STEINEL SZ8085 User manual
Operating instructions
for the SZ8085 control set
2 Operating instructions for the SZ8085 control set Version 05.2020
Legal notices
This documentation is intended solely for the owners and their personnel.
The contents of this documentation (texts, figures, drawings, graphics, plans, etc.) may not be reproduced or distributed, whether fully or partially,
without our written consent, or, for the purpose of competition, be given or made available to third parties.
(English translation of the original German text)
Responsible for content
STEINEL Normalien AG .Winkelstraße 7 .78056 Villingen-Schwenningen .Germany
Copyright STEINEL Normalien AG .All rights reserved.
Operating instructions for the SZ8085 control set
Edition 1.0 English
Date of issue 02/2020
Changes to the design and product that serve to improve the product remain reserved.
Version 05.2020 Operating instructions for the SZ8085 control set 3
Table of contents
1 Introduction 5
1.1 Preface 5
1.2 Product identification/product information 5
1.3 Scope of supply 5
1.4 Obligations of the personnel 5
1.5 Warranty and liability 6
1.6 Symbols in these operating instructions 7
1.6.1 Danger warning levels 7
1.6.2 Danger symbols 7
1.6.3 Prohibiting symbols 8
1.6.4 General symbols 8
2 Safety 9
2.1 Safety measures 9
2.2 Wearing parts 9
2.3 Danger from hidden hazards/remaining risks 9
2.4 Application 10
2.5 Authorised personnel 10
2.6 Personal protective equipment 11
3 Control set components 12
3.1 Control set 12
3.2 Components 13
3.2.1 Base body 13
3.2.2 Discharging screw 13
3.2.3 Charging adapter 13
3.2.4 Charging tubing 14
3.2.5 Pressure reducer 14
3.2.6 Valve key 14
3.2.7 Transition adapter 15
4 Filling of the nitrogen cylinder 16
4.1 Filling the nitrogen cylinder 16
4.2 Nitrogen filling pressure table 17
Version 05.2020 Operating instructions for the SZ8085 control set 5
1 Introduction
1.1 Preface
Dear technical supervisor,
You are facing the task of filling the nitrogen systems using the STEINEL control set. The STEINEL control
set is used for filling, the variable pressure setting of and for checking the gas pressure in various nitrogen
systems. These operating instructions will assist you in performing this responsible job.
Please read these operating instructions carefully and pay particular attention to the safety
instructions!
If you have questions about this product, our employees are available to assist you.
Your STEINEL Normalien AG
1.2 Product identification/product information
Validity
The descriptions contained in these operating instructions solely apply to the control set accessories as
they are described here and as they were developed and built by the manufacturer.
Storage
These operating instructions must be kept accessible so that they are available to the operator at any time.
1.3 Scope of supply
The following components are included in the scope of supply for the SZ8085 control set(OI, 3 Control
set components):
Base body
Discharging screws
Charging adapter
Charging tubing
A pressure reducer, valve key and transition adapter are all optionally available with the expanded
SZ8085.9 control set.
1.4 Obligations of the personnel
Only trained specialist personnel may be tasked with working with the control set (OI, 2.5 Authorised
personnel). Before starting work, you are obligated to observe basic regulations concerning occupational
safety and accident prevention.
In the interest of everybody involved, please observe the following instructions:
Refrain from engaging in any manner of working that could be considered unsafe!
Observe all hazard and warning notices contained in these operating instructions!
In addition to this documentation, observe general, legal and otherwise binding regulations
regarding occupational safety and accident prevention as well as environmental protection!
Take note of all ways in which you can report and fight fires and educate yourself about the
location and operation of fire extinguishers!
6 Operating instructions for the SZ8085 control set Version 05.2020
1 Introduction
Always wear personal protective equipment as described in the relevant safety instructions when
working with the control set. Working with the control set without personal protective equipment is
not permitted.
Wear the appropriate protective clothing corresponding to the work that needs to be performed!
Do not wear long hair open, loose-fitting clothing or jewellery!
Only perform those tasks for which you have been sufficiently trained and instructed!
When a safety threat occurs, immediately disconnect the control set from the power supply,
prevent it from starting again and notify the supervisor in charge and/or the safety representative
right away!
Do not carry out any constructional changes without the expressed written consent of the
manufacturer!
Make sure that persons who do not work with the control set (and therefore do not know the
remaining risks associated with the control set) cannot enter the danger area.
1.5 Warranty and liability
For the use of the control set, our “General Terms and Conditions” always apply.
The “General Terms and Conditions” are accessible via our homepage.
Warranty or liability claims in case of damage to persons or property are precluded if they were the result
of one or several of the following causes:
handling in a non-intended manner
improper assembly, commissioning, operation, maintenance and inspection
non-observance of the notes contained in these operating instructions regarding safety, putting into
service, operation, maintenance and inspection
unauthorised structural alterations
insufficient monitoring and maintenance
external elements or force majeure
performance of maintenance work (repairs)
In order to maintain functional reliability, only original spare parts, tools and appliances of the manufac-
turer may be used.
Version 05.2020 Operating instructions for the SZ8085 control set 7
1 Introduction
1.6 Symbols in these operating instructions
1.6.1 Danger warning levels
Various signal words and colours are used depending on the level of risk.
DANGER
DANGER indicates danger which, if not avoided, has a high chance of
resulting in death or serious injury.
WARNING
WARNING indicates danger which, if not avoided, has a medium chance
of resulting in death or serious injury.
CAUTION
CAUTION indicates danger which, if not avoided, has a low chance of
resulting in minor or moderate injury.
ATTENTION
Obligation to specific conduct or a task for the safe handling of the
nitrogen cylinders in order to avoid property damage.
This symbol points to texts that contain important instructions/comments and tips.
1.6.2 Danger symbols
Warns of dangers leading to serious (irreversible) injuries and possibly death!
Warning of hazardous or irritant substances
Warning of explosive substances
Warning of hand injuries
8 Operating instructions for the SZ8085 control set Version 05.2020
1 Introduction
Warning of hot surface
1.6.3 Prohibiting symbols
Unauthorised access prohibited
Reaching in prohibited
1.6.4 General symbols
This arrow identifies the descriptions of tasks that you must perform.
This square identifies enumerations.
This arrow identifies cross references.
If cross references to other chapters occur within the text, notations are abbre-
viated for reasons of clarity.
Example: (OI, 2 Safety)
This means: Refer to operating instructions, Chapter 2 Safety
If the cross reference refers to a page, figure or position number, then this infor-
mation will be added at the end of the cross reference.
Example: (Fig. 4 - 4, Pos. 1
)
This means: Refer to (in chapter 4 of this manual)
position number 1 of figure 4.
Numbers in a square with a red frame refer to positions in the figures.
3
Version 05.2020 Operating instructions for the SZ8085 control set 9
2 Safety
2.1 Safety measures
The following notices serve to recognise and avoid dangers in order to
ensure a handling of the control set that is as safe as possible when using it.
Read and observe all notices and commands within these operating instructions.
Non-observance of safety instructions and commands can result in very serious
injury.
Keep the operating instructions in a safe place and supply them to the operator.
2.2 Wearing parts
Filling adapters are used for the filling of self-sufficient nitrogen cylinders in order to adapt the various
connecting threads.
These filling adapters are particularly prone to wear and other specific stresses if the correct filling process
is not adhered to. As such issues cannot be ruled out, the filling adapters must be checked for damage
before each filling process.
Furthermore, these adapters, as well as the M8 standard nipples fitted in the base body, must always be
replaced after 100 filling processes or in the event of damage.
Other components of the control set must be checked regularly for wear or damage, and replaced if so
required.
Non-observance may void the guarantee or warranty. In addition, STEINEL Normalien AG is not
liable for damage caused by improperly maintained/replaced materials!
2.3 Danger from hidden hazards/remaining risks
WARNING
When working with the control set, severe and unpredictable remaining
risks generally exist and can only be counteracted with systematic work
planning, working with an awareness of dangers, experience, etc.!
The following list is meant to bring some of these dangers to your attention.
If the filling adapters or M8 standard nipples are subjected to lateral,
impact or bending loads, the adapters may become damaged and
malfunction.
Be sure to wear appropriate personal protective equipment for all tasks!
Therefore perform all tasks with the utmost diligence!
10 Operating instructions for the SZ8085 control set Version 05.2020
2 Safety
WARNING
Danger of injury due to improper operation of nitrogen systems!
Before the nitrogen systems are filled, their safe condition with regard
to accidents and operation is to be checked by suitably qualified
personnel.
The nitrogen systems may only be operated by expert, authorised
and appropriately trained personnel.
2.4 Application
The STEINEL control set is used for filling, the variable pressure setting of and for checking the gas pres-
sure in various nitrogen systems.
Self-sufficient nitrogen cylinders
Tube connected nitrogen cylinders*
Composite plates*
Manifold plates*
* As long as the controls are readily accessible, it is possible with these systems to adjust the pressure while they are in operation.
2.5 Authorised personnel
Only specialist personnel trained by the STEINEL Normalien AG in the handling of nitrogen systems (expert,
commissioned and trained personnel) may fill the nitrogen systems.
Learn more about STEINEL Normalien AG’s training opportunities. “Trained expert personnel” refers to
persons that, based on their training, experience and manufacturer training, as well as their knowledge
of relevant standards, can evaluate the tasks assigned to them and recognise potential dangers.
These persons must be authorised (by the person in charge of the safety of the device) and able to perform
the respectively required tasks and to recognise and avoid potential dangers while doing so.
Version 05.2020 Operating instructions for the SZ8085 control set 11
2 Safety
2.6 Personal protective equipment
When working on the entire system, always wear the personal protective equip-
ment (PPE) stipulated by the owner. Always keep your PPE in a safe condition.
Always wear safety goggles, safety gloves and protective footwear during all
work carried out.
When changing the manifold cylinder, a safety mask must also be worn.
When releasing the nitrogen, ear protection must also be worn.
A helmet must also be worn when putting the system into service, as well as
during assembly and disassembly work.
Observe all safety instructions found in the respective operating instructions for nitrogen systems.
12 Operating instructions for the SZ8085 control set Version 05.2020
3 Control set components
3.1 Control set
Please find information on the control set and individual components in our
current product catalogue under:
www.steinel.com » Downloads » Catalogue » Nitrogen systems
Position Designation SZ8085.8 SZ8085.9
1Base body ü ü
2Discharging screw ü ü
3Charging adapter ü ü
4Charging tubing ü ü
5Pressure reducer –ü
6Valve key –ü
7Transition adapter –ü
1 2 3 4
5 6 7
Version 05.2020 Operating instructions for the SZ8085 control set 13
3 Control set components
3.2 Components
3.2.1 Base body
The base body is used for filling the nitrogen cylinder
1Quick-fit connector
2Connection
3Outlet valve
4Regulating valve
5Manometer
Part number
SZ8085.5
3.2.2 Discharging screw
The discharging screw is used to empty the nitrogen
cylinder before filling
M Part number
M4 SZ7046 2
M6 SZ7046 3
M8 SZ7046 4
M10 SZ7046 5
M12 SZ7046 6
G1/8 SZ7046 7
3.2.3 Charging adapter
The charging adapter is used for the connection of the
base body and nitrogen cylinder.
M Use of the
nitrogen cylinder
Part number
M6 SZ7066.1.019-032
SZ8063.1.032
SZ8065.1.019-032
SZ8066.1.019-032
SZ7045 21
M8 all .2 nitrogen
cylinder 019-038
SZ7045 22
M10 SZ8063.1.050
all .2 nitrogen
cylinder 050-063
SZ7045 23
M12 SZ8063.1.063-095
all .2 nitrogen
cylinder 075-120
SZ7045 24
G1/8 all .2 nitrogen
cylinder V, VB
SZ7045 25
21 3
54
14 Operating instructions for the SZ8085 control set Version 05.2020
3 Control set components
3.2.4 Charging tubing
The charging tubing connects the pressure reducer to the base body.
1Connecting thread M12 x 1.5
2Quick coupling sleeve
Part number
SZ8085.4
3.2.5 Pressure reducer
The pressure reducer is the fitting for the nitrogen bottle.
1.1 Connection for nitrogen bottle
300 bar W30 x 2
1.2 Connection for nitrogen bottle
200 bar W24 x 1/14"
2Manometer for cylinder pressure
3Manometer for filling pressure
4Regulating valve
5Connection for charging tubing M12 x 1.5
6Pressure adjustment valve for filling pressure
Part number
SZ8085.6
3.2.6 Valve key
The valve key is used for the assembly/disas-
sembly of the changeable valves.
Part number
K100-000-0300
21
21.1 4
61.2
3 5
Version 05.2020 Operating instructions for the SZ8085 control set 15
3 Control set components
3.2.7 Transition adapter
The transition adapter is required for a prede-
cessor system. The adapter is used for connect-
ing the charging tubing to the filling system.
Part number
SZ7045.9
16 Operating instructions for the SZ8085 control set Version 05.2020
4 Filling of the nitrogen cylinder
4.1 Filling the nitrogen cylinder
DANGER
Charging tubing may be put under pressure.
During the end coupling of the charging tubing via the quick coupling,
ensure that the coupling is fixed by hand. The pressure at the end
coupling immediately escapes with a loud bang.
DANGER
When filling the nitrogen cylinder with nitrogen, the pistons can extend
suddenly.
During the filling process, slowly increase the pressure in order to
prevent sudden extension.
Maintain a sufficient distance and do not reach into the piston’s
movement space.
ATTENTION
Only use nitrogen N2(class 2.8) for filling! Be mindful of filling pressure
specifications (OI, 4.2 Nitrogen filling pressure table) With nitrogen
cylinders with a higher filling pressure, use appropriate nitrogen bottles
(Manufacturer’s recommendation: 300 bar nitrogen bottles).
1. Chuck the base body into a vice.
2. Connect the charging tubing to the nitrogen bottle pressure reducer.
3. Connect the charging tubing to the quick-fit connector on the base body. First
close the control set regulating valve, and then the outlet valve.
Version 05.2020 Operating instructions for the SZ8085 control set 17
4 Filling of the nitrogen cylinder
4. Close the regulating valve at the pressure reducer and turn the pressure adjust-
ment valve for filling pressure back to minimum. Carefully open the nitrogen
bottle. The cylinder pressure and the nitrogen cylinder filling pressure can be read
on the manometers. Set the nitrogen cylinder filling pressure using the pressure
adjustment valve for filling pressure.
5. Open the regulating valve on the base body. Open the regulating valve on the
pressure reducer. The nitrogen cylinder will then be filled with the set filling
pressure. This pressure can be read on the base body’s manometer.
When the filling pressure has been reached, close the regulating valve on the
base body and then open the outlet valve.
After opening, the residual pressure will escape from the base body and the
filled nitrogen cylinder can then be unscrewed.
6. For other nitrogen cylinders that have to be filled with the same pressure, repeat step 5.
7. Following a functionality and tightness test, the nitrogen cylinders can be used
again.
8. For the tightness test, STEINEL Normalien AG provides a force measuring device.
(STEINEL Normalien AG .Winkelstraße 7 .78056 Villingen-Schwenningen
9. The nitrogen bottle will be closed if no additional springs are filled. Then, open
the outlet and regulating valve on the base body, as well as the regulating valve
on the pressure reducer, in order to release the residual pressure. The charging
tubing can now be removed in a depressurised state.
4.2 Nitrogen filling pressure table
WARNING
The pressure values specified in this table correspond to the maximum
filling pressures. Only the specified filling pressure may be used during
filling. A higher filling may lead to damage or malfunctioning, and is
prohibited for safety reasons.
The relevant filling pressure is specified on the respective nitrogen cylinder and
must be obtained from there (see labelling on the nitrogen cylinder).
SZ7066.1
SZ7080.1
SZ7066.2
SZ7080.2
SZ8060.1
SZ8060.2 SZ8063.1 SZ8065.1 SZ8065.2
SZ8066.1
SZ8080.1
SZ8066.2
SZ8080.2
Nominal diameter
mm
Filling pressure bar
Ø 19 191 158 – 179 191 158 128 105
Ø 25 195 195 157 195 196 196 129 129
Ø 32 196 196 155 196 197 196 137 137
Ø 38 197 197 162 197 205 205 131 131
Ø 50 212 212 159 212 209 209 141 141
Ø 63 196 176 153 176 189 189 147 132
Ø 75 189 189 142 189 203 203 157 157
Ø 95 189 210 158 210 182 182 151 168
Ø 120 – – 141 – – – 147 147
Tolerance filling -10%
18 Operating instructions for the SZ8085 control set Version 05.2020
5 Filling of the manifold plate, compo-
site tube and composite plate system
5.1 Safety instructions
DANGER
When filling the manifold plate, tube composite or composite plate
system with nitrogen, the pistons can extend suddenly. This can cause
severe injuries or damage to the superordinate machine!
During the filling process, slowly increase the pressure in order to
prevent sudden extension.
Do not stand or linger directly at the plate, nor reach into the piston’s
movement space.
5.2 Filling of the manifold plate, tube composite and composite
plate system
DANGER
Charging tubing may be put under pressure.
During the end coupling of the charging tubing via the quick coupling,
ensure that the coupling is fixed by hand. The pressure at the end
coupling immediately escapes with a loud bang.
Fill the plate via the control panel and according to the identification plate. With regard to the composite
systems, the permissible nitrogen cylinder filling pressure with the lowest pressure is decisive for the filling.
1. Connect the charging tubing to the nitrogen bottle pressure reducer.
2. Shut the regulating valve at the control panel.
3. Connect the hose at the control panel.
Version 05.2020 Operating instructions for the SZ8085 control set 19
5 Filling of the manifold plate, compo-
site tube and composite plate system
4. Close the regulating valve at the pressure reducer and turn the pressure
adjustment valve for filling pressure back to minimum. Carefully open the
nitrogen bottle. The cylinder pressure and the plate/composite system fill-
ing pressure can be read on the manometers. Set the plate/system fill-
ing pressure using the pressure adjustment valve for filling pressure.
5. Open the regulating valve on the pressure reducer. The filling pressure can now
be read on the control panel manometer.
6. When the desired filling pressure has been reached, close the regulating valve
on the pressure reducer. The charging tubing can now be decoupled at the
control panel.
STEINEL Normalien AG .Winkelstraße 7 .78056 Villingen-Schwenningen .Germany
We do not accept liability for printing errors and mistakes. Progress results in improvements as well as changes to design, dimensions and materials. We therefore
reserve the right to make technical changes. Copyright STEINEL Normalien AG.
design by com-a-tec.de
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