Pnomatikkatalog

PNEUMATICS
TECHNICAL PRINCIPLES
Pneumatics   480
Use of Pneumatic Seals   482
Sealing Mechanism and Influencing Quantities   487
Fitting of Pneumatic Seals   503
PRODUCTS
Products   508
Design Types   513

Technical Principles | Pneumatics
PNEUMATICS
With approx. 500 different dimensions, Freudenberg REQUIREMENTS

Sealing Technologies (FST) has a comprehensive
range of rod and piston seals, wipers and guides for • Seals for small forces and fast movements
pneumatics. • Medium: Compressed gases and air
A comprehensive, cost-effective, complete program of • Only minimal spare parts requirement
standard products in a variety of different mixtures • Most frequent application area: Automation industry
for diverse applications is available to the customer. • Large amounts
In addition, we also gladly develop individual solutions • Few standard dimensions
for our customers. • Strong innovation and great creativity from FST is in
FST is with you as partner from the product design, demand.
to the selection of materials, to the individual product
manufacture.
480 © Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual

FEATURES APPLICATION RANGE
• Broad selection of dimensions in the diameter range Merkel Pneumatic seals are used in pneumatic
from 1 mm to 500 mm cylinders as well as for the pneumatic control and
• Application-specific material matching depending regulation of valves. In addition, FST also offers
on the application solutions for the sealing of rod-less cylinders with
• Application possibilities within a wide temperature r ange polyurethane sealing strips.
from –40°C to +200°C
• Cost-effective manufacturing procedures geared to Application areas are:
application and amounts. • General mechanical engineering
• Automation engineering
• Foodstuffs and packaging industry
• Materials handling
• Individual customer solutions for special appli
cations e.g. for hand-guided power tools.
© Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual 481

USE OF PNEUMATIC SEALS
Pneumatics, a subgroup of fluid power technology, is APPLICATION EXAMPLES

the study of the behaviour of gases. Today the term
"pneumatics", derived from the Greek "pneuma" primar- The starting point for the design of a pneumatic drive
ily refers to the transport of energy by compressed air. is the cylinder. The most frequently used cylinders for
the creation of a straight-lined movement are shown in
Pneumatic drives and controls, increasingly used for → Fig. 1 and → Figs. 3 to 5.
mechanisation and automation of production processes,
consist primarily of valves and cylinders. A simple cylinder design is shown in → Fig. 1. A com-
Pneumatic devices require sealing of volumes of air bination element is fitted to the rod. It combines the
subject to pressure for their function. The pneumatic functions of sealing and wiping away dirt. A complete
seals used for this purpose can be classified into piston with injection-moulded guides and snap-on,
cylinder and valve seals (→ Fig.  2). There is no point double-acting seal (Merkel Complete Piston Pneuko G)
to making a more detailed classification for valve seals is screwed to the end of the rod. The complete piston
similar to that used for cylinder seals. Valve seals are has a square elastomer ring for static sealing between
special seals designed for the different valve designs piston and rod. The end stop of the piston at the final
of individual manufacturers. positions is damped by elastomer discs. In some cases,
particularly with small cylinders, complete pistons with
vulcanised damping bars (Merkel Complete Piston
NADUOP) are used instead of the elastomer discs.
Combination element
Seal-wiper Damping disc
Complete piston with moulded guides Damping disc

and double acting seal
Fig. 1 Pneumatic cylinder I

Pneumatic
seals
Cylinder Valve
seals seals
Rod Piston Seat Slide

seals seals seals seals
Individual Single acting seal

seal
Combination Double acting seal

seal + wiper
Combination
Complete
seal + wiper
piston
+ guide
Damping Damping
seal seal
Static seals Static seals
Fig. 2 Categorisation of pneumatic seals

Wiper Complete piston with vulcanised sealing
Rod seal (U-ring) Piston damper seal
Fig. 3 Pneumatic cylinder II
→ Fig. 3 shows a cylinder design with adjustable damp- control the directional control valve by an electrical
ing. Piston damping seals are installed on both sides of circuit.
the double-lip seal (Merkel Complete Piston TDUOP),
which acts as a complete piston. When the damper The functions of sealing, guiding and wiping away dirt
seals are retracted into the damping cylinder the pres- are distributed over three separate components in these
sure created is relieved by an adjustable throttle valve. cylinders. The brass rod guide ring is installed between
The kinetic energy of the piston, rod and the external the seal and the wiper.
mass is absorbed over a few millimetres without a hard A standard cylinder design is shown → Fig. 4. The rod
end stop. is guided in a bronze, plastic or brass bush and is fitted
with a combined wiper and rod seal (Merkel Combi-
The double-lip seal can also be used for positioning nation Seal AUNIPSL). The piston is sealed using two
when using aluminium, brass or plastic cylinder bores. pneumatic U-rings (Merkel U-Ring NAP 300, Merkel
Sensors attached to the exterior of the cylinder are U-Ring NAP 310). A separate guide is installed be-
activated by the steel washer of the double-lip seal and tween the U-rings.
Combination element
"Seal-wiper" Rod damper seal Guide element
Single acting piston seal (U-ring) Rod damper seal
Fig. 4 Pneumatic cylinder III

Rod damper seal
Single acting special piston seal
Fig. 5 Pneumatic cylinder without piston rod
This has either a guide belt of PTFE or injection-moulded Rotating cylinders are used to generated a limited
guide rings. rotary movement. They are designed as double-acting
piston cylinders, where the piston rod is driven by a
An alternative is pistons of plastic, which do not have gear on a tooth profile, or a rotary blade cylinder.
the separate guide element. The pistons have a ring
magnet inserted in them for positioning such cylinders. The dynamic sealing of rotary blade cylinders is not
simple because of the complex geometry and requires
Damping at the end positions is achieved using the special designed for the seals.
same principle as shown in → Fig. 3. In contrast to the
cylinder shown in → Fig. 3, rod damper seals ( Merkel From the wide variety of valve seals available, a few
Damper Seal DIP, Merkel Damper Seal AUDIP) examples have been chosen and are shown in→ Fig. 6,
→ Fig. 4 are used instead of piston damper seals. to Fig. 8. The diagrams of the valves are greatly simpli-
The static sealing between cylinder bore and cylinder fied to show the mode of operation and the task of the
floor cover as well as between piston and piston rod is valve seals clearly.
handled by O-rings.
The rod seal is not needed in the rod-less cylinder

shown in → Fig. 5. Damping at the end positions is
achieved in the same way as in → Fig. 4. The longitu-
dinal slit in the cylinder barrel is sealed with two steel R P
strips that are held in position by a permanent magnet.
Alternative designs use special belts of polyurethane,
which are snap-fitted into longitudinal grooves in the
cylinder bore. The geometry of the sealing surface is
distorted in the area of the inside sealing belt. This is
A
why special seals have been developed for sealing the
piston.
Fig. 6 Pneumatic quick-venting valve
In addition to the piston cylinders described above
there are diaphragm cylinders for very small linear
movements. Here the function of the piston is carried out
by a diaphragm of elastomer or plastic material.

ZP R
Fig. 7 Pneumatic 3/2-way valve
The quick-venting valve shown in → Fig. 6 is used to and very good wear properties. Special polyurethane
increase the piston speed in cylinders. The decisive fac- materials that meet these requirements are used.
tor for its operation is the cup-like design of the seal and An important factor in the operation of the 5/2-way
the elastic sealing material. When pressure is applied valve in → Fig. 8 is the snap-on diaphragms at the left
at port P the seal covers vent R and releases the path and right end of the valve rod. The design of the dia-
to A via the flexible lips. If there is no pressure at P, phragms in connection with highly dynamically loaded
and the air is returning from the cylinder via A, the seal polyurethane material ensures that this valve operates
closes port P, and the air can flow freely over the short correctly. The valve is actuated alternately by the pres-
distance outside via R. sure applied at ports Y and Z and retained the position
The 3/2-way valve shown in → Fig. 7 has 2 double- until the next impulse is applied. The fluid can flow from
acting sealing components, a differential piston and a P to A or from P to B with the seal in the centre of the
U-ring. The differential piston consists of a basic plastic control piston.
body, which is surrounded by an elastomeric material
or is a fully polyurethane component. The action thresh-
old is favourably influenced by appropriate design of
the sealing lips and the use of a low-friction elastomer
material. The U‑ring with its dynamic loading requires
an elastic material with very high mechanical strength
AB
YR PS Z
Fig. 8 Pneumatic 5/2-way valve

SEALING MECHANISM AND INFLUENCING QUANTITIES
Whether it is drive applications, control or regulation: FORMATION OF LUBRICANT FILMS AND

air plays a major role in engineering! Pressure and SEALING LIP GEOMETRY
suction air in pistons can move, lift and retract work-
pieces and tools as well as use valves to control start, It is well known that friction and wear between two bod-
stop, direction, pressure and flow. It is now wonder ies sliding over each other can be minimised if the two
that pneumatics is at home in handling and automation friction surfaces are completely separated by a layer
technology. of lubricant.
In the case of elastic seals the formation of the lubricat-
There are three major requirements for pneumatic seals: ing film between the seal and sliding surface depends
• High sealing effect primarily on the following:
• Low friction • The sliding speed
• Long service life. • The dynamic viscosity of the lubricant
• The pressure curve in the lubricating gap.
The sealing effect at rest without pressure is guaranteed
with elastic seals because of the radial pressure result- The sliding speed and viscosity of the lubricant are
ing from the overdimensioning. The sealing pressure is mostly preset, so the formation of the lubricating film
superimposed on the basic compression. This means can only be influenced by the pressure curve in the lu-
that the compression between the seal and the mating bricating gap. The pressure curve in the lubricating gap
surface is always greater than the sealing pressure. This during movement and the static pressure distribution
effect, known as "automatic sealing effect" is shown in between the seal and the mating surface are virtually
→ Fig. 9 using an O-ring as an example. identical for elastic seals. The pressure distribution can
be influenced by the geometric design of the sealing lip.
To reduce friction and wear a lubricant is frequently The majority of pneumatic seals are lubricated for
used, which must be able to withstand very different life when mounting. Therefore, the sealing lips of the
conditions: ambient temperature, sliding speed, normal pneumatic seal must be designed so the lubricating film,
forces etc. – a complex tribological system with high which is applied once, is retained for the entire service
demands on the manufacturer of pneumatic drives. life.
To ensure this maximum cleanliness is essential before
The results of cooperation with well-known manufactur- greasing and commissioning: the system must be com-
ers of pneumatic components and university research pletely free from machining residue and old lubricants
establishments are seal and lubricant combinations that as well as any other contaminants. This is the only way
are the optimum solutions for a wide variety of applica- that both the seals and the mating surfaces can be ad-
tions for pneumatic systems. equately lubricated. This ensures a uniform coating of
lubricant over the friction pair.
Tip for greasing cylinder contact surfaces:

Application of lubricants with fitted round brushes
or automatic greasing by lubrication pistons are two
proven methods. It is important to move the working
piston throughout the complete stroke several times
after fitting – this distributes the lubricant and also coats
the seal with lubricant adequately with only one-sided
greasing.

Seal fitted in the

housing
Seal compressed
in unpressurised state
Contact pressure distribution

as a result of initial compression
pv
Seal
under pressure
p
Contact pressure distribution d
as a result of initial
compression and pressure
to be sealed p
pdv = p + p
Fig. 9 Automatic sealing effect with elastic seals
X X
P P
Hydraulics Pneumatics
 
Fig. 10 Different lip geometry and pressure distribution with hydraulics and pneumatics

Tip for greasing valves: SEALING SYSTEM

The procedure is similar to that with cylinders. Depend-
ing on the size and circumference excess greasing of Tribological view of the sealing system
the piston seal also ensures an even coating of lubrica- Friction and service life are interrelated in the operation
tion on the mating surface after several strokes. of a sealing system. The interaction depends on operat-
ing parameters (temperature, pressure and speed)
In contrast to that hydraulic seals are intended to as well as the fitting characteristics, the seal geometry,
spread the medium as much as possible. Pneumatic the seal material, the surface design and the lubricant
seals therefore have a very different lip geometry from (→ Fig. 11).
that of hydraulic seals (→ Fig. 10). The friction describes the proportion of energy lost as
a result of the physical energy transfer. With a linear
The typical pneumatics sealing lip is relatively long movement it represents the movement resistances in the
compared to the thickness. In combination with the very form of a friction force.
blunt, angled sealing edge there is a small, equally
large angle between the sealing lip and the mating This consists of the interplay between the friction pairs
surface when it is pressed to the sliding surface. The and the resistance of the materials against deformation
resulting symmetrical pressure distribution has a favour- during a movement or the possibility of a movement.
able effect on the retention of the lubricating film and
thus on the friction and wear. • Adhesive proportion of friction
The surface activity and polarity of the friction pair
tends to pull them apart and thus generate
a resistance that corresponds to the adhesive
proportion of the friction (→ Fig. 11).
• Deformation of proportion of friction

Macro and microgeometric attachments cause plastic
and/or elastic deformation of the friction pairs. The sur-
faces of two friction pairs always have some irregulari-
ties as a result of manufacturing processes that obstruct
one another during a relative movement.
• Internal proportion of friction

Internal friction is the energy losses in the form of heat
that occur when a material is deformed (hysteresis,
damping).

Housing Static Surface layers Sliding speed Overlap

tolerance sealing side in contact Stroke frequency
Dynamic
System sealing side
pressure
Seal Friction
geometry temperature
Seal Casing
material material
Ambient “Roughness”
temperature micro-geometry
Dirt from Medium

outside to be sealed
Gap width Pressing and Counterface Direction Dirt/water

Guide play pressing behaviour of motion in the medium
Down time
Lubricant
Sliding surface
Seal material
Adhesion friction Deformation friction Internal friction
Fig. 11 Basic influences on the tribosystem

G
M F
G = Start up friction
M = Mixed friction
Friction index (µ)
F = Fluid friction
Release point
Velocity (v)
Lubricant
Sliding surface
Seal material
Start up friction (G) Mixed friction (M) Fluid friction (F)

Normal force Normal force Normal force
Frictional force Velocity Frictional force Velocity Frictional force Velocity
Fig. 12 Stribeck graph describes the dependency of the friction force on the speed
Dominant friction states • Mixed friction

Different friction states are generated by factors such as In this case a relative movement takes place, which
the sliding speed of the friction pairs together. is prevented primarily by the proportion of micro
The Stribeck graph shows the friction force depending interlocking and adhesive friction as well as internal
on the speed. The friction states shown in → Fig. 12 are friction. The friction force overall is generally less than
generated depending on the sliding speed: that with boundary friction, because the penetration of
the interlocking is significantly less and the lubrication
• Boundary friction component of the lubricant comes into effect.
When a movement is imminent the friction pair adheres
together by micro interlocking resulting from adhesive
The higher the speed the less possibility there is of the
friction. The internal friction also acts as a resistance
surface irregularities adhering together, therefor the
force to displacement of the micro interlocking. The
friction is reduced.
friction pair has no movement relative to each other.

• Fluid friction A surface structure that is too "smooth" (→ Fig. 14) has

At sufficiently high sliding speed the viscosity of the only very small surface indentations in which the lubri-
lubricant forms a pressure between the friction pair, cant can be deposited. The result is that the lubricant is
which completely separates the contact surfaces wiped away by the sealing lip because the shape-asso-
(grease-planing). The friction is primarily influenced by ciated residues is too small and the remaining lubricat-
operating parameters (pressure, temperature, speed) ing film is not sufficient. The wear of the sealing lip and
and by internal friction components of the lubricant. the mating surface is greatly increased.
Housing and surface characteristics A surface that is too rough (→Fig. 15) has a primarily
The housing for pneumatic seals should be designed so negative effect on the surface of the sealing lip, be-
the seal can be easily installed and provides an opti- cause the back and forth movement affects it more.
mum sealing effect during operation.
Both surfaces – too rough or too smooth – cause a
Individual seals must not have any guidance functions; reduced running performance (leakage) and higher
combination components form an exception. During the friction (wear).
use of individual sealing components the guides should
be designed in the fit pair H9/f8, unless separate guide
elements (guide belt of PTFE or guide rings of plastic)
are used (→ Fig. 16).
The surface characteristics of the groove base and

the dynamic mating running surface have a great
influence on the operation and service life of the seal-
ing component. The surface roughness Rmax is the most
important quantity for the specification of the surface
quality as per DIN ISO 4287 (→ Fig.  17). In addition,
the profile support component tp should be as high as
possible (50% up to 70%). Instead of the explicit value
of tp the quotient from the individual measured values
depth of surface smoothness Rp and the measured
surface roughness Rz should be used to evaluate the dy-
namic mating surface. Profiles with Rp/Rz <0,5 (closed
profiles) are favourable with reference to the wear and
service life of elastomer seals. In contrast open profiles
with Rp/Rz >0,5 result in premature wear of seals.
These recommendations are intended to present an

ideal surface for seal running surfaces (→ Fig. 13).

Schematic views of surfaces → Tbl. 1 shows a table with the most important informa-
tion on the design of the sealing point.
1. Cylinder bore
Material: St, Ms, Al, GFK
Tolerance: H 11 / H 12
Surface: Rmax ≤4 µm,
Rp/Rz <0,5
tp (25% Rmax) = 50 … 70%
Machining method: Honing, drawing, roller burnishing.

No additional chemical treatment
permissible. Al tubes must be hard-
anodised.
2. Rods
Fig. 13 Ideal surface structure Material: St
Tolerance: f8
Surface: Rmax ≤4 µm,
Rp/Rz <0,5
tp (25% Rmax) = 50 … 70%
Machining method: Grinding, roller burnishing (rolling).

The hardness of the running surface
should be 55 HRC up to 60 HRC.
Hard-chromed surfaces (coating
thickness 30 µm) must be reworked to
the required surface quality.
3. Housings
Material: St, Ms, Al, plastic
Tolerance: Seals:
  see detailed descriptions.
Fig. 14 Too smooth surface structure
Rod guide: H–8
  Piston guide: h8
Surface: Rmax ≤10 µm

 
Rp/Rz <0,5
 
tp (25% Rmax) = 50 … 70%
Machining method: Turning, grinding.
Tbl. 1 Surface roughness and machining methods
Fig. 15 Too rough surface structure

Ø D H9
f8
Ø D1 Ø dNf8
D1 = d N +0 ,6
Ø DNH11Ø DK
DK = DN –0 ,6
Ø DNH11
Fig. 16 Fitting and tolerances for seals and guides

Ra
Rp
Rt
Im
R t ... Peak-to-valley height

R p ... Smoothing depth
Ra ... Arithmetic mean roughness
Z1 Z2 Z3 Z4 Z5
Ie
Im = 5 x Ie
R z ......... Peak-to-valley height determined

1
Rz = – (Z 1 + Z2 + Z3 + Z4 + Z5)
5
Rmax .... Maximum peak-to-valley height
(here Rmax = Z3)
Fig. 17 Roughness terms

Seals and lubricants for ISO cylinders
Pressure max
Lubricant a) Seal profile Type c) Material Temperature (°C)
(MPa)
Klübersynth Damper Seal

90 NBR 108 1,6 –30 … +100
AR 34-402 DIP
POLYLUB Damper Seal

94 AU 925 2,5 –30 … +90
GLY 151 AUDIP
BARRIERTA Damper Seal

75 FKM 595 1,6 –5 … +150
L 55/1 b) DIP
–20 … +80
Klübersynth U-Ring
80 NBR 186349 1,0 (for FKM
AR 34-402 NAPN
–5 … +150)
Complete Piston with

Klübersynth
venting passages 72 NBR 708 1,2 –20 … +100
AR 34-402
T DUO P
Klübersynth Complete Piston

72 NBR 708 1,2 –20 … +100
AR 34-402 T DUO P
Complete Piston
Klübersynth with magnet and
72 NBR 708 1,2 –20 … +80
AR 34-402 guide belt
T DUO PM
Tbl. 2
a) Application in food industry: Klübersynth UH1 14-151/PARALIQ GTE 703 – approved by USDA
(United States Department of Agriculture) H1
b) High temperature application
c) Operating conditions and fitting information → see product description.

Pressure max
Lubricant a) Seal profile Type c) Material Temperature (°C)
(MPa)
Klübersynth U-Ring
80 NBR 99079 1,2 –25 … +100
AR 34-402 NAP 210
POLYLUB Complete Piston

80 AU 21000 1,2 –25 … +80
GLY 151 Pneuko M
POLYLUB U-Ring
80 AU 20994 1,2 –35 … +80
GLY 151 NAP 310
BARRIERTA U-Ring
75 FKM 230553 1,0 –5 … +150
L 55/1 b) NAPN
BARRIERTA Complete Piston

75 FKM 181327 1,2 –5 … +150
L 55/1 b) Pneuko M
Complete Piston with

BARRIERTA
venting passages 75 FKM 595 1,2 –5 … +150
L 55/1 b)
T DUO P
BARRIERTA Complete Piston

75 FKM 595 1,2 –5 … +150
L 55/1 b) T DUO P
BARRIERTA U-Ring
75 FKM 99104 1,2 –5 … +200
L 55/1 b) NAP 210
POLYLUB U-Ring
80 AU 941 1,2 –35 … +80
GLY 151 NAP 300
Klübersynth Combination Seal

72 NBR 708 1,2 –20 … +100
AR 34-402 NIPSL
POLYLUB Combination Seal

94 AU 925 1,2 –30 … +90
GLY 151 AUNIPSL
BARRIERTA Combination Seal

75 FKM 595 1,2 –5 … +150
L 55/1 b) NIPSL
Tbl. 2

Seals and lubricants for short stroke and compact cylinders
Lubricant a) Seal profile Type c) Material Pressure max Temperature (°C)

(MPa)
Klübersynth Compact Seal

80 NBR 186349 1,2 –20 … +80
AR 34-402 Airzet PK

72 NBR 708 1,0 –20 … +100
AR 34-402 KDN

72 NBR 708 1,0 –20 … +100
AR 34-402 NADUOP
U-Ring
BARRIERTA L 55/1 b) 75 FKM 99104 1,2 –5 … +200
NAP 210
Klübersynth U-Ring
80 NBR 99079 1,2 –25 … +100
AR 34-402 NAP 210
U-Ring
POLYLUB GLY 151 80 AU 20994 1,2 –35 … +80
NAP 310
Tbl. 3

Lubricant a) Seal profile Type c) Material Pressure max Temperature (°C)

(MPa)

72 NBR 708 1,0 –20 … +100
AR 34-402 Pneuko G
Complete Piston
POLYLUB GLY 151 80 AU 21000 1,2 –25 … +80
Pneuko M
Complete Piston
BARRIERTA L 55/1 b) 75 FKM 181327 1,2 –5 … +150
Pneuko M

80 NBR 186349 1,2 –20 … +80
AR 34-402 Airzet PR

80 NBR 4005 1,0 –20 … +100
AR 34-402 NIPSL 200
Combination Seal
BARRIERTA L 55/1 b) 75 FKM 181327 1,0 –5 … +150
NIPSL 210
 
Combination Seal
POLYLUB GLY 151 85 AU 20991 1,0 –30 … +90
NIPSL 300
 
Combination Seal
POLYLUB GLY 151 85 AU 20991 1,0 –30 … +80
NIPSL 310
Combination Seal
POLYLUB GLY 151 94 AU 925 1,2 –30 … +90
NIPSL 320

90 NBR 108 1,0 –20 … +100
AR 34-402 NIPSL SF
Combination Seal
BARRIERTA L 55/1 b) 75 FKM 595 1,0 –5 … +150
NIPSL SF
 
Tbl. 3

Seals and lubricants for valves
Valve type Lubricant Seal profile a) Type Material Pressure max Temperature
(MPa) (°C)
PETAMO GHY
Directional 133 N
special shapes 80 NBR 186349 1,2 –30 … +100
Control Valve UNISILKON
L 641
PETAMO GHY
Directional 133 N 80 HNBR
special shapes 1,2 –15 … +120
Control Valve UNISILKON 181572
L 641
PETAMO GHY
Directional 133 N
special shapes AU a) 1,2 –35 … +80
L 641
PETAMO GHY
Directional 133 N
NAP 310 AU a) 1,2 –35 … +80
L 641
PETAMO GHY
KDN
Directional 133 N
NAP 210 NBR a) 1,2 –30 … +100
Control Valv UNISILKON
Airzet
L 641
PETAMO GHY
133 N
Seat Valve special shapes AU a) 1,2 –35 … +80
UNISILKON
L 641
Tbl. 4
a) on enquiry

Product data
Lubricants Base oil/ Operational Density at Base oil viscosity Walk pen- Consistency Miscellaneous
oil temperature 20 °C DIN DIN 51 562 T1 etration NLGI class instructions
thickener range a)[°C] 51 757 [mm2/s] DIN ISO DIN 51 818
approxi- [g/cm3] at approximately 21 37
mately approxi- [0,1 mm]
mately 40 °C 100 °C
Lubrication of pneumatic cylinders
Synth. Adhering lubricating grease

hydro- for high piston speed ranges;
Klübersynth carbon 265 … reduced stick-slip tendency
–30 … +130 0,90 400 40 2
AR 34-402 oil/special 295 at very low piston speeds;
calcium low breakaway force even
soap after extended downtime
Mineral oil/
synth. hydro- Light-running grease; also
POLYLUB 310 …
carbon oil/ –50 … +130 0,85 150 18,5 1 preferred for applications at
GLY 151 340
Li special low temperatures
soap
Adhering lubricating
grease for high-temperature
applications;
BARRIERTA 310 …
PFPE/PTFE –40 … +260 1,95 415 40 1 very good resistance to most
L 55/1 340
chemicals; good compat-
ibility with most elastomers
and plastics
Approved by USDA H1, and

Synth. hy-
Klüber- designed for applications
dro-carbon 310 …
synth UH1 –40 … +120 0,92 150 22 1 in the food industry; good
oil/Al com- 340
14-151 water resistance and good
plex soap
corrosion protection
Approved by USDA H1, and

designed for applications in
the food industry;
PARALIQ Silicone 220 …
–50 … +150 1,31 1000 360 3 wide temperature range;
GTE 703 oil/PTFE 250
resistant to hot and cold
water and also compatible
with EPDM
Adhering lubricating grease

for a wide temperature
Mineral oil/
range; reduced adhesion
PETAMO synth hydro- 265 …
–30 … +160 0,88 150 18 2 and movement friction;
GHY 133N carbon oil/ 295
good wear resistance;
polyurea
good corrosion protection
effect
Approved by USDA H1;

adhering lubricating grease;
UNI
Silicone 300 … particularly for applications
SILKON –40 … +160 1,25 75000 30000 –
oil/PTFE 320 with high switching frequen-
L 641
cies and high air flow as well
as at low temperatures
Tbl. 5
a) Operating temperature data are recommended values oriented to lubricant structure, the specified use and the application technology.
Lubricants change consistency depending on the type of mechanical-dynamic loading with the temperature, pressure and time, apparent
viscosity and viscosity. The change in the characteristics of the product may influence the function of components.

COMPRESSED AIR ating conditions "dried and de-oiled compressed air” is

recommended for the pneumatic components. In these
Depending on the application various compressed-air cases a compressed air oiler is installed immediately
classes are recommended in PNEUROP Guideline before the consumer. With the frequently encountered
6611. The criteria dried and de-oiled compressed air the service life of the
• particle size pneumatic seals depends greatly on the one-time initial
• pressure dew-point lubrication. The lubricants must adhere well to the metal
• oil content and elastomer surfaces. They must be compatible with
are listed in PNEUROP 6611 tables the sealing material, have high resistance to ageing,
in which the quality classes are specified. good corrosion protection, a consistency suitable for
  smooth running and be suitable for use in the required
The most general distinction of prepared and unpre- temperature range.
pared compressed air. Unprepared air is compressed
with oil-lubricated compressors and only coarsely fil- If oiled compressed air is used, the compatibility
tered. It still contains fine dirt particles, water and oil. between the lubricant and the oil is important with
reference to maintaining a stable lubricating film.
To prevent premature wear of valves, cylinders and
seals, particles larger than 40 µm should be removed
by appropriate filters.
Prepared air is prefiltered after compression, dehydrat-
ed by cold dryers (pressure dew-point +2°C) and then
cleaned in very fine filters. This air quality is frequently
referred to as "dried and de-oiled compressed air”.
For particularly critical applications the air can be dried
in an absorption dryer (pressure dew-point –40 °C up
to –60 °C) after the fine filtering. Under extreme oper-

FITTING OF PNEUMATIC SEALS
Before fitting of sealing components the complete Length Z (chamfer) Nominal diameter
system must be cleaned of machining residue, chips, dirt
2 <20
and other particles. Seals must not be pulled over sharp
edges, threads, feather key grooves or similar during 3 0 … 49
fitting. Cover these parts before fitting (→ Fig. 19). 4 50 … 99
5 100 … 159
Sharp edges must be de-burred or chamfered or
smoothed off. Never use sharp-edged tools. 6 160 … 249
The seal, piston rod and cylinder bore must be oiled or 7 250 … 400
greased before fitting.
8 >400
Tbl. 6
INSERTION CHAMFERS ON RODS AND PIPES
Cylinder bores and piston rods must be chamfered to
prevent damage to the sealing components during fit-
ting. The length of the chamfer depends on the nominal
diameter.
The dimensions are shown in → Tbl. 6. The edge at the
transition from the chamfer to the sliding surface must
be rounded and polished.
Rounded, polished
20°
20°
Rounded, polished
Fig. 18 Chamfering rods and pipes

Fig. 19 Covering threads when mounting seals

Installation recommendation I
Installation recommendation II
Fig. 20 Fitting types of rod seals
FITTING OF PNEUMATIC SEALS All edges around the seal housing must be carefully
When mounting individual sealing components two de-burred and rounded.
types of fitting are possible (→ Fig. 20):
• Snap-in fitting in an undivided housing The individual sealing components can generally be
(recommendation I) installed by hand without equipment (snap-in fitting).
• Fitting in a divided housing
(recommendation II).

Fitting can be simplified by using suitable fitting tools

(→ Fig. 21 and → Fig. 22). When using the two-
component fitting tool II the seal is pushed through the
tapered mounting sleeve with the mandrel and it snaps
into the grooves (→ Fig.  23).
Another option is to use a suitable fitting tool
(→ Fig. 24). In this regard the seal is initially positioned
by hand in the groove and then pushed with a rod until
is snaps into the groove.
Fig. 21 Fitting tool for rod seals
Fig. 23 Fitting of rod seals
Rod
Plug
Fig. 22 Fitting tool for rod seals Fig. 24 Fitting aid for rod seals

Fig. 27 Fitting tool for piston seals
Fig. 25 Fitting of combination components
Fig. 28 Assembly of pneumatic complete pistons
Combination components (AUNIPSL, NIPSL), which

in some cases contain metal reinforcements or plastic
support components, are always installed in axially
accessible grooves (→ Fig. 25). They can be installed
without equipment and fitting can be automated for
production lines.
Pneumatic complete pistons (TDUOP, Pneuko M) are

positioned on a piston rod and fastened with hex
nuts (→ Fig. 28). An additional lock on the threaded
connection using a self-locking nut or an adhesive is
recommended.
Fig. 26 Snap-in fitting of a piston seal

Products | Pneumatics
PRODUCTS
Pre-Selection Pneumatics   509
ROD SEALS GUIDES
Merkel Combination Seal AU NIPSL   513 Merkel Guide Strip SF   539
Merkel Combination Seal NIPSL   515 Merkel Guide Ring EKF   543
Merkel Combination Seal NIPSL 200   517 Merkel Guide Strip KF   545
Merkel Combination Seal NIPSL 210   518
Merkel Combination Seal NIPSL SF   522
Merkel Compact Seal Airzet PR   523
DAMPER SEALS
Merkel Damper Seal AU DIP   524

Merkel Damper Seal DIP   525
PISTON SEALS
Merkel U-Ring NAP 210   526

Merkel U-Ring NAPN   529
Merkel Compact Seal Airzet PK   530
Merkel Compact Seal KDN   531
Merkel Complete Piston NADUOP   532
Merkel Complete Piston Pneuko G   533
Merkel Complete Piston Pneuko M 210   534
Merkel Complete Piston Pneuko M 310   535
Merkel Complete Piston TDUOP   536
Merkel Complete Piston TDUOP
with Venting Passages   537
Merkel Complete Piston TDUOP M   538

Pre-Selection I Pneumatics
PRE-SELECTION PNEUMATICS
Note:
The information on minimum operating temperatures is to be considered genaral, as alongside the material,
the type of seal, the housing and the operating conditions can also affect the function. The maximum operating
temperatures can be exceeded, in this case a reduction in the service life of the seals can be expected.
The effect of media (e.g. unsuitable lubricants) can reduce the operating temperature limits.
Pressurised
Hardness Temperature
Type Material area Speed in m/s
Shore A range in °C 2)
in MPa (bar)
Rod Seals
Merkel Combination Seal AU NIPSL
AU 94 ≤1,2 (12) –30 … +90 ≤1
Merkel Combination Seal NIPSL

NBR ≤1,2 (12) –20 … +100
90 ≤1
FKM 1) –5 … +150
Merkel Combination Seal NIPSL 200
NBR 80 ≤1,0 (10) –20 … +100 ≤1
FKM 75 ≤1,0 (10) –5 … +150 ≤1
AU 90 ≤1,0 (10) –30 … +90 ≤1
AU 85 ≤1,0 (10) –30 … +80 ≤1
1) On request
2) Usual temperature range for pneumatic cylinders: –20 … +80 °C

Pressurised
in MPa (bar)
AU 94 ≤1,2 (12) –30 … +90 ≤1
Merkel Combination Seal NIPSL SF

NBR ≤1,0 (10) –20 … +100
80 ≤1
FKM 1) –5 … +150
Merkel Combination Seal Airzet PR

NBR 80 –30 … +80
≤1,2 (12) ≤1
FKM 75 –5 … +150
Piston Seals
Merkel U-Ring NAP 210
FKM 1) 75 –5 … +200
≤1,2 (12) ≤1
NBR 80 –25 … +100
AU 80 ≤1,2 (12) –35 … +80 ≤1
AU 80 ≤1,2 (12) –35 … +80 ≤1
Merkel U-Ring NAPN

NBR –20 … +80
80 ≤1 (10) ≤1
FKM 1) –5 … +150
1) On request

Pressurised
in MPa (bar)
Merkel Compact Seal Airzet PK

NBR 80 –20 … +80
≤1,2 (12) ≤1
FKM 75 –5 … +150
Merkel Compact Seal KDN
NBR 72 ≤1,2 (12) –20 … +100 ≤1
Merkel Complete Piston NADUOP
NBR 72 ≤1 (10) –20 … +100 ≤1
Merkel Complete Piston Pneuko G
NBR + PA 72 ≤1 (10) –20 … +100 ≤1
Merkel Complete Piston

Pneuko M 210 / Pneuko M 310 FKM 75 –5 … +150
≤1,2 (12) ≤1
AU 80 –25 … +80

NBR 72 –20 … +100
≤1,2 (12) ≤1
FKM 1) –5 … +150
Merkel Complete Piston TDUOP with

Venting Passages
NBR 72 ≤1,2 (12) –20 … +100 ≤1
1) On request

Pressurised
in MPa (bar)
Merkel Complete Piston TDUOP M
NBR 72 ≤1,2 (12) –20 … +80 ≤1
Damper Seals
Merkel Damper Seal AU DIP
AU 94 ≤2,5 (25) –30 … +90 ≤1
Merkel Damper Seal DIP

NBR –30 … +100
90 ≤1,6 (16) ≤1
FKM 1) –5 … +150
Guides
Merkel Guide Ring EKF
PA — — –30 … +100 ≤1
Merkel Guide Strip KF
PTFE — — –40 … +200 ≤1
Merkel Guide Strip SF
PTFE — — –40 … +200 ≤1
1) On request

Products I Pneumatics I Rod Seals
MERKEL COMBINATION SEAL AU NIPSL
PRODUCT ADVANTAGES
• Combination seal with minimal space requirements,

which seals inwards and wipes outwards
• The component needs no additional element
(circlip) for axial fixing within the housing
• Long service life
• Robust design.
APPLICATION
Rod seal e.g. for ISO cylinders.

Merkel Combination Seal AU NIPSL
PRODUCT DESCRIPTION
Merkel combination wiper seal without metal rein

forcement with special pneumatic sealing edge.
MATERIAL
Material Code Hardness
High performance polyurethane 94 AU 925 94 Shore A
OPERATING CONDITIONS
Medium Prepared, dried and de-oiled compressed air (after greasing for fitting)
Operating pressure p ≤1,2 MPa (12 bar)
Temperature T –30 … +90 °C
Running speed v ≤1 m/s

DESIGN NOTES
Surfaces
Surface roughness Rmax Rp/Rz
Rod ≤4 µm <0,5
tp (25% Rmax) = 50 … 75%
Groove base ≤10 µm <0,5
FITTING & INSTALLATION
Careful fitting is a prerequisite for the correct function of the seal. The Merkel Combination Seal AU NIPSL is ressed
into the housing from outside. The bead on the outside diameter snaps into the circlip groove and fixes the seal in
the housing.

MERKEL COMBINATION SEAL NIPSL
PRODUCT ADVANTAGES
• Combination seal with minimal space requirements,

which seals inwards and wipes outwards.
• The component can be replaced from the outside
(without dismantling the equipment)
• Broad supply range.
APPLICATION
Rod seal for pneumatic cylinders.

Merkel Combination Seal NIPSL
PRODUCT DESCRIPTION
Combination wiper seal with metal reinforcement and

special pneumatic sealing edge.
MATERIAL
Material Code Hardness Base plate
mild steel according to

Acrylonitrile-butadiene rubber 72 NBR 708 72 Shore A
DIN 1624
FKM on enquiry.
Medium Prepared, dried and de-oiled compressed air (after greasing for fitting)

DESIGN NOTES
Surfaces
Surface roughness Rmax Rp/Rz
Rod ≤4 µm <0,5
tp (25% Rmax) = 50 … 75%
Careful fitting is a prerequisite for the correct function of the seal. The Merkel Combination Seal NIPSL is pressed
into the housing from outside. The back is supported by a circlip (DIN 7993). To remove the seal, it is advisable to
provide an axial cut-out in the ring groove that allows the circlip to be easily removed.

MERKEL COMBINATION SEAL NIPSL 200
MATERIAL
NBR rubber 80 NBR 4005 80 Shore A
Prepared, dried and de-oiled

Medium compressed air (after greasing
for fitting)
Merkel Combination Seal NIPSL 200 Operating pressure p ≤1 MPa (10 bar)
PRODUCT DESCRIPTION
Combination wiper seal without metal reinforcement DESIGN NOTES

with special pneumatic sealing edge.
Surfaces
Surface
PRODUCT ADVANTAGES Rmax Rp/Rz
roughness
• Combination seal with minimal space requirements, Rod ≤4 µm <0,5

which seals inwards and wipes outwards tp (25% Rmax) = 50 … 75%
• The special pneumatic sealing edge gives very good Groove base ≤10 µm <0,5
tightness with low friction and maintains an effective
lubricating film.

APPLICATION
Careful fitting is a prerequisite for the correct function
Small cylinders. of the seal. The Merkel Combination Seal NIPSL 200
for small cylinders can be snapped by hand into the
housing grooves provided, with the piston rod removed.

MATERIAL
FKM rubber 75 FKM 181327 75 Shore A

for fitting)
Merkel Combination Seal NIPSL 210 Operating pressure p ≤1 MPa (10 bar)
DESIGN NOTE
Compact combination wiper seal without metal rein- DESIGN NOTE

Surfaces
PRODUCT ADVANTAGES Surface

Rmax Rp/Rz
roughness
• Combination seal with minimal space requirements, Rod ≤4 µm –

which seals inwards and wipes outwards tp (25% Rmax) = 50 … 75%
lubricating film
• Suitable for high-temperature applications.
APPLICATION Careful fitting is a prerequisite for the correct function

of the seal. The Merkel Combination Seal NIPSL 210
Small cylinders, compact cylinders. Small cylinders, for small cylinders can be snapped by hand into the
compact cylinders. housing grooves provided, with the piston rod removed.

MATERIAL
High
performance 85 AU 20991 85 Shore A
polyurethane

Merkel Combination Seal NIPSL 300 for fitting)
Operating pressure p ≤1 MPa (10 bar)

PRODUCT DESCRIPTION Running speed v ≤1 m/s
Combination wiper seal without metal reinforcement

with special pneumatic sealing edge (previous code:
AUNIPSL SF). DESIGN NOTES
Surfaces
Rmax Rp/Rz
roughness
• Combination seal with minimal space requirements, Rod ≤4 µm <0,5
• The special pneumatic sealing edge gives very good tp (25% Rmax) = 50 … 75%
tightness with low friction and maintains an effective Groove base ≤10 µm <0,5
lubricating film
• Material with high wear resistance.
APPLICATION
Small cylinders.

MATERIAL
High
polyurethane

Merkel Combination Seal NIPSL 310 for fitting)

Compact combination wiper seal without metal rein-

DESIGN NOTES
PRODUCT ADVANTAGES Surfaces
Surface
• Combination seal with minimal space requirements, roughness
Rmax Rp/Rz
Rod ≤4 µm –
• The special pneumatic sealing edge gives very good
tightness with low friction and maintains an effective tp (25% Rmax) = 50 … 75%
lubricating film Groove base ≤10 µm <0,5

APPLICATION
Small cylinders, compact cylinders.

MATERIAL
High
polyurethane

Merkel Combination Seal NIPSL 320 for fitting)
Temperature T –30 °C … +90 °C


DESIGN NOTES
Surface
Rmax Rp/Rz
Rod ≤4 µm –
lubricating film Groove base ≤10 µm <0,5

APPLICATION
Careful fitting is a prerequisite for the correct function of
Small cylinders, compact cylinders.
the seal. The Merkel Combination Seal NIPSL 320 for
small cylinders and compact cylinders can be snapped
by hand into the housing grooves provided, with the
piston rod removed.

MERKEL COMBINATION SEAL NIPSL SF
MATERIAL
Acrylonitrile-
90 NBR 108 90 Shore A
butadiene rubber
FKM on enquiry.

Merkel Combination Seal NIPSL SF
for fitting)

PRODUCT DESCRIPTION

DESIGN NOTES
Surface
Rmax Rp/Rz
• The special pneumatic sealing edge gives very good Rod ≤4 µm <0,5
lubricating film
• Optimal material for high loads.
APPLICATION FITTING & INSTALLATION
Small cylinders. Careful fitting is a prerequisite for the correct function

of the seal. The Merkel Combination Seal NIPSL SF for
small cylinders can be snapped by hand into the hous-
ing grooves provided, with the piston rod removed.

MERKEL COMPACT SEAL AIRZET PR
MATERIAL
Fluoro elastomer 75 FKM 230553 75 Shore A
Material NBR FKM
Prepared, dried and de-oiled compressed

Merkel Compact Seal A
irzet PR Medium
air (after greasing for fitting)
Operating
≤1,2 MPa (12 bar)
pressure p
PRODUCT DESCRIPTION Temperature T –20 … +100 °C –5 … +150 °C

Merkel Compact Seal can be pressurised on both sides
with grooves on the front side for pressure activation.
DESIGN NOTES
PRODUCT ADVANTAGES
Surfaces
• The compact design permits short cylinder cover Surface
designs Rmax Rp/Rz
roughness
• The rounded sealing profile and the flexible c entre Rod ≤4 µm <0,5
part give good tightness with low friction and
maintain an effective lubricating film tp (25% Rmax) = 50 … 70%
• Widely proven design Groove base ≤10 µm <0,5

• Large supply range available
• Very good tribological properties
(wear, friction and long service life).

APPLICATION
of the seal. The Merkel Compact Seal Airzet PR is
snapped over the de-burred housing edge into the
• Short cylinders housing groove. An axiallyaccessible housing is
• Short solution for cylinders (short stroke) and valves required for rod diameters less than 15 mm.
for high-temperature applications (only FKM).

Products I Pneumatics I Damper Seals
MERKEL DAMPER SEAL AU DIP
MATERIAL
High
90 AU 924 all Ø ≤10 90 Shore A
performance
94 AU 925 Ø >10 94 Shore A
polyurethane
Prepared, dried and de-

Medium oiled compressed air
Merkel Damper Seal AU DIP (after greasing for fitting)

Merkel Damper Seal AU DIP with spacer lug and flow

passages. Integrated non-return valve function due to
axial seal, spacer lugs and flow passages. DESIGN NOTES
Surfaces
Rmax Rp/Rz
roughness
• Constant, reliable damping function due to automatic
Rod ≤4 µm <0,5
centring.
tp (25% Rmax) = 50 … 75%
Groove base ≤10 µm

APPLICATION
Damping element e.g. for ISO cylinders.


the seal. Merkel damper seals can be snapped by hand
into the housing grooves provided.

Products I Pneumatics I Damper Seals
MERKEL DAMPER SEAL DIP
MATERIAL
Acrylonitrile-
butadiene rubber
FKM on enquiry.
Prepared, dried and de-

Medium oiled compressed air
Merkel Damper Seal DIP
(after greasing for fitting)

PRODUCT DESCRIPTION
Merkel Damper Seal DIP with spacer lug and flow

passages.
DESIGN NOTES
Surface
• Integrated non-return valve function through axial Rmax Rp/Rz
roughness
seal, spacer lugs and flow passages
• Constant, reliable damping function due to automatic Rod ≤4 µm <0,5
centring. tp (25% Rmax) = 50 … 75%
APPLICATION
Damper seal e.g. for ISO cylinders. FITTING & INSTALLATION

the seal. Merkel damper seals can be snapped by hand

Products I Pneumatics I Piston Seals
MERKEL U-RING NAP 210
MATERIAL
Acrylonitrile-
80 NBR 99079 80 Shore A
butadiene rubber
Material NBR FKM

Merkel U-Ring NAP 210 Prepared, dried and de-oiled compressed
Medium
Operating
≤1,2 MPa (12 bar)
pressure p
PRODUCT DESCRIPTION
Temperature T –25 … +100 °C –5 … +200 °C
Compact Merkel U-ring with asymmetrical profile Running

≤1 m/s
and special pneumatic sealing edge on the dynamic speed v
sealing lip.
DESIGN NOTES
PRODUCT ADVANTAGES
Surfaces
• The asymmetrical profile with the longer and thicker
static sealing lip ensures secure seating in the bottom Surface
Rmax Rp/Rz
of the groove roughness
• The special pneumatic sealing edge gives very good Rod/cylinder

≤4 µm <0,5
tightness with low friction and maintains an effective barrel
lubricating film tp (25% Rmax) = 50 … 75%
• Large range Groove base ≤10 µm <0,5
• Minimal axial space requirements
• Integrated pressure relief to prevent an intermediate tp (25% Rmax) = 50 … 75%
pressure build-up.

APPLICATION
• Piston seal for pneumatic cylinders of the seal. Pneumatic U-rings can be snapped by hand
• Piston seal for high-temperature cylinders into the housing grooves provided.
(only FKM).

MATERIAL
High
polyurethane

Merkel U-Ring NAP 300 for fitting)

Merkel U-ring with asymmetrical profile and special

pneumatic sealing edge on the dynamic sealing lip.
DESIGN NOTES
Surface
• The asymmetrical profile with the longer and thicker roughness
Rmax Rp/Rz
static sealing lip ensures secure seating in the bottom
Cylinder barrel ≤4 µm <0,5
of the groove
• The special pneumatic sealing edge gives very good tp (25% Rmax) = 50 … 75%
tightness with low friction and maintains an effective Groove base ≤10 µm <0,5
lubricating film
• Material with high wear resistance
• Good low temperature properties. FITTING & INSTALLATION

APPLICATION
of the seal. Pneumatic U-rings can be snapped by hand
Piston seal e.g. for ISO pneumatic cylinders.

MATERIAL
High
polyurethane

Merkel U-Ring NAP 310 for fitting)

Compact Merkel U-ring with asymmetrical profile

and special pneumatic sealing edge on the dynamic
sealing lip. DESIGN NOTES
Surfaces
PRODUCT ADVANTAGES
Surface
Rmax Rp/Rz
roughness
• The asymmetrical profile with the longer and thicker Cylinder barrel ≤4 µm <0,5
of the groove tp (25% Rmax) = 50 … 75%
tp (25% Rmax) = 50 … 75%
lubricating film
• Material with high wear resistance
• Good low temperature properties.

Piston seal e.g. for ISO pneumatic cylinders. into the housing grooves provided..

MERKEL U-RING NAPN
MATERIAL
Acrylonitrile-
80 NBR 186349 80 Shore A
butadiene rubber
Material NBR FKM
Merkel U-Ring NAPN Prepared, dried and de-oiled compressed

Medium
Operating
≤1 MPa (10 bar)
pressure p
Running
Merkel U-ring with asymmetrical profile and special ≤1 m/s
speed v
pneumatic sealing edge on the dynamic sealing lip.
PRODUCT ADVANTAGES DESIGN NOTES
• The asymmetrical profile with the longer and thicker Surfaces

Surface
of the groove roughness
Rmax Rp/Rz
lubricating film tp (25% Rmax) = 50 … 75%
• Widely proven design Groove base ≤10 µm <0,5
• Large supply range available

Piston seal e.g. in the ISO cylinder (only FKM: for high- into the housing grooves provided.
temperature applications).

MERKEL COMPACT SEAL AIRZET PK
MATERIAL
Material NBR FKM
Prepared, dried and de-oiled compressed

Merkel Compact Seal A
irzet PK Medium
Operating
≤1,2 MPa (12 bar)
pressure p
Running
≤1 m/s
Merkel Compact Seal Airzet PK can be pressurised on speed v
both sides with grooves on the front side for pressure
activation.
DESIGN NOTES
PRODUCT ADVANTAGES
Surfaces
• The compact design permits short piston designs Surface

Rmax Rp/Rz
• The rounded sealing profile and the flexible cen- roughness
tre part give good tightness with low friction and Cylinder barrel ≤4 µm <0,5
maintain an effective lubricating film
tp (25% Rmax) = 50 … 70%
• Widely proven design
• Large supply range available Groove base ≤10 µm <0,5

of the seal. The Merkel Compact Seal Airzet PK is snap-
• Short-stroke cylinders ped over the de-burred housing edge into the housing
• Valves and cylinders, especially short-stroke cylinders groove.
for high-temperature applications (only FKM).

MERKEL COMPACT SEAL KDN
MATERIAL
Acrylonitrile-
butadiene rubber

Medium compressed air
Merkel Compact Seal KDN

PRODUCT DESCRIPTION
• Merkel Compact Seal can be pressurised on both

sides with grooves on the front side for pressure DESIGN NOTES
activation.
Surfaces
Surface
PRODUCT ADVANTAGES roughness
Rmax Rp/Rz

• The compact design permits short piston designs
• The rounded sealing profile and the flexible cen- tp (25% Rmax) = 50 … 75%
tre part give good tightness with low friction and Groove base ≤10 µm <0,5
maintain an effective lubricating film.
APPLICATION FITTING & INSTALLATION
Short-stroke cylinders. Careful fitting is a prerequisite for the correct function

of the seal. The Merkel Compact Seal KDN is snapped
over the de-burred housing edge into the housing
groove.

MERKEL COMPLETE PISTON NADUOP
MATERIAL
Acrylonitrile- mild steel

72 NBR
butadiene 72 Shore A according to
708
rubber DIN 1624

Merkel Complete Piston NADUOP for fitting)

Short Merkel complete piston with steel base plate,

vulcanised buffers and sealing lips with special pneu-
matic sealing edges. Ready to install Merkel complete DESIGN NOTES
piston with integrated guide that can be pressurised on
both sides. Surfaces
Surface
Rmax Rp/Rz
roughness
PRODUCT ADVANTAGES
• Vulcanised buffers for end-position damping of tp (25% Rmax) = 50 … 75%

piston in the cylinder
• Radial venting passages for reliable pressure
application at the end of the stroke. FITTING & INSTALLATION

APPLICATION the seal. The Merkel Complete Piston NADUOP is fitted
to shouldered end of the piston rod and fastened with
Pneumatic cylinders. washers and a nut. The threaded fitting is to be protec-
ted against loosening.

MERKEL COMPLETE PISTON PNEUKO G
MATERIAL
Material Acrylonitrile-butadiene rubber
Code 72 NBR 708
Hardness 72 Shore A
Base plate Al (POM 20 for Ø ≤25)
Guide PA 4601 (POM for Ø ≥25)
Static seal 72 NBR 872
Merkel Complete Piston P neuko G


Medium compressed air
PRODUCT DESCRIPTION
Merkel complete piston with light alloy/polyamide Temperature T –20 … +100 °C
body, snap-action seal and integrated guide.
PRODUCT ADVANTAGES
DESIGN NOTES
• Ready to fit Merkel complete piston with very low
height to which pressure can be applied on both Careful fitting is a prerequisite for the correct function
sides of the seal. The complete piston is fitted to shouldered
end of the piston rod and fastened with washers (up to
• Easily fastened to the piston rod
• Integrated static seal on the inside diameter. and including Ø 25 DIN 125 ≥ Ø 25 DIN 1440) and
a nut. The threaded fitting is to be protected against
loosening.
APPLICATION
Surfaces
Pneumatic cylinder without request, frequent special Surface
cylinder. Rmax Rp/Rz
roughness
tp (25% Rmax) = 50 … 70%
Prior to installation in the cylinder, grease all cylinder

contact surfaces evenly. Do not introduce any grease
into the piston groove.

MERKEL COMPLETE PISTON PNEUKO M 210
APPLICATION
Broad range of uses, only one piston for short stroke

cylinders, compact cylinders, round cylinders and ISO
cylinders.
MATERIAL
Merkel Complete Piston P neuko M 210
PRODUCT DESCRIPTION Prepared, dried and de-oiled

for fitting)
The compact, short, Merkel complete pneumatic piston
Pneuko M consists of an aluminium body, guide strip, Operating pressure p ≤1,2 MPa (12 bar)
a magnet and the sealing body with a special sealing Temperature T –5 … +150 °C
edge on the sealing lip and integrated buffers made
of very wear r esistant fluoro elastomer FKM for special
applications.
DESIGN NOTES
PRODUCT ADVANTAGES
Surfaces
Surface
• Low start friction due to optimised sealing lip roughness
Rmax Rp/Rz
eometry and additional venting passages
g
• Constant good sealing behaviour over a wide Cylinder barrel ≤4 µm <0,5
pressure range (to 1,2 MPa) tp (25% Rmax) = 50 … 70%
• Running properties without tendency to tilt due to
a guide strip optimised for the application
• Aluminium body brings weight saving and permits FITTING & INSTALLATION
high energy absorption
• Easily fastened to the piston rod Careful fitting is a prerequisite for the correct function of
• Integrated static seal the seal. The Merkel Complete Piston Pneuko M 210 is
• Supplied suitable for storage and fitting in fitted to shouldered end of the piston rod and fastened
deep-drawn inserts
with washers and a nut. The threaded fitting is to be
• Simple provisioning protected against loosening.
• Integrated magnet for a position check using a
sensor.

MERKEL COMPLETE PISTON PNEUKO M 310
APPLICATION
Broad range of uses, only one piston for short stroke

cylinders, compact cylinders, round cylinders and ISO
cylinders.
MATERIAL
High
Merkel Complete Piston Pneuko M 310 polyurethane
PRODUCT DESCRIPTION
The compact, short, Merkel complete pneumatic piston Medium compressed air (after greasing
Pneuko M consists of an aluminium body, guide strip, for fitting)
a magnet and the sealing body with a special sealing
edge on the sealing lip and integrated buffers made of
very wear resistant polyurethane. Temperature T –25 … +80 °C
PRODUCT ADVANTAGES
DESIGN NOTES
• Low start friction due to optimised sealing lip
eometry and additional venting passages
g Surfaces
• Constant good sealing behaviour over a wide Surface
pressure range (to 1,2 MPa) Rmax Rp/Rz
roughness
• Running properties without tendency to tilt due to Cylinder barrel ≤4 µm <0,5
a guide strip optimised for the application
• Aluminium body brings weight saving and permits tp (25% Rmax) = 50 … 70%
high energy absorption
• Easily fastened to the piston rod
• Integrated static seal FITTING & INSTALLATION
• Supplied suitable for storage and fitting in deep-
drawn inserts Careful fitting is a prerequisite for the correct function of
• Simple provisioning the seal. The Merkel Complete Piston Pneuko M 310 is
• Integrated magnet for a position check using a sensor. fitted to shouldered end of the piston rod and fastened
with washers and a nut. The threaded fitting is to be
protected against loosening.

MERKEL COMPLETE PISTON TDUOP
MATERIAL
mild steel
NBR
72 NBR 708 72 Shore A according to
rubber
DIN 1624
FKM on enquiry.

for fitting)
PRODUCT DESCRIPTION Temperature T –20 … +100 °C

Merkel complete piston with steel base plate and vulca-
nised sealing lips with special pneumatic sealing edges.
DESIGN NOTES
PRODUCT ADVANTAGES
Surfaces
• Ready to fit complete piston to which pressure can Surface
be applied on both sides with integrated guide Rmax Rp/Rz
roughness
• Easily fastened to the piston rod without additional
sealing components Cylinder barrel ≤4 µm <0,5
• Long service life tp (25% Rmax) = 50 … 70%

• Constant good sealing behaviour over a wide
pressure range (to 1,2 MPa)
• Simple provisioning. FITTING & INSTALLATION

APPLICATION
of the seal. The Merkel Complete Piston TDUOP is fitted
to shouldered end of the piston rod and fastened with
Pneumatic cylinder without request.
washers and a nut. The threaded fitting is to be protec-
ted against loosening.

MERKEL COMPLETE PISTON TDUOP WITH VENTING PASSAGES
MATERIAL
mild steel
NBR 72 Shore
72 NBR 708 according to
rubber A
DIN 1624
FKM on enquiry.

Merkel Complete Piston TDUOP with Venting Passages
for fitting)
PRODUCT DESCRIPTION Temperature T –20 … +100 °C

• Merkel complete piston with steel base plate and vul-
canised sealing lips with special pneumatic sealing
edges
• Ready to fit complete piston to which pressure can DESIGN NOTES
be applied on both sides with integrated guide
• Easily fastened to the piston rod without additional Surfaces
sealing components
Surface
• The design with radial venting passages on the front roughness
Rmax Rp/Rz
sides facilitates reliable pressure application at the
end of the stroke.
tp (25% Rmax) = 50 … 75%
PRODUCT ADVANTAGES
• Low start friction due to optimised sealing lip geome- Careful fitting is a prerequisite for the correct function of
try and supported by additional venting passages
the seal. The Merkel Complete Piston TDUOP with Ven-
• Constant good sealing behaviour over a wide ting Passages is fitted to shouldered end of the piston
rod and fastened with washers and a nut. The threaded
• Easily fastened to the piston rod fitting is to be protected against loosening.
• Simple provisioning.
APPLICATION
Pneumatic cylinder without request.

MERKEL COMPLETE PISTON TDUOP M
APPLICATION
Pneumatic cylinder with request.
MATERIAL
Acrylonitrile-buta-
diene rubber
Merkel Complete Piston TDUOP M OPERATING CONDITIONS

PRODUCT DESCRIPTION for fitting)

The compact, short, Merkel Complete Piston TDUOP M
consists of an aluminium body, a guide strip, a magnet Temperature T –20 … +80 °C
and a sealing element with a special sealing edge on Running speed v ≤1 m/s
the sealing lip.
PRODUCT ADVANTAGES DESIGN NOTES
• Broad range of uses, only one complete piston for Surfaces

round cylinders and ISO cylinders
Surface
• Long service life roughness
Rmax Rp/Rz
• Low start friction due to optimised sealing lip Cylinder barrel ≤4 µm <0,5
geometry
• Constant good sealing behaviour over a wide tp (25% Rmax) = 50 … 75%
• Running properties without tendency to tilt due to
a guide strip optimised for the application FITTING & INSTALLATION
• Aluminium body brings weight saving and permits
high energy absorption Careful fitting is a prerequisite for the correct function of
• Easily fastened to the piston rod the seal. The Merkel Complete Piston TDUOP M is fitted
• Integrated static seal to shouldered end of the piston rod and fastened with
• Supplied suitable for storage and fitting in deep- washers and a nut. The threaded fitting is to be protec-
drawn inserts ted against loosening.
• Simple provisioning
• Integrated magnet for a position check using
a sensor.

Products I Pneumatics I Guides
MERKEL GUIDE STRIP SF
MATERIAL
Material Code
PTFE bronze compound PTFE B500
Material PTFE B500
Temperature range in °C
Hydraulic oils HL, HLP –40 … +200

Merkel Guide Strip SF HFA fluids –
HFB fluids –
HFC fluids –
PRODUCT DESCRIPTION HFD fluids –40 … +200
Water –
Non-metallic Merkel Guide Strip SF, available ready to
fit cut to size or by the metre. HETG (rapeseed oil) –40 … +80
HEES (synthetic esters) –40 … +100
HEPG (glycol) –40 … +80

PRODUCT ADVANTAGES
Mineral greases –40 … +200
As a non-metallic guide element for rods, also for
standardised housings according to ISO 10766 Surface quality
• Low friction, free of stick-slip.
Surface
Ra Rmax
roughness
APPLICATION Sliding surface 0,05 … 0,3 µm ≤2,5 µm
Groove base ≤2 µm ≤10,0 µm

Control and regulation equipment, handling equipment,
injection moulding machines. Side of groove ≤3 µm ≤15,0 µm
Percentage contact area Mr >50% to max. 90% at cutting depth

c = Rz/2 and reference line C ref = 0%..

DESIGN NOTES Manufacturing tolerance
Please observe our general design notes. Production tolerance profile thickness S
–0,05
Calculating straight length L2
L2 Production tolerances Surface load

>20 … 80 … 0,5
p <15 N/mm² up to 20 °C
>80 … 250 … 1,0
p <7,5 N/mm² up to 80 °C
>250 … 500 … 1,5
p <5 N/mm² up to 120 °C
>500 … 1000 … 2,0
For running speed, see sealing system.
>1000 … 2000 … 3,0
>2000 … 4000 … 4,0 Cutting rolls to size

The following dimensions are available from stock
Tolerance recommendation by the metre. The straight length L2 of blanks is to be
determined using the formula. The gap k produced
D1
after fitting is necessary due to thermal expansion. We
H8 recommend a straight cut on the strips. In the event of
butt joints the tips may be damaged and break-off. Our
The tolerance definition for the dimensions D and dF cutter (Article No. 507228) facilitates time-saving and
must be viewed in connection with the seal used. The accurate cutting to size.
diameter d1 specified in the table of dimensions is
to is to be viewed exclusively in relation to the guide
ring. The corresponding diameter of an adjacent seal
housing should be tailored to the sealing component.

Calculation of the straight length L2 for rods:

L2 = (d + S) x 3,11 – 0,5
L2
Ø D Ø d
Groove length L k
Profile thickness S Article No.
8 2,5 24226174
9,7 2,5 24102775
10 2,5 24102563
12 2,5 24099191
15 2,5 24102564
20 2,5 24076217
25 2,5 24107955
15 4,0 24160019
20 4,0 24238052
25 4,0 24148093
Surface force
The pressure distribution on the guide rings is non-linear. The non-linear pressure curve over the contact range was
taken into account when calculating the permissible specific surface pressure. The permissible load on the guide
strip is calculated by multiplying the projected surface with the permissible specific surface pressure. However, the
figure for the permissible specific surface pressure takes into account the possible angular offset of the rods when
the recommended guide elements are used.

F F
F = PxA
H = F / (d x P)
H = guide strip width [mm]

F = radial loading [N]
A = projected area [mm²]
P = perm. compression per unit area [N/mm²]
d = rod diameter with rod guidance;
piston diameter with piston guidance [mm].

MERKEL GUIDE RING EKF
Material PA 4201
HFA fluids +5 … +50
HFB fluids +5 … +50
HFC fluids –30 … +50
HFD fluids –
Water +5 … +50
Merkel Guide Ring EKF
HETG (rapeseed oil) –30 … +60
HEES (synthetic ester) –30 … +80
HEPG (glycol) –30 … +50

PRODUCT DESCRIPTION
Slit, non-metallic Merkel Guide Ring EKF. Running speed v in m/s 1
Loading
≤25 N/mm² at 20 °C
(permitted specific surface
≤15 N/mm² at 100 °C
PRODUCT ADVANTAGES pressure*)
* For the simple determination of the loading, a constant surface

Non-metallic guide element for pistons.
pressure is calculated using the projected area (D x H). The actual
surface pressure is clearly greater in the centre of the surface than
the calculated surface pressure. This is taken into account in the va-
APPLICATION lue for the permissible specific surface pressure.
Standard cylinders, mobile hydraulics, injection Surface quality

moulding machines.
Surface
Ra Rmax
roughness
MATERIAL Sliding surface 0,05 … 0,3 µm ≤2,5 µm
Groove base ≤2 µm ≤10,0 µm

Material Code Groove flanks ≤3 µm ≤15,0 µm
Polyamide PA 4201
c = Rz/2 and reference line C ref = 0%.

DESIGN NOTES
Please observe our general design notes.
Tolerance recommendation
D1 dF dF1
H8 h8 h9
The tolerances give are recommended values. The usage of the guide and tolerance definition are to be considered
in connection with the seal employed. The diameter dF1 given in the table of dimensions is to be considered exclusi-
vely in relation to the guide ring. The corresponding diameter for the adjacent seal housing is to be matched to the
sealing component.
Merkel Guide Ring EKF can be easily snapped into the housing groove. Careful fitting is a prerequisite for correct
function.

MERKEL GUIDE STRIP KF
MATERIAL
Material Code
PTFE bronze compound PTFE B500
Material PTFE B500

Merkel Guide Strip KF
HFA fluids –
HFB fluids –
HFC fluids –
PRODUCT DESCRIPTION
HFD fluids –40 … +200
Non-metallic Merkel Guide Strip KF, available ready to Water –
fit cut to size or by the metre. HETG (rapeseed oil) –40 … +80
HEES (synthetic esters) –40 … +100
PRODUCT ADVANTAGES HEPG (glycol) –40 … +80

Non-metallic guide element for pistons, also for
standardised housings as per ISO 10766
• Low friction, free of stick-slip. Surface quality
Surface
Ra Rmax
roughness
APPLICATION
Sliding surface 0,05 … 0,3 µm ≤2,5 µm
Injection moulding machines, control and regulation Groove base ≤2 µm ≤10,0 µm

equipment, handling equipment. Groove flanks ≤3 µm ≤15,0 µm

c = Rz/2 and reference line C ref = 0%.

DESIGN NOTES Manufacturing tolerance
Please observe our general design notes. Production tolerance profile thickness S
–0,05
Calculating straight length L2
L2 Production tolerances Surface load

>20 … 80 … 0,5
p <15 N/mm² up to 20 °C
>80 … 250 … 1,0
p <7,5 N/mm² up to 80 °C
>250 … 500 … 1,5
p <5 N/mm² up to 120 °C
>500 … 1000 … 2,0
For running speed, see sealing system.
>1000 … 2000 … 3,0
>2000 … 4000 … 4,0 Cutting rolls to size

The following dimensions are available from stock
Tolerance recommendation by the metre. The straight length L2 of blanks is to be
determined using the formula. The gap k produced
d1 after fitting is necessary due to thermal expansion. We
h8 recommend a straight cut on the strips. On impact at
an angle the tips may be damaged and break-off. Our
The tolerance definition for the dimensions D and dF
cutter (Article No. 507228) facilitates time-saving and
must be viewed in connection with the seal used. The
accurate cutting to size.
diameter D1 specified in the table of dimensions is
to is to be viewed exclusively in relation to the guide
ring. The corresponding diameter of an adjoining seal
housing should be tailored to the sealing component.

Calculating stretched length L2 for rods:

L2 = (D – S) x 3,11 – 0,5
L2
Ø D Ø d
Groove length L Profile thickness S Article No.
8 2,5 24226174
9,7 2,5 24102775
10 2,5 24102563
12 2,5 24099191
15 2,5 24102564
20 2,5 24076217
25 2,5 24107955
15 4,0 24160019
20 4,0 24238052
25 4,0 24148093
Surface force
The pressure distribution on the guide rings is non-linear. The non-linear pressure curve over the contact range was
taken into account when calculating the permissible specific surface pressure. The permissible load on the guide
strip is calculated by multiplying the projected area with the permissible specific surface pressure. However, the
figure for the permissible specific surface pressure takes into account the possible angular offset of the piston when
the recommended guide elements are used.

F F
F = PxA
H = F / (d x P)
H = guide strip width [mm]

F = radial loading [N]
A = projected area [mm²]
P = perm. compression per unit area [N/mm²]
d = rod diameter with rod guidance;
piston diameter with piston guidance [mm].

Freudenberg Sealing Technologies GmbH
Höhnerweg 2–4
69469 Weinheim
Germany
www.fst.com

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PNEUMATICS

Use of Pneumatic Seals  482

Sealing Mechanism and Influencing Quantities  487

Fitting of Pneumatic Seals  503

Design Types  513

With approx. 500 different dimensions, Freudenberg REQUIREMENTS

480 © Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual

FEATURES APPLICATION RANGE

© Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual 481

USE OF PNEUMATIC SEALS

Pneumatics, a subgroup of fluid power technology, is APPLICATION EXAMPLES

Complete piston with moulded guides Damping disc

Fig. 1 Pneumatic cylinder I

482 © Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual

Rod Piston Seat Slide

Individual Single acting seal

Combination Double acting seal

Static seals Static seals

Fig. 2 Categorisation of pneumatic seals

© Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual 483

Wiper Complete piston with vulcanised sealing

Rod seal (U-ring) Piston damper seal

Fig. 3 Pneumatic cylinder II

Single acting piston seal (U-ring) Rod damper seal

Fig. 4 Pneumatic cylinder III

484 © Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual

Rod damper seal

Single acting special piston seal

Fig. 5 Pneumatic cylinder without piston rod

The rod seal is not needed in the rod-less cylinder

© Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual 485

Fig. 7 Pneumatic 3/2-way valve

Fig. 8 Pneumatic 5/2-way valve

486 © Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual

SEALING MECHANISM AND INFLUENCING QUANTITIES

Whether it is drive applications, control or regulation: FORMATION OF LUBRICANT FILMS AND

Tip for greasing cylinder contact surfaces:

© Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual 487

Seal fitted in the

Contact pressure distribution

Fig. 9 Automatic sealing effect with elastic seals

488 © Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual

Tip for greasing valves: SEALING SYSTEM

• Deformation of proportion of friction

• Internal proportion of friction

© Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual 489

Housing Static Surface layers Sliding speed Overlap

Dirt from Medium

Gap width Pressing and Counterface Direction Dirt/water

Adhesion friction Deformation friction Internal friction

Fig. 11 Basic influences on the tribosystem

490 © Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual

Start up friction (G) Mixed friction (M) Fluid friction (F)

Frictional force Velocity Frictional force Velocity Frictional force Velocity

Dominant friction states • Mixed friction

© Freudenberg Sealing Technologies GmbH & Co. KG | Technical Manual 491

• Fluid friction A surface structure that is too "smooth" (→ Fig. 14) has

The surface characteristics of the groove base and

These recommendations are intended to present an

Use of Pneumatic Seals   482

Sealing Mechanism and Influencing Quantities   487

Fitting of Pneumatic Seals   503

Design Types   513

• Fluid friction A surface structure that is too "smooth" (→ Fig. 14) has

Lubricant a) Seal profile Type c) Material Pressure max Temperature (°C)

Lubricant a) Seal profile Type c) Material Pressure max Temperature (°C)