring return stroke can be controlledelectrically or pneumatically from either the tool or thepress end.

In the basic version of the gas spring (KF), it returnsabout 1 mm before it is held in the bottom position.This spring back effect can be eliminated, if required,by connecting the KF gas spring to a passive gasspring (KP) via a valve block. This is known as a KF +KP system. Both variants are illustrated in thisbrochure.

General instructionsYou can ensure system safety and reliability by supplying FIBRO with the application data and drawings of theinstallation arrangements for checking.

Please note that the number of the screwed connections and the hose lengths for installation in the system mustbe determined.

Assembly, commissioning, maintenance and servicing of controllable gas springs require special knowledge and may only be carried out by FIBRO appropriately trained, specialist personnel.

You can arrange for the work to be completed by a FIBRO customer service engineer, the invoiced cost includingthe assembly kits.

Just contact us to schedule the work for you.

We shall be pleased to answer any technical queries you may have, now or at any time in the future.

As controllable gas springs include parts which are specially made to specific stroke length, we recommend that you keep reserve systems in stock to avoid the risk delay when the need arises.


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ohne Rückfederung

max. Pressenhub

max. Federhub

0

Hub

Gasdruck

federPres

se

Zeit

Rückfederung max. 1 mm

max. Pressenhub

max. Federhub

0

Hub

Gasdruck

federPres

se

Zeit

2489.14.2489.16. Controllable Gas Springs

2489.14.KF (max. spring back 1 mm)

2489.14. + 2489.16.KF+KP system (without spring back)

KF

max. press stroke

max. spring travel Pres

s

Gas sprin

g

time

max. spring back 1 mm

max. press stroke

max. spring travel

time

no spring back

Pres

s

Gas sp

ring

stroke

Stroke

KFAktiv

KPPassiv

Ventilblock

KFactive

valve block

KPpassive

Description of thecomponents

Active gas springs KF2489.14.The KF controlled Gas Spring 2489.14. can be lockedin its bottom position.

The Gas Spring consists of a cylinder (1), a guide (2),the piston and piston rod assembly (3), return valves(6), and internal piston rod (4) and a cartridge valve inthe bottom of the Gas Spring (5).

There is also a version with a cooling jacket (7) (seepp 15 & 52).

There are three ports in the base of the Gas Spring:two nitrogen (1) and (3), connected to the gas cavitiesin the Gas Spring, and a compressed air port (4) forthe compressed air to operate the cartridge valve.

Port (1) is used for emptying the Gas Spring via thepassive GDF (KP), port (3) for filling it with nitrogen.

Compressed air applied at port (4) closes thecartridge valve. In the absence of air pressure thevalve opens.

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Controllable Gas Springs 2489.14.

3

2

1

4

5

6

7

4 1 3Stickstoffanschlüsse Druckluftanschluss

489.14.

2489.14.

2489.14.

Compressed air port Nitrogen ports

Passive gas springs (KP)2489.16.The passive KP gas spring 2489.16 is used to prevent theKF gas spring(s) springing back.

The KP gas spring must not be used in the operational working area of the tool, but must be compressed by the tool.

The passive gas spring consists of one cylinder (1), a guide(2) and piston and piston rod (3). The piston divides thegas spring into two gas compartments, the upper (4) andthe lower (6).

The upper compartment has four G 1/8” ports (5), thelower a G1/8" gas filling port (7).

2489.16. Controllable Gas Springs


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2489.16.

2

4

3

6

7

5

1

2489.16.

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Controllable Gas Springs 2489.00.47.01

Valve block with no facilities forfilling or emptying(2489.00.47.01)This valve block is used for controlling the flow of gasfrom the KF Gas Spring to the KP Gas Spring.

This valve block must be used with control fitting2480.00.31.01 for filling or emptying nitrogen .

The valve block consists of a block (4), return valves(2) and a cartridge valve (6). The block has two ports(1,3) for connecting to the KF Gas Spring(s) and aport (5) for connecting the passive KP spring. Thecompressed air port (C) is used for controlling thecartridge valve.

Valve block 2489.00.47.01

Filling port

C

2

6 4

1 5

3

Befüllanschluss

Anschluss zurEntleerung

Filling port

Emptying port

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2489.14. Controllable Gas Springs2489.16. Description of the functions

Description of the functionsControllable gas springsKF 2489.14.The KF gas spring has a locking function at thebottom position. Before the gas spring is heldcompletely at the bottom position there is a slightspring back of 1 mm (or less). The completestroke must be used, with a tolerance of 0.5 mm.

Note:If the full stroke length is not used the spring back is more than 1 mm.

Fig. A, return stroke

Fig. B, Gas spring at bottom position.

1

3

2

4

Down stroke The KF gas spring has two compartments, anupper one (1) and a lower one (2) which areseparated by the piston of the gas return spring.The gas flow between these two compartments isas follows:

Fig. A shows the gas spring piston down stroke.During the down stroke the gas flows unimpededthrough the return valve of the piston (3) from thelower (2) to the upper (1) gas compartment of thegas spring. The cartridge valve (4) in the base ofthe spring is closed.

As soon as the press and the gas spring reach thebottom position the return valves (3) close. (Fig. B).The gas spring is now "locked".

The pressure of the gas above and below thepiston is the same. But as the surface exposed tothe gas on the underside of the piston is largerthan that on the upper side, there is a greater forceapplied. On the return stroke of the press (relief ofspring) this force is released and causes the springto return 1 mm. This results in a reduction of thepressure under the piston as the gas has beenallowed to expand. The pressure in the uppercompartment increases until there is a state ofequilibrium.

At this moment the gas spring stops completely.

Rückfederung max. 1 mm

max. Pressenhub

max. Federhub

0

Hub

Gasdruck

federPres

se

Zeit

max. press stroke

max. spring travel Pres

s

Gas sprin

g

time

max. spring back 1 mm

Stroke


Controllable Gas Springs 2489.14.Description of the functions 2489.16.

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Return strokeThe Gas Spring is released from its locked position whenthe cartridge valve (4) in the Gas Spring base is openedby the removal of pressure. (Fig. C). This causes the gasto flow through the piston rod (5) from the uppercompartment (1) via the cartridge valve (4) back into thelower chamber (2). The speed of the upstroke isapproximately 0.2 m/s in models 2489.14.01500. and.03000. and approximately 0.15 m/s in models2489.14.05000. and .07500.

5

1

4

2

Fig. C, return stroke

Pneumatic control (controlled compressed air availablefrom the press)

If there is a line for controlled compressed air from thepress, this can be used directly to operate the cartridgevalve.

Gasdruck-federverriegelt

t 2t10t

offen geschlossen

Hub

Gasdruck

feder

Pres

se

00

Zeit

max. Federhub

max. Pressenhub

Ventil KF-Gasdruckfeder

offen

t 0 vor UT der Presset 1 UT der Presset 2 Beginn des Rückhubs der Gasdruckfeder

KF control systemAs described above, the return stroke of the Gas Spring iscontrolled by the cartridge valve in the base of the GasSpring. The valve is closed by compressed air and openedby the absence of pressure.

Valve KF gas spring

max. press stroke

max. spring travel

Stroke

Gas sprin

g

time

open openclosed

Press

before UT of pressUT of the pressbeginning of return stroke of gas spring

gas springlocked

Min. 5 bar0 bar

Druckluftsignal ASignal an Anschluss 4oder pneumatischesVentil.

240 0V (offen)

24 V DC

t 2t10t

ElektrischesSteuersignal

A constant supply of compressed air is required forboth the pneumatic and the electro-pneumatic valves.The required minimum pressure is 4 bar.

A control valve can control up to 6 Gas Springs.

The control signals for the Gas Springs and the valvesare shown in the diagrams.

Electric control (electric control signal from thepress available)If there is an electrical control signal available fromthe press then the 2489.00.41.32 electro-pneumaticcontrol valve can be used to convert the electricalsignal into a pneumatic one.

Min. 4 bar0 bar

24 V DC0V (open)

t 2t10t

Steuersignal

Compressed air signal ASignal at port 4 orpneumatic valve.

Electrical control signal

Control signal


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4

Controllable gas springs 2489.14. + 2489.16. KF + KP system without spring backIn a KF + KP system the locking function can be arranged that a spring back is completelyeliminated.

Between one and four controlled gas springs (1) canbe connected to a passive KP gas spring (2) via a valveblock (3).

The KF spring is connected to the valve block by 2hoses. The valve block has a hose connection to theupper gas compartment. There is the same gaspressure in all parts of the system at the start of theworking cycle.

During the down stroke the KF gas spring works asdescribed on p. 11.

At the end of the press stroke the KP gas spring iscompressed. This increases the volume of the uppergas compartment in the KP gas spring with a resultantdecrease in pressure. The gas pressure has increasedin the KF gas spring(s) as the gas has beencompressed.

At bottom dead center (Fig. B) the cartridge valve (4) inthe valve block opens so that the gas from the bottomgas compartment of the KF gas spring can flow into theupper compartment of the KF gas spring.

There is a resultant decrease in pressure in the bottomcompartment of the KF gas spring, so that the forcepushing the piston of the KF gas spring upwards is lessthan that from the upper compartment acting in adownward direction.

This means there is no spring back of the KF springwhen the press relieves the load. The KP gas springfollows the press stroke to its home position (Fig. C).

The return stroke of the KF spring is as described onpage 12.

To ensure the effectiveness of the locking function, the supply to the KP gas spring must be separate from the supply to the KF gas spring. This means that unlike the KF gas spring, the KP gas spring must not be used in the operational working area.

Abb. A

3 21

KF gas spring valve block KP gas spring

ohne Rückfederung

max. Pressenhub

max. Federhub

0

Hub

Gasdruck

federPres

se

Zeit

max. press stroke

max. spring travel

time

no spring back

Pres

s

Gas sprin

g

StrokeKF gas spring valve block KP gas spring

Fig. B

Fig. A

Fig. C

KF gas spring valve block KP gas spring


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Controllable Gas Springs 2489.14.Description of the functions 2489.16.

GasdruckfederVentilblock

Druckluftsignal BSignal an Anschluss 2an der KF-Gasdruck-feder.

Druckluftsignal A

VentilVentilblock

Ventil KF-Gasdruckfeder

geschl. offenoffen geschl.

offengeschl.

max. Pressenhub

Pres

se

Gasdruck-federverriegelt

00

Zeit

Gasdruck

feder

Hub t t 2t10

max. Federhub

geschl. geschl.

t 0 vor UT der Presset 1 UT der Presset 2 Beginn des Rückhubs der Gasdruckfeder

Min. 5 bar0 bar

Signal an Anschluss 4an der KF-Gasdruck-feder oder an daspneumatische Steuer-ventil 2489.00.40 füraktive Gasdruckfedern.

Min. 5 bar0 bar

Valve KFgas spring

Valve valve block

open open closed closed

closed closed closedopen

Stroke

max. press stroke

max. spring travel

gas springlocked

time

Gas sp

ring Pre

ss

before UT of pressUT of the pressbeginning of return stroke of gas spring

Compressed air signal ASignal to port 4 at theKF gas spring or to the2489.00.40 pneumaticcontrol valve for activegas springs.

Compressed air signal Cto port C of the valveblock or to the2489.00.40 pneumaticcontrol valve

KF + KP control systemThe control signals for a KF + KP system areshown in the diagram. The system function, as described, is controlledby the cartridge valves in the base of the KF gasspring(s) and in the valve block. These two valvesare not opened and closed simultaneously.

Pneumatic control (controlled compressed airavailable from the press)

If there are two lines for controlled compressedair from the press, these can be used directly tooperate the cartridge valves.

Electric control (electric control signal fromthe press available)

If there are two electrical control signals availablefrom the press then two 2489.00.41.32 electro-pneumatic control valves can be used to convertthe electrical signals into pneumatic ones.

A constant supply of compressed air is requiredfor both the pneumatic and the electro-pneumaticvalves. The required minimum pressure is 4 bar.

The control signals for the gas springs and thevalves are shown in the diagrams in the nextcolumn.

A maximum of four KF gas springs can be linked to one KP gas spring. The stroke length of the KP gas spring doesnot depend on the stroke length of the KF gas spring(s). The extent to which the KP gas spring has to be compressed depends on the number ofKF gas springs in the system. (see p. 25)

Druckluftsignal A

Druckluftsignal C

t 2t10t

Steuersignal anelektropneuma-tisches Steuer-ventil 2489.00.41für den Ventilblock.

Steuersignal anelektropneuma-tisches Steuer-ventil 2489.00.41für die KF-Gas-druckfeder(n).

240 0V (offen)

24 V DC

240 0V (offen)

24 V DC

t 2t10t

Control signal at2489.00.41.32 electro-pneumatic control valvefor the valve block.

Control signal to the2489.00.41.32 electro-pneumatic control valvefor the KF gas spring(s).

Compressed air signal A

Compressed air signal B

Min. 4 bar0 bar

24 V DC0V (open)

Min. 4 bar0 bar

24 V DC0V (open)


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Heating - cooling When a gas spring is compressed, a certainamount of energy is transmitted by the press tothe gas spring. This amount of energy can becalculated by multiplying the spring force by thestroke length. In a conventional gas spring, thepiston rod follows the gas spring during thepress return stroke. The amount of energygenerated, excluding any losses due to frictionetc, is transmitted back to the press.

If controlled gas springs are used, the active gasspring does not follow the return stroke of thepress. Indeed it generally requires a very lowenergy value for its own return stroke comparedto the spring force used during compression. Thedifference between the amount of energytransmitted to the gas spring during compressionand the amount of energy consumed during thereturn stroke is converted into heat.

This means that in some applications gas springsneed cooling to prevent overheating. The amountof cooling required is calculated using the "heatfactor".

The heat factor is calculated by multiplying thestroke rate by the stroke length of the gas spring.If this heat factor exceeds the values shown inthe diagram opposite for various sizes of gasspring, then the gas spring must be cooled. Theheat factor is calculated on the basis of a fillingpressure of 150 bar.

(See also page 52)

In-tool control systemThe control system required for locking the KF GasSpring can be integrated in the tool as a mechanicalpressure switch. Then the control system required forlocking and unlocking the KF Gas Spring(s) isindependent of the press control system.

The KF Gas Spring or Springs remain locked as longas the mechanical pressure switch [1] is operated bythe tool [2].

A control system integral within the tool requires aconstant supply of compressed air (at least 4 bar) forthe mechanical pressure switch.

Please note:It can also be used for controlling the valve of thevalve block for forced locking systems.

[1]

[2]

erforderlicheKühlleistung (kW)pro KF-Gasdruckfederbei max. Wärmefaktor

21,40,90,3

MaximalerWärmefaktormit Kühlung

MaximalerWärmefaktorohne Kühlung

800

400

200

1400

Wärmefaktor =Hublänge (mm) x Hubzahl (Hübe/min)

600

1400

1200

1050950

1200

1000

2489

.13.

0150

0.

2489

.13.

0300

0.

2489

.13.

0500

0.

2489

.13.

0750

0.

Maximum heatfactor withcooling

Maximum heat factorwithout cooling

Heat factor = stroke length (mm) x numberof strokes (strokes/min)

Cooling required

No cooling required

Heat quantity [kW]per KF Gas Springat max. heat factor

0,3 0,9 1,4 2,0

2489

.14.

0150

0.

2489

.14.

0300

0.

2489

.14.

0500

0.

2489

.14.

0750

0.

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Selecting the components

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Selecting the componentsThis section describes step by step how to select thevarious components for a complete KF system. Aseach tool offers different options, the step by stepprocedure should be followed in each case.

Select the components for your system. Use theinformation pages, then decide on the system youneed, and the parameters and components. We shallbe pleased to answer any queries you may have.

Fill in the order form list (KF on p. 20, KF + KP on p.21) and for each component you select enter theorder code and the number you require.

Step 1Type of system, KF or KF + KPThe KF system has a locking function with amaximum spring back of 1 mm. If you need toeliminate spring back totally use a KF + KP system. A KF system can be converted into a KF + KP systemby the addition of a KP spring.

Step 2.1KF gas springs 2489.14.Technical dataKF gas springs do not work like traditional gassprings. KF springs generate heat which isdetermined by the force (filling pressure), stroke andstroke rate. If the filling pressure is less than 80 barthen a low pressure cartridge valve is required.

The full stroke length of the KF gas spring must always be used.

Components Catalogue pageInformation to select Additional informationcomponents

Components Catalogue pageKF - max. spring back 1 mm 11- 12orKF+KP - no spring back 13- 14

Components Catalogue pageForce per gas spring 24Number of gas springsFilling pressureStroke (4-167 mm) 24Stroke rate (strokes/min)Cooling required 52

2489.14.Controllable Gas Springs 2489.16.

Step 2.2KP gas spring 2489.16.Technical dataThe passive KP gas spring must not be used in atool. A maximum of four KF gas springs can belinked to one KP gas spring.

Step 2.3Valve blockEvery KP gas spring must have a valve blockconnected.

Components Catalogue pageSize of gas spring 25Stroke used 25

Components Catalogue pageValve block 36


2489.14.2489.16. Controllable Gas Springs

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Step 3.1Control systemCheck whether there is a pneumatic signal or anelectrical signal (24 V) available from the press. Ineither case the control valves need compressed air(at least 4 bar) to control the cartridge valves. Donot connect more than four KF gas springs to onecontrol valve.

Step 3.2Overheating protectionFit a thermal relay to protect the gas springs fromoverheating.

Components Catalogue pagePneumatic signal from the pressor 31Electrical signal from the pressPneumatic hose, blue 29Compressed air connections 29 - 30Example 28

Components Catalogue pageThermal relay 44

Step 4.1Filling and emptying gas in the KF system.KF Gas Springs can be used independently of eachother or in conjunction with each other. For each KFGas Spring two hoses are required: one for filling andone for emptying.

Step 4.2Filling and emptying gas in the KF + KP system.KF and KP gas springs must always be connected toeach other. You need hoses of different sizes for fillingand emptying.

Components Catalogue pageControl unit 37Measuring hose 38Measuring connector 39Example 33

Components Catalogue pageValve block + control unit 36 - 37Control fitting for KP Gas Spring 37Gauging hose 38Gauging coupling 3924° cone hose 4124° cone hose adapter 40Example 35

Step 5FixingWe recommend that you use the tapped bore in thebase of the gas spring for fixing. Alternatively you could use the mounting variations2480.055./057./007. .

Step 6Cooling systemThe cooling jacket is mounted on the gas spring asshown in the illustration on p. 52.All gas springs are connected in parallel to thecooling unit. We recommend that you use colourcoded hoses for the connections between the gassprings and the distributor block. The hoses areconnected to the cooling jacket with tubular screwconnectors with push lock connection. There is norisk of overheating provided that you fit all gassprings with thermal relays. (see p. 44)

Components Catalogue pageFixings 24 - 25

F146 - F152 in the main catalogue

Components Catalogue pageCooling unit 10 kW / 25 kW 54Connections 55Hose 55Connector block 56Quick-release coupling 56

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Customer: Comment:

Tool no.:

Technical contact:

Tel:

Fax:

Step 2KF gas springsComponents Order no. NumberKF gas spring 2489.14.

Step 4Filling and emptying gas in the KF systemComponents Order no. NumberControl unit 2489.00.31.01Gauging hoseGauging hoseGauging hoseGauging hoseGauging coupling G1/8" 2480.00.24.01

Step 6Cooling systemComponents Order no. NumberCooling unit 10 kW 2489.00.50.10Cooling unit 25 kW 2489.00.50.25Hose connectorHose connectorHose, blue, Ø 16 2489.00.52.16.11Hose, red, Ø 16 2489.00.52.16.12Distributor block 2489.00.54Hose, blue, Ø 23 2489.00.52.23.11Hose, red, Ø 23 2489.00.52.23.12Connector block 2489.00.55Quick connector, plug 2489.00.56Quick connector, socket 2489.00.57

Step 1Technical dataComponents information requiredForce per gas spring daNNumber of gas springsFilling pressure barStroke (4-167 mm) mmStroke rate (strokes/min)Cooling required yes no

Step 3Control systemComponents Order no. NumberControl valveElectrical/pneumaticCompressed air hose, blue 2489.00.42.06.11 xx mCompressed air connectionsCompressed air connectionsCompressed air connectionsCompressed air connectionsThermal relay 2489.00.70

Step 5FixingComponents Order no. NumberFixings

Controllable Gas SpringsKF order list


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Step 2KF+KP gas spring croupsComponents Order no. NumberKF gas springsKP gas springsKP gas springs: stroke used mmValve block

Step 4Filling and emptying gas, KF + KP systemComponents Order no. NumberValve block without manometer* 2489.00.47.01Gauging hoseGauging hoseGauging hoseGauging hoseCompressed air connections G1/8" 2480.00.26.03Control unit 2480.00.31.0124° cone hose 2480.00.25.0x.xx24° cone threaded connectors24° cone threaded connectorsThreaded coupling G 1/4" 2489.00.26.04* Control unit with manometer 2489.00.31.01

for valve block without manometer

Step 6Cooling systemComponents Order no. NumberCooling unit 10 kW 2489.00.50.10Cooling unit 25 kW 2489.00.50.25Hose connectorHose connectorHose, blue, Ø 16 2489.00.52.16.11Hose, red, Ø 16 2489.00.52.16.12Distributor block 2489.00.54Hose, blue, Ø 23 2489.00.52.23.11Hose, red, Ø 23 2489.00.52.23.12Connector block 2489.00.55Quick connector, plug 2489.00.56Quick connector, socket 2489.00.57

Step 1KF gas springs, technical specificationsComponents information requiredForce per gas spring daNNumber of gas springsFilling pressure barStroke (4-167 mm) mmStroke rate (strokes/min)Cooling required yes no

Step 3Control systemComponents Order no. NumberControl valveelectricalCompressed air hose, blue 2489.00.42.06.11 xxCompressed air connectionsCompressed air connectionsCompressed air connectionsCompressed air connectionsThermal relay 2489.00.70

Step 5FixingComponents Order no. NumberFixings

Controllable Gas SpringsKF + KP order list

Customer: Comment:

Tool no.:

Technical contact:

Tel:

Fax:

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Dimensions and Order Numbers

Controllable Gas SpringsActive gas springs (KF)

Passive gas springs (KP)

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Controllable Gas SpringsActive Gas Springs (KF) 2489.14.

2489.14.

Description:In some applications it is difficult toestablish in advance the exact strokelength required.We have designed the active Gas Springwith adjustable stroke length to solve thisproblem. The stroke is adjustable bymeans of four special adjusting washers(2489.14.451.xxxxx.01,2489.14.451.xxxxx.02,2489.14.451.xxxxx.04 and2489.14.451.xxxxx.08) in the Gas Spring.The total adjustment available is 15 mm (-7mm and + 8 mm relative to rated stroke).For information on adjusting the strokelength see pages 65/66.The following table shows the stroke lengthadjustments and the resulting installationheights.

Technical data:Pressure medium nitrogenFilling pressure max. 150 barFilling pressure min. 25 barOperating temperature 0 to +80°CTemperature related force increase ±0.3 %/°CPiston rod speed max 0.8 m/smax. piston rod return speed2489.14.05000. - .07500. 0.15 m/s2489.14.01500. - .03000. 0.2 m/s

Note:For best results, the stroke length of theGas Spring must always be fully utilizewith a tolerance of ±0.5 mm.– the Gas Springs are normally supplied

with connections as above and unfilled.– We recommend that you use the tapped

bores in the base of the Gas Spring for fixing.

– Alternatively the fixing versions 2480.055./057./007. can be used.See Standard Parts Catalogue.

28

Nen

nhub

AL

Nen

nhub

8c

eins

tellb

arer

Hub

ll

eins

tellb

arer

Hub

(2x)

ø18

19

d3

dd

1d

2b

37

61

G1/ 4

(2x)

min

.lm

in.

Boden für Befestigung (2x)

)Gasanschluss (G1/8

Gewindebohrungen M im

1

1 3

Druckluftanschluss 42489.00.42.06.xx(für Druckschlauch ø6 mm)

Kühlung

)Gasanschluss (G1/83nur bei passiver Gasdruck-feder (2489.16.)

nicht bei 2489.14.01500.

Ad

just

able

stro

ke Cooling

Ad

just

able

str

oke

c+ N

omin

al s

trok

e +

8

L=N

omin

al s

trok

e +A

Threaded bores in base

not on 2489.14.01500.

for fixing (2)

Compressed air connector 42489.00.42.06.xx(for compressed air hose 6 mmdiameter)

Gas connection G 1/8”3 only with passive GasSpring (2489.16)

Gas connection G 1/8”

Controllable Gas Springs2489.14. Active gas springs (KF)


2489.14.Start Stop

Adjustable force force*Order no Rated stroke stroke min. -strokemax. [daN] [daN] I min. L b c d d1 d2 d3 � M A2489.14.01500. 010. 004 017 1500 2200 142 45 22,5 75 95 36 11011050 30° M12x15 35

020. 012 027 152 55030. 022 037 162 65040. 032 047 172 75050. 042 057 182 85060. 052 067 192 95070. 062 077 202 105080. 072 087 212 115090. 082 097 222 125100. 092 107 232 135110. 102 117 242 145120. 112 127 252 155130. 122 137 262 165140. 132 147 272 175150. 142 157 282 185160. 152 167 292 195

2489.14.03000. 010. 004 017 3000 4200 152 55 24,5 85 120 50 135 95 60° M12x15 45020. 012 027 162 65030. 022 037 172 75040. 032 047 182 85050. 042 057 192 95060. 052 067 202 105070. 062 077 212 115080. 072 087 222 125090. 082 097 232 135100. 092 107 242 145110. 102 117 252 155120. 112 127 262 165130. 122 137 272 175140. 132 147 282 185150. 142 157 292 195160. 152 167 302 205

2489.14.05000. 010. 004 017 5000 7400 177 80 26,5 110 150 65 180 110 60° M16x18 70020. 012 027 187 90030. 022 037 197 100040. 032 047 207 110050. 042 057 217 120060. 052 067 227 130070. 062 077 237 140080. 072 087 247 150090. 082 097 257 160100. 092 107 267 170110. 102 117 277 180120. 112 127 287 190130. 122 137 297 200140. 132 147 307 210150. 142 157 317 220160. 152 167 327 230

2489.14.07500. 010. 004 017 7500 9800 197 100 32,5 130 195 80 210 120 60° M16x18 90020. 012 027 207 110030. 022 037 217 120040. 032 047 227 130050. 042 057 237 140060. 052 067 247 150070. 062 077 257 160080. 072 087 267 170090. 082 097 277 180100. 092 107 287 190110. 102 117 297 200120. 112 127 307 210130. 122 137 317 220140. 132 147 327 230150. 142 157 337 240160. 152 167 347 250

Ordering example:Controllable Gas Springs (active) = 2489.14. *with complete strokeinitial spring force = 3000 daN = 03000.2489.13.03Rated stroke = 80 mm = 080. Stroke lengths from 4 to 167 mm, in increments of 1 mmstroke set = 78 mm = 2489.13.03000.078 078Cooling (optional) = KOrder number = 2489.14.03000.080.078 K

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Description:The same size should be selected for theKP Gas Spring 2489.16. as for the KF GasSpring 2489.14. The only exception is2489.14.07500 (see below). The extent to which the KP Gas Spring hasto be compressed depends on the numberof KF Gas Springs in the system. Therecommended stroke length is 5 mm per KFGas Spring. For example, if there are four KFGas Springs in the system then the strokelength used should be 4 x 5 mm = 20 mm.Use KP 2489.16.05000 for type2489.14.07500. The stroke used should thenbe 7.5 mm per KF Gas Spring in the tool. The passive Gas Spring does not requirecooling. The passive Gas Spring is alwaysconnected to a valve block using the 24°cone hose system via one of the four G 1/8"connections.The connection at the base of the Gas Springis for filling and emptying the lower gascompartment in the KP Gas Spring. It mustbe filled before the KF system is filled. Whenthe KP Gas Spring is mounted in a tool, afilling fitting 2480.00.31.01 can be used forfilling. The KP Gas Spring is filled to the samepressure as the KF Gas Springs in thesystem, i.e. up to a maximum of 150 bar.

Technical data:Pressure medium nitrogenFilling pressure max. 150 barFilling pressure min. 25 barOperating temperature 0 - 80°CTemperature related force increase ±0.8 %/°CPiston rod speed max 0.8 m/s

Additional information is available inSection F Gas Springs in the StandardParts main catalogue.

2489.16.

e

Hub

läng

ege

nutz

te

8b

l

d 3

1d

d

X

Ansicht X

Ventil/1 8(G

Gewindebohrung M im

max

.H

ub

c(G1/8)Füllanschluss

G1/8 Anschluss (4x)zum Ventilblock

Boden für Befestigung (4x)

)

2489.16.Force in daN for given stroke length in mm*Order no 5 10 15 20 25 30 352489.16.01500 3600 05200 06700 08200 09900 11900 –2489.16.03000 6000 08300 10400 12300 14400 16800 –2489.16.05000 7800 10200 12500 14700 16800 19000 21300

*Forces are calculated on the basis of a filling pressure of 150 bar in the KP and the KF Gas Springs.

StrokeOrder no d d1 d3 b e l c max. M2489.16.01500 095 36 060 24 7 220 140 30 M8x12,52489.16.03000 120 50 080 25,5 7 220 140 30 M10x162489.16.05000 150 65 100 27,5 8 300 182 35 M10x16

Controllable Gas SpringsPassive Gas Springs (KP) 2489.16.

Port G 1/8 (x4) to the

valve block

Str

oke m

ax.

Str

oke

leng

th u

sed

Filling connection (G 1/8)

Threaded bores M (4)

in base for fixing

Valve

View X


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Control SystemFilling and Emptying the System

Control system for valve block for KF + KPsystem, Example

Item No. Description Order no.. Page2 1 Compressed air hose, blue 2489.00.42.06.11.xx 294 1 Electric-pneumatic valve 2489.00.41.32 31

orregulated compressed air from the press

6 2 straight screwed connector G1/4" 2489.00.43.02.01 29

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Controllable Gas SpringsControl system

Control systemKF Gas Springs and the valve block for KF+KP are supplied with compressed air connections for DN 6 hoses.

Never control more than six KF Gas Springs or one valve block from one control valve.

Select suitable connections for the system.

Cut the hoses to the correct length at installation (Push-Lock connects).

Select the control valve on p. 31 to suit the type of signal from the press (pneumatic or electric). The controlvalve requires a continuous supply of filtered compressed air at a pressure of at least 4 bar.

A KF Gas Spring (or a group of KF Gas Springs) requires one control valve, but a KF+KP system requires twocontrol valves.

KF gas spring control systemExample

Item No. Description Order no.. Page1 2 KF gas springs 2489.14.03000 242 3 Compressed air hose, blue 2489.00.42.06.11.xx 294 1 Electric-pneumatic valve 2489.00.41.32 31

or regulated compressed air from the press

5 1 T connector 2489.00.44.06.05 296 1 straight screwed connector

G1/4" 2489.00.43.02.01 29

1

2 4

kontinuierlicheDruckluftzufuhr

Steuerungssystem KF - Gasdruckfedern,Beispiel

5 6

Steuerungssystem für Ventilblock fürKF + KP - System,Beispiel

kontinuierlicheDruckluftzufuhr

2 6

C

4

KF gas spring control systemExample

Example

Control system for valve block for KF + KP system

continuoussupply ofcompressedair

continuoussupply ofcompressed air


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Controllable Gas Springs2489.00.42./43./44. Control system

Compressed air connections for DN 6hose connections

Note:Material polyurethaneMaximum temperature 60°CMaximum pressure 16 bar

Order no. Color

Compressed air hose = 2489.00.42.06.11.xx blue 20Lenght .xx, order in complete metres

Min. radiuspermitted

ø1316

208

ø640

ø13

ø3,2 (2x)

ø13ø6

ø13ø6

16

38

12

ø3,2

ø6

/8G1

41,537

23

ø12

,5

SW 14

22

dø6

GS

Wl 1

Mindes

tbieg

e-

radiu

s 20

ø6

2489.00.43.01.02Right angle connector, simple, 90° - G 1/8

2489.00.42.06.11.Compressed air hose

2489.00.43. .01Straight plug-in connector

2489.00.44.06.06Y connector (hose to hose)

2489.00.44.06.05T connector (hose to hose)

Mini

mum ra

dius

permitt

ed

Order no. G d l1 SW

Straight plug-in connector = 2489.00.43.01.01 1/8" 13 4,6 4= 2489.00.43.02.01 1/4" 17 6,6 4

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Controllable Gas SpringsControl system 2489.00.43.

SW 19

ø6

4G1/

3023

29

ø12

,5

/4G1

ø6

14

3844

,5

SW 17

SW 1425

ø12

,5

ø6

14

51

1457,5

/4G125

SW 17

ø12

,5

SW 14

2489.00.43.02.02Right angle plug-in connector 90°

2489.00.43.02.03Right angle plug-in connector, two way, 90°

2489.00.43.02.04Right angle plug-in connector, three way, 90°

Controllable Gas Springs2489.00.41.32. Control system


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20

7

5

M5(2x)

(3x)/4G1

19

18

45 57

98

60

26,5 1044,5

32,512

12169

ø4,4(2x)

2489.00.41.32.2Steckdose

2489.00.41.32.13/2-Wegeventil

2489.00.41.32.3leuchtende Dichtung

2489.00.41.14Schalldämpfer fürMagnetventil CPE

Technical data:Fluid: Air or inert gas, filtered oily or dry

Voltage: 24V - (1.5 W)

– the valve is supplied complete with muffler.– One valve can control up to 6 Gas Springs or one valve block

(KF+KP system).

2489.00.41.32.Electro-pneumatic valve

Connector socket 3/2 way valve

Bright seal

Muffler for solenoidvalve CPE

+ 24V von Pressensteuerung

Y11

2 PE

1

2 PE

1

- Masse

PE2

12

2

S2 31

Grundstellung geschlossenohne Steuerhilfsluft GL

Connetion symbol: socket Connetion symbol: valve

+ 24V from press control

- Ground

Normally closed when GL controlair assistance


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Controllable Gas SpringsFilling and Emptying gas, KF

Filling and Emptying gas, KFKF Gas Springs have to be connected to a control fitting for filling and checking the gas pressure. For eachKF Gas Spring one hose is required for filling and emptying. This hose is connected to the control fitting via a distributor block. We recommend the use of the micro hose system (2480.00.23./24. see pp. 38-39) and thecorrect connectors. As supplied, connections 1 & 3 of the KF Gas Spring are closed off with blanking plugs.The filling valve in connection 1 must be removed before the hose system is installed.

Controllable Gas SpringsFilling and Emptying gas, KF

Example of a micro hose system (2480.00.23./24.) for three KF Gas Springs


Order no.Item No. Description Order no. Page1 3 KF gas springs 2489.14.01500.031 242 1 Control unit 2480.00.31.01 373 1 G 1/8" distributor block with 4 ports 2480.00.24.34 394 1 Gauging coupling with valve G 1 /4" 2480.00.24.03 395 4 Hose straight – straight 2480.00.23.01.xxxx 386 7 Gauging coupling with G 1/8" Valve 2480.00.24.01 39

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1

5

6

36 5

2

4

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Controllable Gas SpringsFilling and Emptying gas, KF + KP

Filling and Emptying gas, KF+KPThese have to be connected to each other for checking or modifying the filling pressure of KF Gas Springs.There are two hoses for each KF Gas Spring - one to fill it and one to empty it. The micro hose system(2480.00.23./24. see p. 38-39) is used for port 1. A more robust hose is required for the connection betweenport 3 of the KF Gas Spring, the valve block and port 5 of the KP Gas Spring. We recommend our 24° conehose system (2480.00.25./26. see p. 40-42).

A KF+KP system is filled in two stages. First the lower gas compartment of the KP Gas Spring is filled andthen the KF Gas Springs. If the valve block and the KP Gas Spring are mounted in a tool, control units may be used to make the job of filling and emptying the system easier. As supplied, connections 1 & 3 of the KFGas Spring are closed off with blanking plugs. The filling valve in connection 1 must be removed before thehose system is installed.

Example of a KF + KP system with four active gas springs and one passive gas spring

Controllable Gas SpringsFilling and Emptying gas, KF + KP


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13

9

1

8

2

7

5

6

4

3

10

11

C

9

9

12

3

Order no.Item Quantity Description Order no. Page

1 4 KF Gas Spring 2489.14.01500.030 242 1 KP Gas Spring 2489.16.01500 263 2 Control unit 2480.00.31.01 374 1 Valve block without pressure gauge 2489.00.47.01 365 2 Distributor block G 1/8" 2480.00.24.33 396 1 24° cone hose 90°/90° 2480.00.25.03.xxxx 417 10 Connector thread G 1/8" 2480.00.26.03 408 5 24° cone hose 90°/straight 2480.00.25.02.xxxx 419 6 Gauging hose straight/straight 2480.00.23.01.xxxx 38

10 1 Gauging hose, 90°/straight 2480.00.23.02.xxxx 3811 12 Gauging coupling with valve G 1/8" 2480.00.24.01 3912 2 Gauging coupling with valve G 1/4" 2480.00.24.02 3913 2 Connector thread G 1/4" 2480.00.26.04 40

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Controllable Gas SpringsValve block without manometer 2489.00.47.01

Valve block without manometerValve block without facility for emptying and filling

Order no 2489.00.47.01 (Filling pressure 25 -150 bar)

ø7 (2x)

84 100

Anschluss 5G /1 4

114130

Anschluss C

75

Anschluss C

Anschluss 1G /1 4

Anschluss 3G /41

Anschluss 1G /41

Anschluss 3G /41

Anschluss 5G /1 4

Anschluss zur Entleerung

Befüllen

2489.00.47.01

Port 1 Port 5

Port 3Port C

Port 1

Port 5

Port 3

Port CFilling

Emptying port

Controllable gas springsControl unit with manometer, KF


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6

4586

50

60

26 75

9127

32

Description:The control unit 2480.00.31.01 providescontinuous monitoring of the fillingpressure of the KF+KP Gas Springs. During operation the pressure can bechecked in two ways: a) by watching the pressure displayb) by automatic monitoring using a

membrane pressure switch. This turns the machine off or triggers a signal if the pressure drops.

Note:* 2m long filling hose with quick release

coupling and gas bottle connectorOrder no: 2480.00.31.02(order separately)

2480.00.31.01 Control unit

Connection thread for gauging coupling2480.00.24.02

Port for membranepressure switch2480.00.45.01

Bleeder valve

Manometer display Fixing holes Ø 7

Quick release coupling for compressedair supply*

°

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Controllable Gas SpringsGauging hoses 2480.00.23.

ø20

ø5

ø20

173333

17

l*

2480.00.23.01.Messschlauch - beidseitig gerade

2480.00.23.01.----.1Knickschutzwendel einseitig

2480.00.23.01.----.2Knickschutzwendel beidseitig

KlemmhülseS 12,65 x 1,5 (2x)Anschlussgewinde

ø20

1729

ø5

ø20

1729

4646l*

2480.00.23.03.Messschlauch - beidseitig mit 90°-Winkel

S 12,65 x 1,5 (2x)Anschlussgewinde

Klemmhülse

2480.00.23.03.----.1Knickschutzwendel einseitig


ø5

ø20

S 12,65 x 1,5 (2x)Anschlussgewinde

ø20

1729

1733 46

l*2480.00.23.02.Messschlauch-einseitig gerademit 90°-Winkel

2480.00.23.02.----.1Knickschutzwendel einseitig gerade


2480.00.23.02.----.3Knickschutzwendel einseitig 90°

Klemmhülse

2480.00.23.01.

2480.00.23.01.0200 2000300 3000400 4000500 5000630 6300800 8001000 10001200 12001500 15002000 20002500 25003000 3000

Order no. l *

* other lengths availableShortest factory lengths: without antikink protection: 90 mmantikink protection at one end: 150 mmantikink protection at both ends: 300 mm

2480.00.23.03.

2480.00.23.03.0200 2000300 3000400 4000500 5000630 6300800 8001000 10001200 12001500 15002000 20002500 25003000 3000

Order no l *


2480.00.23.02.

2480.00.23.02.0200 2000300 3000400 4000500 5000630 6300800 8001000 10001200 12001500 15002000 20002500 25003000 3000

Order no. l *


2480.00.23.01. .1

2480.00.23.01. .2

2480.00.23.02. .1

2480.00.23.02. .2

2480.00.23.02. .3

2480.00.23.03. .1

2480.00.23.03. .2

Gauging hose - both ends straight

Gripping sleeve

Threadedconnection

Antikink spiral, at one end

Antikink spiral, at both ends

Gauging hose, oneend straight 90°-angle

Gripping sleeve

Antikink spiral, at one end, straight


Antikink spiral, at one end, 90°

Gauging hose - both ends 90°-angle

Gripping sleeve

Antikink spiral, at one end


Threaded connection

Threaded connection

Controllable Gas SpringsGauging couplings,

2480.00.24./.40 distributor block


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2480.00.24.33Distributor block G 1/813 ports

2480.00.24.34Distributor block G 1/84 ports

20m

in.

min

. 75

R

35

1 /8

G

ø14

8

22

S 1

2,65

x1,5 SW 14

ø19

10

21

1 /4

GS 1

2,65

x1,5 SW 19

2480.00.24.01Gauging coupling with valve and protective cap for connecting to Gas Spring

2480.00.24.03Gauging coupling without valve for connecting to Gas Spring

2480.00.24.02Gauging coupling with valve for connecting to control fitting

2480.00.24.04Gauging coupling without valve for connecting to control fitting

Installationdimensions 1

Installationdimensions 2

Anschluss G

ø6,5 (x2)

(x4)

24

40

40

20

1/8

Note:The gauging coupling with valve is used in standard permanentconnections. The valveless gauging coupling is used in systemswhere changes to the filling pressure are necessary on a regularbasis (e.g. die cushions).

Note:The gauging coupling with valve is used in standard permanentconnections. The valveless gauging coupling is used in systemswhere changes to the filling pressure are necessary on a regularbasis (e.g. die cushions).

25

2522

120140

25 25 25

13

9

(1x)1/4G

Connection G1/8 (x4)

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Controllable Gas Springs24° cone threaded connectors (DIN 2353/DIN EN ISO 8431-1) 2480.00.26.

24

10

ø6

ø4

M12

x1,5

(2x

)

19

ø6

12

ø4

M12x1,5(2x)

19

ø6

12

ø4

M12x1,5(3x)

M12x1,5ø6ø4

29 148

G1/8

14 )1

2480.00.26.03Connector thread-G1/8

G1/4

M12x1,5ø6ø4

29 1019 )1

12

2480.00.26.04Connector thread-G1/4

16

M12x1,5ø6

26

)2

9

M12x1,5

ø6ø4

2480.00.26.2145° swivel coupling, complete

2480.00.26.25Hose to hose adapter, straight

19

M12x1,5ø6

26

M12

x1,5

ø6

ø4

)2

12

2480.00.26.2290° swivel coupling, complete

2480.00.26.2690° hose to hose adapter

2114

M12x1,5ø6

26

M12

x1,5

ø6

ø4

)2

2480.00.26.23L-shaped swivel coupling,complete

2480.00.26.27T-shaped hose to hoseadapter

2114

M12x1,5ø6

26

M12

x1,5

ø6

ø4

)2

2480.00.26.24T-shaped swivel coupling,complete

19

ø6

12

ø4

M12x1,5(4x)

2480.00.26.28Adapter, KHose to hose

SW 12 SW 12 SW 12

SW 14

SW 14

SW 14

SW 14

SW 12

SW 14

1) Elastic seal ED

2) O-Ring

1) Elastic seal ED

SW 19

SW 14

SW 14

SW 12

SW 14

2) O-Ring 2) O-Ring 2) O-Ring

Controllable Gas Springs24° cone threaded connectors

2480.00.25. (DIN 2353/DIN EN ISO 8434-1)


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M12x1,5

50

*l 1

*l 1

DN

5

ø11

DN

5

ø11

43 43

43

M12

x1,5

M12

x1,5

M12

x1,5

M12x1,5

30

50

*l 1

DN

5

ø11

M12x1,5

30

50

M12x1,5

30

DN

5

ø11 43

M12

x1,5

62

17

M12x1,5*l 1

DN

5

ø1162

17

M12x1,5*l 1

17

62

62

17

M12x1,5

*l 1

DN

5

ø11 50

M12x1,5

30

2480.00.25.01.Hose with seal cones with union nuts and O-ring (straight/straight)

Dimension I1 specified in the order, e.g. 765 mm, gives order no. 2480.00.25.01.0765



2480.00.25.02.Hose seal cones with union nuts and O-ring (90° elbow/straight)

2480.00.25.04.Hose seal cones with union nuts and O-ring (45° elbow/straight)


* Shortest factory lengths: 140 mmMinimum bending radius R40

2480.00.25.03.Hose seal cones with union nuts and O-ring (90° elbow at both ends)

2480.00.25.05.Hose seal cones with union nuts and O-ring (45° elbow at both ends)


2480.00.25.06.Hose seal cones with union nuts and O-ring (45° elbow / 90° elbow)


SW 14SW 14

SW 14

SW 14

SW 14

SW 14

SW 14

SW 14SW 14

SW 14

SW 14

SW 14

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Controllable Gas Springs, Direct connection dimensions24° cone threaded connectors (DIN 2353/DIN EN ISO 8431-1) 2480.00.26.

851

Direct connectionHose, straightAdapter 2480.00.26.03

M12x1,5

46

34

45°

10

8

Direct connectionwith 45° connector2480.00.26.21

33

19

M12x1,5

8

Direct connection with 90°angle connector2480.00.26.22

33

21

M12x1,5(2x)

46

8

Direct connectionwith L-shaped connector2480.00.26.23

33

42

M12x1,5(2x)

8

Direct connectionwith T-shaped connector2480.00.26.24

70

50 45°

8

Direct connectionhose with 45° adapter 2480.00.26.03

37

50

8

Direct connectionHose with 90° adapter 2480.00.26.03.


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MonitoringProcess Safety

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Controllable Gas SpringsSystem monitoring

Overheating protection A bimetallic thermostatic relay should be used forprotection against overheating, which will stop thepress or prevent locking of the KF gas springs. Therelay opens if the temperature of the gas springexceeds 80°C. The relay closes again automaticallywhen the gas spring returns to its normaltemperature range. Operating the gas spring athigher temperatures would shorten its service life.In a gas spring system without cooling it is sufficientto fit one gas spring with a thermostatic relay.In a cooled gas spring system each spring musthave a relay. The relays must then be switchedsequentially.

Technical data:Initial position closedTrigger temperature 85 ±3°CHysteresis <7°CMaximum voltage 110V ~Supplied with a 1.5 m electrical cable. The relay is a push fit in the base of the gas spring.

Thermostatic relay 2489.00.70 Connetion symbol 2489.00.70

24V DC

Elektrische Leitung

ø19,5

26

Signal zum Anhalten derPresse oder zumAusschalten des elektro-pneumatischen Ventils

S1

12

11

Electic cable

Signal to stop the press orto switch off the electro-pneumatic valve



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Monitoring air pressureA pressure sensor can be used to ensure that gas springs receive the locking signal. If the pressure sensor islinked to the compressed air supply at port 4 of the gas springs, the press can be stopped if the KF gas springshave not received the locking signal or the control pressure is too high or too low.

Signal an Presse(Presse sollte angehaltenwerden, wenn der Strom-kreis unterbrochen ist)

Thermo-relais2489.00.70

Elektro-pneumatisches Ventil

Luftfilter

Druckluftversorgung5 bar min.

elektrisches Signal von derPresse zum Verriegeln der Feder

oder T - Anschluss

Verteilerblock2480.00.24.34

Drucksensor2489.00.45.01.025

2 1

RelaisTherrmostaticrelay2489.00.70

Signal to press (the press shouldbe stopped if the circuit isbroken.)

Electro-pneumatic valve

Air filter

Distributor block2480.00.24.34or T connector.

Pressure sensor2489.00.45.01.025

electric signal from the press to lock thespring

Compressed airsupply 5 bar minimum



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Thermo-relais2489.00.70

Drucksensor2489.00.45.01.025

3

Luftfilter

Verteilerblock2480.00.24.34

Oberteil

Signal an Presse(Presse sollte angehaltenwerden, wenn der Strom-kreis unterbrochen ist)

Position, an derNiederhalteraktiviert/deaktiviertwird

1

Unterteil

mechanischerDruckschalter2489.00.42

2

Druckluftver-sorgung5 bar min.

Mechanical control systemThis system does not require a control signal from the press. The locking function control is integratedcompletely in the tool. The KF gas springs remain locked as long as the mechanical pressure switch (2) isactivated by the tool (1). A pressure sensor is included to ensure that the compressed air supply is working. Thepressure sensor (3) should be connected in series with the thermostatic relay in the gas spring(s).

Thermostaticrelay2489.00.70

Signal to press (the press shouldbe stopped if the circuit isbroken.)

Air filter

Distributor block2480.00.24.34

Pressure sensor2489.00.45.01.025

Position at wich theclamp isactivated/deactivated

Mechanicalpressure switch2489.00.42

Compressed airsupply 5 barminimum

Upper part

Lower part

Please note:Up to 6 KF Gas Springs or valve blocks can be controlled with one mechanical pressure switch. The mechanical pressure switch requires a continuous supply of filtered compressed air at a pressure of at least 4 bar.


Controllable Gas SpringsPressure sensorAccessories

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9,2ø5,

5ø

9,2

443058

ø5,5

7,620

42

ø3456

7-Segment-Anzeige M

12 x

1/4G1

13,5

57,3

91,5

1,3

ø27ø21,5

49ø34

2489.00.45.01.025

Programmier-taste

SW 30

2489.00.45.01.025Electronic pressure sensor PN

2489.00.45.01.01Mountings for pressure sensor 2489.00.45.01.025

Technical dataMeasuring range 0...25 barPermitted overload pressure 100 barSetting rangeSwitching point sP1 1,25...25 barRelease point rP1 0,75...24,5 barSwitching increments 0,25 barProtection IP 65Repeat accuracy < ± 1,0%Ambient temperature - 25°C...+ 80°COperating voltage [V] 18...30 DC

7 segmentdisplay

Programmingswitch

2

2

R1/4

10

2489.00.42.01

Schraubendreher-schlitz

25

25 42

55°

Übe

rhub

2,5

Bet

ätig

ungs

hub

8

1236

8060

1/4G12 tief

Rolle ø2010 breit

ø5,5(2x)

kontinuierliche Druck-luftzufuhr min. 4 bar

Steuerluftanschluss fürKF-Feder o. Ventilblock

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Controllable Gas SpringsPressure switchesAccessories 2489.00.42

Technical data:Pressure switchesAluminium casingMin. permitted pressure pe 0 barRated pressure pe 10 barAmbient temperature 80° C

Pressure switch with roller3/2 way valve NG 6 (G 1/4) mechanical

a bb

A

RP

a

Muffler for pressure switch

Roller ø 20 mm10 mm wide

Ove

rtra

vel 2

,5 m

m

Act

uatio

n st

roke

8 m

m

Screwdriver slot

deepContinuous air pressuresupply min. 4 barControl air port for KF spring or valve block


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Order no.ID plate = 2489.00.110.150.2

To be affixed to all machines wichincorporate KF gas springs.

FIBRO GmbH · D-74851 Hassmersheim · Postfach 1120 · Made in Germany · Telefon +49 (0)6266-73-0*

Tool no.Number of active KF gas springs No.max. KF spring force daNTravel KF mmNumber of KP passive gas springsSize KPStroke length usedMax stroke rate Strokes/minFilling pressure - active gas springs KF min. bar max. barPressure of filtered compressed air min. 5 bar max. 12 bar

The following must bechecked before the start ofproduction or after a fault:

1. Filling pressure of thegas spring

2. Compressed airpressure

3. Compressed air signalor electrical signalfrom the press

4. Temperature of gasspring (max. 70°C)

Attention!NEVER WORK INSIDE THE TOOL WHEN THE GAS SPRING IS LOCKED

Note:- The termostatic relay must be in use.- If the KF gas springs are to be operated at a filling pressure outside the range specified above,

the cartridge valves in the gas spring base or in the valve block may need matching.

DIN dimensions: 105 x 210 mm, holes-Ø 3,6 mm, hole pitch 85/128 mm

FIBRO controllable gas spring systems

Controllable Gas Springs2489.00.110.150. ID plate

We recommend that the ID plate should be mounted in an easily visible position on the tool when controllablegas springs are incorporated.

- the thermostatic relay must be working

4


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Cooling

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Controllable Gas SpringsCooling 2489.14.

CoolingIn every cycle energy is transferred from the pressto the gas cylinder. This energy is converted intoheat on the gas spring return stroke after locking.

The heat factor is calculated by multiplying thestroke rate by the stroke length of the gas spring.The gas spring requires cooling if the heat factor fora specific gas spring exceeds the values shown inthe diagram.

Example:Let us take a Gas Spring KF 2489.14.03000.060with a stroke of 60 mm. The number of strokes is 8strokes per minute. The heat factor is: stroke lengthx stroke count = 60 x 8 = 480.As can be seen from the diagram below, cooling isrequired when the heat factor exceeds 380, socooling is necessary for this KF 2489.14.03000.060.

Method for reducing the coolingrequirementThe cooling requirement reduces in the case of alarger Gas Spring operating at a lower pressure. The example above could for example be resolvedin this way:We can use the next larger Gas Spring KF2489.14.05000. instead of the KF 2489.14.03000.The pressure in the KF 2489.14.05000. is reduced tobring the Gas Spring force down from 5000 daN to3000 daN. The new filling pressure is 3000/5000 x150 bar = 90 bar. The cooling requirement for the5000 Gas Spring reduces by the same proportion asthe filling pressure.The heat factor = 60 x 8 x 3000/5000 = 228.The heat factor is under 360, the maximum for the5000 Gas Spring, so no cooling is required.

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2489.14. . .1

C +

Hub

4G

1 /

40d2

stro

ke

erforderlicheKühlleistung (kW)pro KF-Gasdruckfederbei max. Wärmefaktor

21,40,90,3

MaximalerWärmefaktormit Kühlung

MaximalerWärmefaktorohne Kühlung

800

400

200

1400

Wärmefaktor =Hublänge (mm) x Hubzahl (Hübe/min)

600

1400

1200

1050950

1200

1000

2489

.13.

0150

0.

2489

.13.

0300

0.

2489

.13.

0500

0.

2489

.13.

0750

0.

Maximum heatfactor withcooling

Maximum heat factorwithout cooling

Heat factor = stroke length (mm) x numberof strokes (strokes/min)

Cooling required

No cooling required

Heat quantity [kW]per KF Gas Springat max. heat factor

0,3 0,9 1,4 2,0

2489

.14.

0150

0.

2489

.14.

0300

0.

2489

.14.

0500

0.

2489

.14.

0750

0.


Controllable Gas SpringsCooling

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Example of a cooling system arrangement

Verbindungsblock2489.00.55

Verteilerblock2489.00.54

SchnellkupplungMuffe2489.00.57

SchnellkupplungStecker2489.00.56

Luft

Kühlaggregat 10kW 2489.00.50.10mit Verbindungsschläuchen (5m). DieSchläuche sind mit Schnellkupplungenversehen, die an 2489.00.56 oder2489.00.57 angeschlossen werden.

Pumpe

Schlauch, rot DN 162489.00.52.23.12- Länge

Schlauch, blau DN 162489.00.52.23.11- Länge

Verteilerblock2489.00.54

Kühlmantel, drehbar

gerader Schlauchverbinder2489.00.53.02.0190° Schlauchverbinder2489.00.53.02.02

Schlauch, blau DN 102489.00.52.16.11. - Länge

Schlauch, rot DN 102489.00.52.16.12. - Länge

aktive Gasdruckfedernmax. 10 Stück

A: Schlauchsystem für bis zu 10 Gasdruckfedern B: Erweiterungssystem (optional) C: Kühlaggregat

SchnellkupplungStecker/Muffe2489.00.56/ 2489.00.57oder Schlauchverbinder2489.00.53.03.01/2489.00.53.03.02

Direktanschlussoptional

Direktanschlussoptional

Hose, blue DN 102489.00.52.16.11. - length

Distributor block2489.00.54

Direct connection,optional

Straight hose connector2489.00.53.02.0190° hose connector2489.00.02.02

Hose, blue DN 162489.00.52.23.11. - length

Quick releaseconnector/socket2489.00.56/2489.00.57 orhose connector2489.00.53.03.01/2489.00.53.03.02

10 kW cooling unit 2489.00.50.10. withconnecting hoses (5 m). The hoses are fittedwith quick release connectors which areconnected to 2489.00.56 or 2489.00.57.

Pump

Cooling jacket

Connector block2489.00.55

Distributor block

Quick releasesocket2489.00.57

Quick releaseconnector

Air

Active gas springs, max10

Hose, red DN 102489.00.52.16.12 - length

Hose, red DN 162489.00.52.23.12 - length

Direct connection,optional

A: Hose system for up to 10 gas springs B: Extension system (optional) C: Cooling unit


Controllable Gas SpringsCooling 2489.00.50.

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Pressure gauge formonitoring systempressure

Electric motor 380 V ~ 1.5 / 3 kW

Filter

Return flow connector, blue

Circulation pumpCheck direction of rotation on start.

Note:Never start the cooling unitwithout coolant in it. Running theunit without coolant may causedamage.

Cooling unit

Switch On/off button

Fluid level gauge

Thermostatic valvemax. temp. = 70°C

Power plug 380V ~ 16 A

Drain connection

Flow connector, red

Coolant filler connector 60 l / 90 l

Cooling unit 2489.00.50.10for controlled Gas Springs, KF (10 kW)

Dimensions H = 1000L = 900B = 700

Circulation rate 40 l/min

Tank capacity = approx. 60 l

Electric motor = 1,5 kW

Supply voltage = 380 V AC

Weight = 170 kg

Cooling unit 2489.00.50.25for controlled Gas Springs, KF (25 kW)

Dimensions H = 1070L = 1070B = 890

Circulation rate 60 l/min

Tank capacity = approx. 90 l

Electric motor = 3 kW

Supply voltage = 380 V AC

Weight = 220 kg

CoolantThe cooling unit is suppliedwithout coolant. The cooling unitmust always be run using aspecial coolant which is availablefrom FIBRO, part no. 281.620.05(5 litres) 281.620.10 (10 litres) or281.620.50 (50 litres).

Hose and hose connector, cooling system

90° hose connectorOrder No. m l1 l2 h ød SW2489.00.53.02.02 G1/4" 23 8 44 16 172489.00.53.03.02 G1/2" 30 12 68 23 27

Hose connector, straightOrder No. m ød l SW2489.00.53.02.01 G1/4" 16 28 122489.00.53.03.01 G1/2" 23 58 27

HoseOrder No. ød DN Color R min2489.00.52.16.11 16 10 blue 752489.00.52.16.12 16 10 red 752489.00.52.23.11 23 16 blue 1502489.00.52.23.12 23 16 red 150

Ordering example:

Hose DN10 Colour blue = 2489.00.52.16.11Length 10 m .10

Order No. 2489.00.52.16.11.10

Controllable Gas Springs2489.00.52./53. Cooling


ød

2489.00.52.Schlauch

Min

dest

bieg

e-

radi

us R

ød

hm

1

l 2

l

2489.00.53.Schlauchverbinder, 90°

SW

ød

l

m2489.00.53.Schlauchverbinder, gerade

SW

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90° hose connector

Hose connector, straight

Hose

Min

imum

ben

ding

radi

us R


Controllable Gas SpringsCooling 2489.00.54.-57.

Schnitt A - A

(4x)/2G1 (10x)/4G1

/2G1

B

B

10 (

2x)

60

60

ø9 (2x)

290

260

34

15

20 25

25

45 45 45 45

Schnitt B - B

A

A

2·17

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2001

·1▼

50

/ 2G

1

11595

ø8,

5 (2

x)

==

(6x)

40

2489.00.55Connector block, cooling system

2489.00.57Quick connector, socket

2489.00.54Distributor block, cooling system

ø 3

9,6

87,474,9

26

/2G

1

Verbindungsblock 2489.00.55 oderVerteilerblock 2489.00.54

SW 1 /41SW 22

2489.00.56.Quick connector, plug

26

6249,5

21,1

31,2

Verbindungsblock 2489.00.55 oderVerteilerblock 2489.00.54

SW 22 SW 1 /161

/2G

1

Section A - A

Section B - B

Connector block 2489.00.55 orconnector block 2489.00.54

Connector block 2489.00.55 ordistributor block 2489.22.54



Typical Applications

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Controllable Gas Springs 2489.14.Examples of applications 2489.16.

Example of application with KF gas spring system (1 mm return)Dies are used for drawing a beam (detail A). The dieshave to be locked at the bottom position to avoiddistortion of the workpiece on the return stroke.

In this application a KF gas spring is used for eachdrawing die.

Working cycleThe drawing die (1) is activatedwhen the upper part of the tooldescends.

KF-Gasdruck-feder

Zieh-matrize (1)

The KF gas springs are locked atthe bottom position. Slight springback will not damage theworkpiece in this case.

When the press opens, the clampreleases the workpiece. Theworkpiece can then be removedand the gas spring unlocked.

Detail A

Examples of Installations

Drawing die (1)

KF gasspring


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2489.14. Controllable Gas Springs2489.16. Examples of applications

Working cycleWhen the top part of the toolmoves down, it actuates theclamping pad (3) that holds thesheet metal workpiece (1) inposition.

Example of application with KF + KP gas spring systemIn the application described below an automobilefender gutter (1) is being shaped. The die (2) has tobe locked in the back position to avoid distortion ofthe tool. In this case the problem was solved by usingthe KF + KP controlled gas system. The systemconsists of three KF gas springs connected to apassive KP gas spring.

The illustration shows only the KF gas springs.

KF-Gasdruckfeder2

1

3

At the bottom point the KF gassprings are locked with no springback and the drawing die (2)remains in the back position. Thisprevents any deformation of theworkpiece.

When the press opens, the clampreleases the workpiece and it canbe removed. Then the gas springis unlocked.

Examples of Installations

KF gas spring

2·20

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Controllable Gas SpringsExamples of applications

Working cycleThe lower part of the toolcontains the controllable GasSprings KF which provide theactive clamping force for themost deeply drawn area of the part.

When the tool is closed, thepassive Gas Springs KP (notshown) are compressed and thisprovides the necessary counterpressure for locking of the KF GasSprings in the bottom part of thetool without spring back.

When the tool opens, the GasSprings remain locked untilreceiving a signal from the press.Then the KF Gas Springs assist inejecting the undamaged part fromthe tool.

Example of application with KF + KP gas spring systemThe KF + KP-system is ideal for use in themanufacture of parts where Gas Springs withoutspring back are required.

The press completes a two-stage drawing process ina single stroke.

The KF + KP-system makes possible the locking ofclamps which prevent distortion of the part on thepress return stroke.

This large pressing mould for an inner door paneluses a total of 12 KF Gas Springs in association with3 KP passive Gas Springs.

KF+KP gas spring system


2·20

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Controllable Gas SpringsExamples of applications

Work cycleThe upper part of the toolcontains the controllableKF Gas Springs whichprovide the clamping forcefor the “Baby” clamps.

Example of application with KF + KP gas spring systemThe manufacture of high quality side panels oftenpresents tool manufacturers with a major challenge.The areas where the side door posts interface withthe outer panels are especially problematic

If clamped down too hard, the part may tear, if notclamped down hard enough ripples may occur in theworkpiece.

A current solution to this problem is to use “Baby”clamps for these problem areas, whose spring forcecan be controlled by controllable Gas Springs

The result is higher quality parts, improved control ofthe drawing process and a reduction in the number ofrejects.

KP Spring KF2 Spring

Standard Gas Spring

Valve Block

When the tool beginsto close, the rawworkpiece is firstclamped down by the“Bay” clamps in theproblem areas.

The valve in the valveblock opens at bottomdead centre of thepress and the KP GasSpring is used toprevent a spring backof the KF Gas Springs.

When the tool opens, theGas Springs remain lockeduntil receiving a signal fromthe press. Then the KF GasSprings assist in ejectingthe finished part from the tool.

Baby clamp

Rear side window

Rear door

Valve block

KP Gas Spring KF Gas Spring

Standard Gas Spring

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FAQsGeneralWhat is the air pressure required foroperating cartridge valves?

What is the maximum recommendedpressure for operating cartridge valves?

What is the expected service life of acontrollable Gas Spring (KF)?

Can other hose systems be used?

Can KF Gas Springs of different ratings beused in the same system?

Can an old active KF Gas Spring (2489.13.)be replaced by a new KF Gas Spring(2489.14.)?

To close the cartridge valve which is normally open (NO) an airpressure of at least 4 bar is required.

The maximum permissible air pressure for operating cartridgevalves is 10 bar.

When using a thermostatic relay the life expectancy is typically:For strokes up to 50 mm: 500,000 strokes. For strokes over 50 mm: 50,000 stroke/metres.

We cannot guarantee correct functioning of the system if hosesother than those authorized in this manual are used. For furtherinformation please contact your agent or FIBRO GmbH, StandardParts Division.

No. For further information please contact your agent or FIBROGmbH, Standard Parts Division.

Yes, but the new KF Gas Spring (2489.14.) is 7 mm longer. The KFGas Spring 2489.13.xxxxx.xxx.E is interchangeable but the strokeis not adjustable.

Can the stroke length of the KF GasSpring be adjusted or is it necessaryalways to use 100% of the nominal stroke± 0.5 mm?

How fast can the KF Gas Spring beoperated?

How can I avoid KF spring back?

Can a controllable KF Gas Spring belocked in any position?

Two types of controllable KF Gas Springs are available. thestandard model 2489.14. (adjustable) and model2489.13.xxxxx.xxx.E (non adjustable) which can be used as areplacement for the previous 2489.13.

The maximum compression speed is 0.8 m/sec The maximumstroke count at which a KF Gas Spring can operate depends onthe stroke length of the Gas Spring and the cooling capacityavailable. For further information see the section on Cooling.

When using 100% of the stroke length of the KF Gas Spring ± 0.5mm a spring back of up to 1 mm is to be expected. This can beprevented at any time by converting the standard lockingarrangement to a forced locking system. For further informationplease contact your agent or FIBRO GmbH, Standard PartsDivision.

Theoretically, yes. The less the KF controllable Gas Spring iscompressed, the stronger the spring back. For further informationplease contact your agent or FIBRO GmbH, Standard PartsDivision.

For KF gas spring system


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FAQs on the Gas Spring System KF+KPHow many KF controllable Gas Springs can be connected to a KP passive gas spring?

How many valve blocks are needed in thesystem?

Can the KP Gas Spring in tht tool be used for pressing?

Can the mini-measuring hose system be used for connecting the KF + KP-system?

Can the 24° cone hose system be used forconnecting the KF +KP-system?

Up to four KF gas springs can be linked to one KP gas spring.

One valve block is needed for each KP passive gas spring in the system.

No. The KP gas spring in the tool cannot be used for anypurpose other than preventing spring back of KF gasspring.

No. The 24° cone hose system (or corresponding product)must be used for connecting the KF gas spring(s), thevalve block and the KP passive spring.

Yes.

Is cooling always necessary?

How many KF controllable Gas Springscan be connected to one cooling unit?

Can other cooling units be used?

What coolants are approved for use?

Not always. Generally speaking, greater stroke lengths and higherstroke counts usually require cooling. For further information seethe section on Cooling.

The total maximum heating effect of all the springs must notexceed the cooling capacity of the cooling unit.

See the Table on page 15 or the one on page 52.

Yes. The press cooling system or other cooling units can be used

We recommend the water/glycol coolant (HFC) ULTRA SAFE

620. ULTRA SAFE 620 is approved by all major systemmanufacturers and is often used when running in new machines.

Other coolants equivalent to this water/glycol coolant may beused, but FIBRO GmbH cannot accept any responsibility for anyresultant malfunctions.

On cooling

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Trouble shootingSystem Problem Solution

KF gas spring system

Ensure that there is at least 4 bar air pressure at compressed airport 4 of the KF Gas Spring before the press reaches bottomdead center.

Check that all hose connections are OK.

Ensure that 100% of the nominal stroke of the KF Gas Spring (±0.5 mm) is being used.


Ensure that there is no pressure at compressed air port 4 of theKF Gas Spring when it is supposed to open.

Check whether the piston rod is prevented from returning byobstructions in the tool.

Check whether there is gas pressure in the KF Gas Spring.

System Problem Solution

KF Gas Springdoes not lock.

KF piston rod hasmore than 1 mmspring back.

KF piston roddoes not return toits starting point.


Check that all hose connections are OK

Ensure that the cartridge valve in the valve block is closed duringthe downward stroke of the press and that the KP passive GasSpring is compressed sufficiently for this application.

Ensure that 100% of the nominal stroke of the KF Gas Spring (±0.5 mm) is being used.

Check whether the cartridge valve in the valve block is opening atbottom dead centre. Check that the required gas pressure ispresent in the KP gas spring.

Ensure that there is no pressure at compressed air port 4 of theKF Gas Spring when it is supposed to open.

Check whether the piston rod is prevented from returning byobstructions in the tool.

Check whether there is gas pressure in the KF Gas Spring.

Check whether return of the piston rod is prevented by anobstruction in the tool.

Check that the required gas pressure is present in the KP gasspring.

KF Gas Spring isnot locking

KF piston rod hasmore than 0 mmspring back

KF piston rod doesnot return to itsstarting point.

KP piston rod does not return toinitial position

KF + KP gas springsystem


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·1�

2489.14. Controllable Gas Springs - KF

Matching the stroke lengthin KF Gas Springs (2489.14.)The guide is made up of the following maincomponents:

The length of the guide and the stroke are adaptedby adding or removing adjusting washers betweenthe top and bottom guide. The correct stroke can beobtained by adding adjusting washers as in Table 1.Example 1:

The stroke length needs increasing to 4 mm longerthan the rated stroke length.

Solution: Open the Gas Spring and the guide,remove the 4 mm adjusting washer. Leave the 1mm and the 2 mm adjusting washers in theguide/Gas Spring. This process is described on the next page.

Important

● Only qualified engineers experienced in the repair and maintenance of Gas Springs shouldmodify the stroke length.

● The workbench for working on the GasSprings must be clean and free fromcontamination.

● Never work on a Gas Spring containing air orgas under pressure.

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Thickness FIBRO Order no1 mm 2489.14.451.xxxxxx.012 mm 2489.14.451.xxxxxx.024 mm 2489.14.451.xxxxxx.048 mm 2489.14.451.xxxxxx.08(not illustrated)

Table 1

For modifying rated stroke length

Adjusting washers (mm)

Stroke length 1 2 4 8

max. +7 0 0 0 0

+6 1 0 0 0

+5 0 1 0 0

+4 1 1 0 0

+3 0 0 1 0

+2 1 0 1 0

+1 0 1 1 0

rated* 0 1 1 1 0

-1 0 0 0 1

-2 1 0 0 1

-3 0 1 0 1

-4 1 1 0 1

-5 0 0 1 1

-6 1 0 1 1

-7** 0 1 1 1

min. -8** 1 1 1 1

*The rated stroke length is always specified on the GasSpring cylinder.

** Not for nominal stroke length of 10 mm.

Example 1:

Top guide

Adjustingwasher

Bottom guide

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Controllable Gas Springs - KF 2489.14.

Modifying the stroke length inKF Gas Springs (2489.14.)

Instructions

1. Release any gas from the Gas Spring.

2. Using an assembly sleeve and a plastic hammertap down the guide and remove the snap ring.

3. Remove the top guide and insert the combination of adjusting washers to produce the required stroke length.

4. Insert the top guide again and tap down with the assembly sleeve and plastic hammer until the groove is clear for the snap ring.

5. Fit circlip and raise the piston assembly with a T-handle.

6. Ensure that the guide is flush with the top edge of the cylinder. (If not, check that the circlip is correctly seated.)

7. Fill the Gas Spring with gas.

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Top guide

Circlip

Adjustingwasher


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2489.13.2489.13.xxxxx.xxx.E Controllable Gas Springs - KF

Differences between thereplacement model2489.13.xxxxx.xxx.E and theearlier KF Gas Spring 2489.13:

The replacement model is usually fitted with anopened cartridge valve which has a number ofadvantages:

● simplified control system

● single port for filling and emptying

● low pressure version no longer necessary

● only 4 bar pressure required

How the replacement model is connected toexisting KF systems:

Controllable Gas Springs 2489.13.xxxxx.xxx.E arecompletely compatible with existing KF GasSprings (2489.13).

Example of KF-gas spring-system:

Replacing an existing 2489.13 with areplacement model

When replacing an existing KF Gas Spring with anew 2489.13.xxxxx.xxx.E in a standard lockingsystem the only point to note is that thecompressed air signal line connected tocompressed air port 2 must be closed off.

Example of a KF + KP gas spring system:

Replacing an existing 2489.13 with areplacement model

When replacing an existing KF Gas Springwith a new 2489.13.xxxxx.xxx.E in a KF + KPsystem the only point to note is that thecompressed air signal line connected tocompressed air port 2 must be closed off. If a newvalve block (2489.00.47.01) is fitted, compressedair port 2 of the corresponding valve must beclosed off.

Always remember when replacing the old Gas Spring type 2489.13 with the KF Gas Spring 2489.14 (adjustable stroke) that it is 7 mm longer.

uftan-chluss 4 Gasan-

schluss 3

Gasan-schluss 1

Gasan-schluss 1

Luftan-schluss 2

uftan-chluss 4

Gasan-schluss 3

KF (alt)

KF2 (neu)

uftan-chluss 4

Gasan-schluss 3

Gasan-schluss 1

KF2 (neu)

Gasan-schluss 1

Luftan-schluss 2

uftan-chluss 4

Gasan-schluss 3

KF (alt)

Ventilblock (neu)

2489.13.xxxxx.xxx.E

2489.13.xxxxx.xxx.E

Valve block 2489.00.47.01

2489.13.

2489.13.

Compressedair port 4






Nitrogenport 3

Nitrogenport 3

Nitrogenport 3

Nitrogenport 3

Nitrogenport 1

Nitrogenport 1

Nitrogenport 1

Nitrogenport 1

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HYDRAULIC CAM SYSTEM

A new generation ofgas springs

STANDARD TAPERED SLIDES

ROLLER SLIDE UNIT

Low maintenancesliding devices

Other FIBRO products

Standard Parts 3D catalogue3D Standard Parts Catalog Catalogue de produits normalisés 3D Catalogo misurecampione 3D Catalogo de piezasnormalizadas 3D

Order No. 2000.200.180

Order No. 2000.200.200

Order No. 2000.200.010

Order No. 2000.200.050

Order No. 2000.200.030

Order No. 2000.100.012CD3D


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6 · 4

8 �

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1�� SunNan Enterprises Co. Ltd.2F, No. 7, Alley 6, Lane 235 · Pao-Chiao RoadHsin-Tien City · TaipeiTel. +886 2-29 17 6454 · Fax +886 2-29 11 03 [email protected]

US

123 FIBRO Inc.139 Harrison Ave. · Rockford, IL 61104P. O. B. 5924 · Rockford, IL 61125Tel. +1 815-229 13 00 · Fax +1 815-229 13 [email protected] · www.fibro.com

YU

1�� Andrija Tesic, Dipl. Ing.Partisanska 12/a-II · 11090 BeogradTel. +381 11-533 83 62 · Fax +381 11-533 83 [email protected]

ZA

123 Herrmann & Herrmann Pty. Ltd.24, Shaft Road · P. O. B. 13030 · Knights 1413Tel. +27 11 828 01 00 · Fax +27 11 828 60 [email protected] · www.hermstools.com

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FIBRO GmbH

1Normalien

Postfach 11 20DE-74851 Hassmersheim

August-Läpple-WegDE-74855 Hassmersheim

Telefon +49 (0) 62 66 - 73 - 0*Telefax +49 (0) 62 66 - 73 - 237

e-mail: [email protected]://www.fibro.com

2Rundschalttische

Postfach 11 20DE-74183 Weinsberg

Weidachstrasse 41 – 43DE-74189 Weinsberg

Telefon +49 (0) 71 34 - 73 - 0*Telefax +49 (0) 71 34 - 73 - 120


3Automation+Robotik

Postfach 11 20DE-74851 Hassmersheim

August-Läpple-WegDE-74855 Hassmersheim

Telefon +49 (0) 62 66 - 73 - 0*Telefax +49 (0) 62 66 - 73 - 213


1 2 3

US

1

FIBRO Inc.

P. O. Box 5924US-Rockford, IL 61125

139 Harrison AvenueUS-Rockford, IL 61104

Phone +1 815 - 229 13 00Fax +1 815 - 229 13 03


FIBROBP no 129FR-93172 Bagnolet Cedex

19/21, rue Jean LoliveFR-93170 Bagnolet

Téléphone +33 (0)143621881Télécopieur +33 (0)148591747


FR

SG

1 2 3FIBRO ASIA Pte.Ltd.

121 Genting Lane2nd floorSG-Singapore 349572

Phone + 65 - 68 46 33 03Fax + 65 - 68 46 33 02


2 3FIBROBP no 129FR-93172 Bagnolet Cedex

19/21, rue Jean LoliveFR-93170 Bagnolet

Téléphone +33 (0) 143621889Télécopieur +33 (0) 148187346


FR

2 3FIBRO GmbH Zweigniederlassung

Buechstrasse 10CH-5027 Herznach

Telefon +41 (0) 62-878 18 80Telefax +41 (0) 62-878 18 82


CH

DE

GSA Automation GmbH

Postfach 1165DE-74173 Bad Friedrichshall

Max-Eyth-Straße 7DE-74177 Bad Friedrichshall

Telefon +49 (0)7136-9502-0Telefax +49 (0)7136-9502-240

e-mail: [email protected]://www.gsa-automation.de

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