| NITROGEN GAS SPRINGS |
|
90.5B2 / 90.10 / 90.9 / 90.8 / SC (90.80)
- Charging Medium: Nitrogen Gas
- Charging Pressure Range: 15 - 150 bar (220 - 2175 psi)
- Operating Temperature: -6°C - 71°C (20°F - 161°F)
- Maximum Speed: .5 m/sec (20 in/sec)
L (90.3) / LJ (90.7) Series Gas Springs
- Charging Medium: Nitrogen Gas
- Charging Pressure Range: 15 - 150 bar (200 - 2175 psi)
- Operating Temperature: -6°C - 71°C (20°F - 160°F)
- Maximum Speed: 35 m/min (23 in/sec)
Ultra Force™ Series Gas Springs
- Charging Medium: Nitrogen Gas
- U.0175 - U.0400 Charging Pressure: 15 - 180 bar (200 - 2600 psi)
- U.0600 - U.20000 Charging Pressure: 15 - 150 bar (200 - 2175 psi)
- Operating Temperature: -6°C - 71°C (20°F - 160°F)
- Maximum Speed: .5 m/sec (20 in/sec)
Micro (90.4) Series Gas Springs
- Charging Medium: Nitrogen Gas
- Maximum Charging Pressure: 177 bar (2560 psi)
- Operating Temperature: -6°C - 71°C (20°F - 160°F)
- Maximum Speed: 35 m/min (23 in/sec)
SLC.800 Nitrogen Gas Rail Lifters
- Charging Medium: Nitrogen Gas
- Charging Pressure Range : 20 - 70 bar (250 - 1000 psi)
- Operating Temperature: -6°C - 71°C (20°F - 160°F)
- Maximum Speed: 35 m/min (23 in/sec)
- TRAVEL SHOULD NOT EXCEED 90% OF STROKE
SLN.300 Non-Rotating Nitrogen Gas Lifters
- Charging Medium: Nitrogen Gas
- Charging Pressure Range : 20 - 150 bar (250 - 2175 psi)
- Operating Temperature: -6°C - 71°C (20°F - 160°F)
- Maximum Speed: 35 m/min (23 in/sec)
- TRAVEL SHOULD NOT EXCEED 90% OF STROKE
SL2.090 / SLN.090 / SL2.180 Micro Nitrogen Gas Lifters
- Charging Medium: Nitrogen Gas
- Minimum Charging Pressure: 34 bar (500 psi)
- Maximum Charging Pressure: 177 bar (2560 psi)
- Operating Temperature: -6°C - 71°C (20°F - 160°F)
- Maximum Speed: 600 mm/sec (24 in/sec)
- TRAVEL SHOULD NOT EXCEED 90% OF STROKE
SL.16 Nitrogen Gas Stock Lifters
- Charging Medium: Nitrogen Gas
- Maximum Charging Pressure: 180 bar (2611 psi)
- Operating Temperature: -6°C - 71°C (20°F - 160°F)
- Maximum Speed: 35 m/min (23 in/sec)
- TRAVEL SHOULD NOT EXCEED 90% OF STROKE
|
How do I replace my coil springs with gas springs?
How many gas springs should I use for my application?
1. Determine Force Requirements
The first step in retrofitting an existing die for nitrogen use is to calculate the force requirement. If you know the force required to complete your operation simply use this number when selecting the gas springs. If you do not know the total force required in your application, you can calculate the force provided by the coil springs in your die. You must determine if the force required to do the operation is the initial force (at preload) or the final force (at full travel). Once you determine this, you can calculate the total force requirement.
The most common method of finding coil spring force is to reference the manufacturer's force chart. To use the chart you must know the coil spring size, color, preload and the distance it travels in the die. A load cell may also be used to determine coil spring force.
Once you have found the individual force of the coil springs, multiply it by the total number of coil springs in the die to calculate the total force requirement.
- Example: Ten .75"(19 mm) x 5" (127 mm) diameter coil springs each provide 80 lbs. (.3 kN) of initial force when preloaded .75" (19 mm). Total Initial Force = 80 lbs. (.36 kN) x 10 = 800 lbs. (3.6 kN) of force
2. Calculate Gas Spring Quantity
First, you should match the diameter of the gas spring to the diameter of the coil spring. Gas springs are available in all of the popular coil spring sizes from
.5" (12 mm) to 2" (51 mm) in diameter. To determine how many gas springs you will need, divide the total force requirement by the highest force available at that diameter. In most cases fewer gas springs are required to meet force requirements. Keep in mind, however, that the force must be distributed evenly on the pressure pad. You may need to use more gas springs of a lower force model to balance pressure in the die.
- Example: A .75" (19mm) diameter gas spring is available in a 200 lbs. (.9 kN) force model. Divide total force required by gas spring force to determine gas spring quantity. Quantity = 800 lbs. (3.6 kN) ÷ 200 lbs. (.9 kN) = 4 If necessary to balance pressure in your application, you may choose a lower force model and increase the number of gas springs.
3. Select Gas Spring Stroke Length
The final factor to consider when selecting the gas spring is the stroke length. To choose the right gas spring stroke length, first determine the distance the coil spring travels in the die. Add a minimum of 10% to the coil spring travel and choose the gas spring stroke length that is equal to or greater than this number.
- Example: In our example, the coil spring measures 5" (127 mm) free length, is preloaded .75" (19 mm) and is traveled .75" (19 mm) in the die. Add 10% to coil spring travel to determine minimum gas spring stroke length. Minimum stroke length = .75" (19 mm) + (.75" (19 mm) x 10%) = .825" (21 mm).
Once you have determined the minimum gas spring stroke length you can then select the particular stroke length that is best suited to your space requirements. For example, if your application requires that you preload the gas spring, select a stroke length that is greater than the minimum length to allow for preload. When possible, select the stroke length so that the OAL of the gas spring is as close as possible to OAL of the preloaded coil spring.
- Example: The coil spring is preloaded .75" (19 mm) to meet the force requirements. Its OAL at preload is 4.25" (108 mm). In this example you could select the gas spring with a .98" (25 mm) stroke. This spring would have a corresponding OAL of 3.62" (92 mm). Alternatively, you may select a longer stroke and preload the gas spring to meet your space constraints. In our example, a spring with a stroke length of 1.5" (38 mm) and an OAL of 4.65 (118 mm) could be selected and preloaded .40" (10 mm).
4. Install the Gas Spring
In most applications the nitrogen gas spring can be easily installed in the same cored pocket used for the coil spring. Simply ensure that the bottom of the pocket is flat and that the sides of the hole are square to the pressure pad. The pocket depth should be a minimum of 50% of the length of the gas spring can or 1.25" (32mm), whichever is greater. The pressure pad should have a smooth area for the gas spring rod to contact and should remain in contact with the rod throughout the stroke. In some applications you can take advantage of gas spring mounting options, such as attachable flange mounts, tapped hole(s) in the base of the cylinder, and threaded body styles. These options offer increased flexibility for using nitrogen gas springs in existing dies.
When the size of the gas spring selected does not match the coil spring being replaced there are simple steps that can be taken before installing the gas spring. Spacers or sleeves may be used in the pocket if the gas spring is smaller than the coil spring, or the gas spring may be flange mounted in the appropriate position. If the existing pocket is too shallow it may be cored deeper, if possible, or the gas spring may be preloaded to meet space requirements. When coring a pocket for gas spring installation, maintain a clearance of .02 to .04 in. (.5 to 1.0 mm) to the diameter of the gas spring.
One final concern when installing the gas spring is the use of fluids in the die. Direct contact with certain die lubricants, coolants and cleaners can be harmful to gas springs and should be avoided. Shield gas springs from harmful fluids and provide adequate drainage in gas spring pockets.
|
How do I charge a gas spring?
Charging Nitrogen Gas Springs (Bulletin B00135A)
Step by step instruction on how to charge gas springs.
Gas Spring Installation and Operation (Bulletin B05139A)
Includes information on Operating Specifications, Charging, Discharging, Mounting and Installation Principles for the DADCO's Mini and Large Series gas springs.
Never fill a gas spring unless the rod is in the fully extended position. Filling a gas spring with its rod down can result in an improperly seated retaining ring. Thread a T-handle into the rod end and depress the valve stem with the appropriate tool, then pull the rod cartridge assembly up until it is seated firmly against the retaining ring.
- Prepare the Filling Port.
Self-Contained Operation: Attach a DADCO Filler Valve to the port.
Linked system Operation: Pipe all gas springs back to the control panel. Make sure all hoses and fittings are tight. Attach the charging assembly to the control panel.
- Set the desired charging pressure on the regulator.
- Open the main valve on the nitrogen tank.
- Slowly open the shut-off valve and allow each gas spring to reach the desired charging pressure.
- After each spring has been charged to the desired pressure, close the shut off valve and tank shut-off valve. Disconnect the charging assembly from the control panel or gas spring port. The small amount of nitrogen trapped between the shut-off valve and the filler valve will bleed off as you disconnect the fitting.
|
Which filler valve should be used with each spring?
DADCO's Quick Disconnect Filling Hardware (Bulletin B01122B)
Identifies the proper charging assemblies, pressure regulators, filling assembly and other hardware used for filling DADCO gas springs. |
How long do gas springs last? 
DADCO Nitrogen Gas Springs provide a long, trouble-free life and are backed in writing by the exclusive One Year/One Million
Stroke Gold Guarantee™. Contact DADCO for full warranty details.
DADCO offers a new 2 year / 2 million stroke Select Guarantee™ on the L Series (90.3) nitrogen gas springs. Contact DADCO
for full warranty details. |
How do I convert a gas spring from linked to self-contained operation?
Determine the series that you want to convert and follow the instructions below.
|
90.9 Series
Self-Contained to Linked Operation
90.9.03000-90.9.07500 (G 1/8 port)
Always wear safety glasses when maintaining nitrogen gas springs. When exhausting pressure, place the
gas spring
horizontally with the port up for safety.
Remove Port Plug (F.1).
Keeping the face and hands clear of the port depress the valve stem using one of the appropriate tools. A small screwdriver or allen wrench may also be used to depress the valve stem (F.2).
After the gas pressure is exhausted, be sure that the piston rod will retract into the tube manually.
If not, try depressing the valve stem again. If still unsuccessful STOP and contact your DADCO Service Representative.
Remove the compact valve by unscrewing it using the appropriate tool (F.3).
Install port adapter into the
open port, (F.4). A wide variety of port adapters are available, refer
to
DADCO's 90.10 Series Catalog.
|
F.1
 |
F.2
 |
F.3
 |
F.4
 |
90.9 Series
Self-Contained to Linked Operation
90.9.01500 (M6 port)
Always wear safety glasses when maintaining nitrogen gas springs. When exhausting pressure, place the gas spring horizontally with the port up for safety.
Remove the protective screw from the M6 port (A.1). Keep screw for reuse.
Keeping the face and hands clear
of the
port, depress the valve stem using the appropriate tool.
A small screwdriver or allen wrench may also be used to
depress the valve stem (A.2).
After the gas pressure is exhausted, be sure that the piston rod will retract into the tube manually. If not, try depressing the valve stem again. If still unsuccessful STOP and contact your DADCO Service Representative.
Remove the compact valve by unscrewing it using one of the appropriate tools (A.3).
Insert a port adapter into the open M6 port (A.4). A wide variety of port adapters and fittings are available, refer to DADCO's L or LJ Series Catalogs.
|
A.1
 |
A.2
 |
A.3
 |
A.4
 |
90.8 / 90.5B2 / 90.10 Series
Self-Contained to Linked Operation
Always wear safety glasses when maintaining nitrogen gas springs. When exhausting pressure, place the gas spring horizontally with the port up for safety.
Remove port plug 90.505.110 (F1). With the cylinder in the horizontal position, depress the steel valve stem using the appropriate tool (F2). Cover the port with a cloth to absorb discharge.
After all of the gas pressure is exhausted, be sure that the piston rod will retract into the tube manually. If not, try depressing the valve again. If still unsuccessful stop and contact your DADCO Service Representative.
Remove the valve using the appropriate tool (F3).
Lubricate the threads and o-ring of the port adapter being installed (F4).
Install port adapter in open port (F4). A wide variety of port adapters are available, see DADCO's
90.10 Series Catalog. |
F.1
 |
F.2
 |
F.3
 |
F.4
 |
LJ Series /L Series
Linked Operations (Bulletin B01110B)
Explains how to transform self-contained LJ and L Series gas springs into linked mode. |
U Series
Ultra Force™ Linked Operations (Bulletin B04151)
Explains how to transform self-contained U Series gas springs into linked mode. |
Are there recommendations I should follow when linking DADCO gas springs?
Linked System Recommendations (Bulletin B04104)
Bulletin provides a list of general recommendations you can follow when linking nitrogen gas springs. |
Can I get CAD drawings of DADCO products?
You may register on DADCO's website for access to DADCO's online CAD library. Click here for details. You may also e-mail your request for CAD drawings. Please specify file format and product line interest. CAD drawings are available through e-mail if an address is provided. Click here to send your request. |
How can I reduce the pad bounce of my operation during stamping?
Pad Bounce Reducer (Bulletin B02107A)
Bulletin includes information on DADCO's Pad Bounce Reducer and how it can reduce pad bounce and improve placement of stamped parts.
Reduced Impact Cushion - RIC™ 90.10R Series (Bulletin B00116A)
Bulletin includes information about DADCO's 90.10R Series Nitrogen Gas Springs. |
How do I install my new gas springs?
Micro Series Installation and Operation Specifications (Bulletin B00121D)
Bulletin includes information on operating specifications, charging, discharging, mounting and installation principles for the Micro Series Gas Springs.
Gas Spring Installation and Operation (Bulletin B05139A)
Bulletin includes information on operating specifications, charging, discharging, mounting and installation principles for the L, LJ, U, 90.10, 90.5B, 90.9, and SC Series Gas Springs.
|
How do I order a DADCO Duralene™ Rod Wiper in a gas spring?
DADCO Duralene™ Rod Wiper:
Bulletin B00103A (Micro Series, L Series and LJ Series)
Bulletin explains how to order a DADCO Duralene™ Rod Wiper for the Micro Series, L Series and LJ Series.
Bulletin B00104A (90.4 Series, 90.3 Series and 90.7 Series)
Bulletin explains how to order a Duralene™ Rod Wiper for the 90.4 Series, 90.3 Series and 90.7 Series. |
Can the Micro Series gas springs be linked in a system?
Micro Series Linked Systems (Bulletin B03103B)
Explains the MINILink™ system, MINIFLEX™ hose, along with the other equipment needed to link the Micro Series.
MINILink™ System (Bulletin B00107D)
Details the piping system including the components, fillings and accessories. |
How do I order a DF Tubing Solid Hose assembly?
DF Tubing Assemblies (Bulletin B02118B)
Details the DADCO alternative to traditional hose assemblies. |
How do I make a SEAL-LOK Hose Assembly?
Constructing a SEAL-LOK Hose Assembly (Bulletin B00120B) |
How do I make a MINILink™ Hose Assembly?
Constructing a MINILink™Hose Assembly (Bulletin B00109B)
DADCO's Mini-Crimp (Bulletin B00106A) |
How do I order a Hose Assembly?
How to Order a Hose Assembly (Bulletin 99B105C)
Details the different types of hose used in hose assemblies and how to order the hose assembly.
|
Is there an easy way to gauge the pressure in the gas spring when charging and discharging?
DADCO Adjustable Pressure Analyzer - 90.315.5 (Bulletin B01133D)
Details the Adjustable Pressure Analyzer and how to use it to charge, gauge and discharge DADCO gas springs. |
How do I repair my gas springs?
1. Determine the repair kit needed.
DADCO Repair Kits (Bulletin B02116D)
2. Follow repair bulletin to repair gas springs.
Nitrogen Gas Spring Maintenance Instructions SC Series:
Bulletin B02104B (Model: 01000)
Bulletin B02103A (Models: 01800, 04700, 07500, 11800 & 18300)
Nitrogen Gas Spring Maintenance Instructions 90.5B (Bulletin B06125A)
Nitrogen Gas Spring Maintenance Instructions 90.8 and 90.10 (Bulletin B06124A)
90.10R RIC™ Series Nitrogen Gas Spring Maintenance Instructions
Nitrogen Gas Spring Maintenance Instructions L, LJ and U Series (Bulletin B01103D) |
How do I repair my gas lifters?
1. Determine the repair kit needed.
SL2.090 Nitrogen Gas Spring Two Post Lifter Repair Kit - SL2.RK.090
SLN.090 Nitrogen Gas Lifter Repair Kit - SLN.RK.090
SLN.300 Nitrogen Gas Lifter Repair Kit - SLN.RK.300
SLC.800 Nitrogen Gas Lifter Repair Kit - SLC.RK.800
2. Follow repair bulletin to repair gas lifters.
SL2.090 Nitrogen Gas Spring Two Post Lifter Maintenance Instructions (Bulletin B06100)
SLN.090 Nitrogen Gas Lifter Maintenance Instructions (Bulletin B05107A)
SLN.300 Nitrogen Gas Lifter Maintenance Instructions (Bulletin B04110)
SLC.800 Nitrogen Gas Spring Rail Lifter Maintenance Instructions (Bulletin B04111) |
Is there a way to identify that I have high pressure nitrogen gas springs in my tooling?
DADCO Safety Plates (Bulletin B01130A)
Describes the variety of safety plates offered by DADCO to help identify the use of high pressure nitrogen gas springs.
|
How can I measure the force of my gas springs?
Choose from the equipment below to measure the force of the DADCO gas springs you are using:
Micro Load Cell (Bulletin 97B119B)
Super Compact Load Cell (Bulletin B02119)
Standard Load Cell (Bulletin 97B119F)
Micro Test Stand (MTS-125) (Bulletin B01127)
Details the Micro Test Stand and how it is operated.
Portable Test Stand (PTS-25) (Bulletin 97B121)
Details the Portable Test Stand and how it is operated.
Digital Load Cell (Bulletin B04106A)
Details the Digital Load Cell (used for more accurate readings) and how it is operated. |
Do alternate mounting methods for the DADCO Common Control Panel exist?
DADCO's Riser Blocks (Bulletin B01121A)
Details the riser block mounting options including dimensions. |
Is there a tool to monitor gas spring pressure from outside of the press?
DADCO offers Pressure Monitors that feature an indicator light showing that pressure meets pre-set limits. Choose from the three Pressure Monitor models to suit your application:
DADCO 24 VDC Pressure Monitor 90.421.2 (Bulletin B01115A)
DADCO 120 VAC Pressure Monitor 90.421.1 (Bulletin B00136)
DADCO 24 VDC Pressure Monitor 90.421.2D (Bulletin B00134) |
Is there a simple way to link multiple cylinders together to a Common Control Panel?
Distribution Block (Bulletin B03142)
|
How do I monitor, fill and adjust the cylinders using the Multi Panel?
DADCO Multi Panel (Bulletin B04105A)
|
How do I operate the Portable Crimping Unit?
Portable Crimping Unit (Bulletin B04112)
Provides step-by-step instructions for how to operate the Portable Crimping Unit. |
