Airchoc5 (16.6.16)

TECHNICAL MANUAL NOT AIRCHOC5
INSTALLATION OPERATION AND MAINTENANCE

INSTRUCTION FOR AIRCHOC®
Index J1 - 16/06/2016 1/89
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TECHNICAL MANUAL - NOT AIRCHOC5-E - Index J1 - 16/06/2016 2/89
REVISION INDEX
Revision Date Reason Amended pages

A1 01/07/03 Creation All pages
B1 10/12/04 Update Pages 6 ,9 ,11-16 ,52 ,72 ,78
Pages 9, 10, 11, 12, 13, 60,
C1 07/10/05 Update
62, 47, 49, 52
D1 17/10/06 Update Pages 9, 10, 11, 12, 13, 51, 52
Pages 3, 4 , 6, 7, 9, 10, 11, 12,
E1 14/05/09 Update
13, 51, 52, 53, 54, 62, 63, 72
Pages 4, 14, 79, 80, 81, 82,
G1 07/12/09 Update
83, 84
H1 04/01/11 Update Page 14
I1 18/12/13 Update Pages 6, 8, 9, 70, 74, 79 to 85
Branding indentity
I2 20/04/16 All pages
revision
Updating cutting
I3 15/06/16 88-89
templates
Correction and 9,11,21-22,45-52,55-
J1 16/06/16
change of visuals. 56,73,79,83
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Summary
I - GENERAL DESCRIPTION 4
A - Reminder of the AIRCHOC principle
®
4
B - Presentation 5
C - Principle of operation 6
D - Ratification of tank under pressure and domain of use 13
E - Conditions of installation and maintenance 13
II - INSTALLATION 14
A - General information concerning AIRCHOC® air cannons 14
B - Safety measures 15
C - Preparation of blow pipes and nozzles 16
D - Fitting the blow pipe 26
E - Installing a standard or high temperature AIRCHOC® 46
F - Fitting the hanging device 47
G - Fitting the control device 49
H - Fitting the safety control-unit 51
I - Fitting the consafe device 52
J - Lubricator filter regulator unit 54
K - Use and startup of a filter lubricator unit (G.F.L) 55
III - PNEUMATIC NETWORK 57

A - Capacity requirement of the pneumatic network 59
B - Capacity of the pneumatic network 59
C - Dimensions of the hoses connecting the pneumatic network to the AIRCHOC® 61
D - Filter lubricator unit 61
E - Rules of installation 62
F - Sample installations 63
IV - ELECTRICAL SUPPLY NETWORK 69

A - Connecting up the AIRCHOC AC5 (AC510, AC515, AC520)
®
70
B - Connecting up the AIRCHOC® AC0.4, AC0.5, AC1, AC 5 71
V - CONTROL BOX 72
A - Manualcontrol box 72
B - Automatic, cyclical control box 73
VI - STARTUP 76
A - General 76
B - Safety instructions 76
C - Testing and start-up 77
VII - MAINTENANCE INSTRUCTIONS 78

A - General 78
B - Safety requirements 78
C - Visual inspection ( equipment not under pressure ) 78
D - Confirmation that the AIRCHOC® is working correctly 79
VIII - TROUBLE SHOOTING ON AIRCHOC 5 V5 80

I - GENERALITIES
A - Summarised description
The AIRCHOC® is a pneumatic declogging device specifically designed to break up bridgings and
ratholings in silos and hoppers. Its scope application has been broadened during the past 25 years
to the cleaning of concretions in thermal processes such as in cement or lime works, steel plants and
incinerators.
The operating principle of the AIRCHOC®

aircannon consists in using a quantity of
compressed air which varies in between 1 and
400 liters depending on the type of AIRCHOC®.
The air is released INSTANTLY through a large
outlet which is directly connected to the storage
unit. The effect is an explosion due to the sudden
expansion of the compressed air (Fig.1).
FIG 1
B - Presentation
Models
AC510 DN100 / 25 liters

Models
AC0.4 DN25 / 4 liters

AC0.41/12 DN40 / 4 liters
AC0.5 DN50 / 9 liters
Models big volume

B - Operating principle of AIRCHOC®
POUR LES MODELES AC0.4 /AC0.41/12/ AC0.5 / AC1 / AC5
Step 1 : RECEPTION
■■ The solenoid valve 3/2 is in reception

position.
■■ The air enters the QEV (Quick Exhaust
Valve).
Step 2 : FILLING
■■ The air enters the QEV

■■ The air enters in the rear chamber of the
AIRCHOC®.
■■ The air seeps into the reservoir and fills it.
Step 3 : STAND-BY
■■ Stand by position: the reservoir is full.

■■ There is no air consumption.
■■ There is a balance of pressure between the
network and the reservoir.
Step 4 : TRIGGERING
■■ The solenoid valve is activated and puts the

QEV in exhaust position.
Step 5 : EXHAUST
■■ The QEV piston changes position.

■■ The air escapes from the QEV and the rear
chamber of the AIRCHOC® head.
Step 6 : FIRING THE L’AIRCHOC®
■■ The AIRCHOC® head piston changes

position.
■■ The front chamber of the AIRCHOC® is
opened.
■■ The reservoir is empty instantly.
Description of the parts

FOR MODELES AC510 AC515 AC520 (HT VERSION)
Body Plate
Piston Elbow of exhaust
QEV Piston
Pilote 3/2
QEV Return spring
Base
Spring Silencer
Non-return valve
Operating principle of solenoid valve 3/2
A 3/2 solenoid valve has three openings and two R

positions
Openings P and A are in communication
A
P : Pressure
A : Admission
R : Exhaust P
Chamber C1 and C2 are in communication

In the stand-by position (solenoid valve not activated) the opening A and P are in communication, the
finger blocks the opening R.
In the operating position (solenoid valve electrically activated) the finger tips for jam the opening P and
puts the openings A and R in communication.
Exhaust
Finger
C1
Pressure arrival
Opening A
C2
Manual control
Pressure coming of C2
Stage 1 : FILLING OF THE CANNON (under pressure)
1. The compressed air supply of the AIRCHOC® goes through the non-return valve
2. The air fills the piston rear chamber by the hole located on the piston
3. Vessel is filled
4. due to the pilote 3/2 NO the rear chamber of QEV piston is under pressure ( openings A and P
are in communication )
5. The AIRCHOC® is uniformly pressurized
Filling of rear
chamber of the
piston
R QEV (PEA) piston

in closed position
R1 A
P
Air supply
Air supply of the vessel
Stage 2 : ACTIVATION OF THE PILOT
The pilot of the solenoid is actived by the electrical impulse. The outlet A is then at atmospheric pressure,
the QEV piston moves backwards and the compressed air behind the piston is exhausted through the
silencers.
QEV in open position
Exhaust of pressure by R1
Exhaust of QEV
chamber
R
A
Stage 3 : AIRCHOC® FIRING
Since the rear chamber of the piston is emptied rapidly, it recoils brutally and in turn exhausts very
rapidly the volume of air contained in the vessel, thus setting the firing of the AIRCHOC®.
Piston moves back
Shot
Vessel : Air exhaust
D - Ratification of tank under pressure and

domain of use
be also provided with a manometer allowing to
The air cannon AIRCHOC is a pneumatic
®
visualize at any time the real internal pressure
device of draining which consists of a tank under in the device.
pressure: ■■ The tank is protected against the corrosion
■■ This bowl with simple pressure not subjected by an appropriate cover (internal and
to the flame, for tank of compressor or outside Galvanization and Paint outside anti-
auxiliary circuit of installation fixes in corrosion). This protection must be maintained
compliance with the Directive 2014/29/EU of in good condition during all the life of the
February 26th, 2014 or to the code ASME device.
following the destination. ■■ It is up to the user to choose the pressure the
■■ The domain of use has to be in compliance best adapted according to the foreseen use. If
with the conditions of service indicated in necessary take advice with the manufacturer.
the certificate of the tank. ■■ He is provided with an opening of purge
■■ The tank must not be damaged during the situated in the bottom. He must be equipped
transport or the installation. with a purge automatic or be periodically
■■ In service, he does not have to undergo purged (daily if need be) and inspected to
the other constraint than those due to the check the absence of condensate (in particular
pressure and to his own weight. before any prolonged stop(ruling)).
■■ The tank has to insure on no account the ■■ He must be presented to the visits and periodic
other functions that those for whom it was tests following the regulations in force of the
foreseen. country where he makes use of it.
■■ The tank must be used with the air or the ■■ The control of the thicknesses of walls must
dry nitrogen. be practised at most every 40 months by
adequate means. If the moderate thicknesses
are lower than the minimal thicknesses, the
E - Conditions of installation and maintenance device must be palled.
■■ Also, a hydraulic requalification must be
■■ The user has to verify that a device of realized after 120 months of use.
protection against the excesses of pressure ■■ The user will have to stay up regularly the
is directly linked with the device in case good tightening of accessories or corks gone
the user cannot assure at 100 % the not up on openings.
overtaking of the service pressure. The ■■ No modification, repair or stoking beyond the
device or the safety valve must be settled temperature max of service is allowed.
to begin to start in a pressure not exceeding The non compliance with the prescriptions
the pressure of calculation of the device in its nuncios above would release our responsibility in
temperature of calculation. The device must incident case.
II - INSTALLATION
A - General information regarding the installation of the AIRCHOC®
The implementation of AIRCHOC® units on your installation and their angles are determined by our
technical department. That is the reason why we need to have the plan of your installations to enable
us to achieve the implementation of the AIRCHOC® units - (fig 2)
The blow pipe openings must be positioned as close as possible to the critical areas, that is to say
where the material tends to clog, creates blockages or solidify. They are generally placed on the walls
and tangentially offset in height. The axial and radial inclination of the blow pipe is shown on our
drawings.
FIG 2
B - Safety measures
1) On the AIRCHOC®
AIRCHOC® cannons are pressurised units. The power produced at each firing depends on :
■■ The compressed air pressure
■■ The tank capacity
■■ The AIRCHOC® outlet diameter
Thus
l’AIRCHOC® TYPE AC510 : at 6 bar the firing releases a force of 3500 Newton
These examples make it obvious that it is extremely dangerous to fire the AIRCHOC® outside its normal
operating position.
Any test firing of an AIRCHOC® in the mechanical workshop should be strictly FORBIDDEN.
Furthermore, the triggering of an AIRCHOC® in the open air or in an empty silo generates a high decibel
level.
Also, an intervention on an AIRCHOC® may only be undertaken after draining the unit of its compressed
air. Various means are at the disposal of the user to avoid all risks :
■■ the pressure gauge located on the AIRCHOC® tank enables verification at all
■■ times whether or not the AIRCHOC® is under pressure.
■■ the isolation valve enables the compressed air supply to the AIRCHOC® to be cut-off.
■■ the drain valve in the AIRCHOC® tank enables the draining of the unit.
■■ the CONSAFE facility enables draining of the AIRCHOC® while cutting the compressed air
supply.
2) During installation
The safety regulations governing the installation of an AIRCHOC® must be respected for the safety of
the intervention staff as well as for the persons working at the site of installation but also to avoid any
deterioration of installation.
C - Preparation of insertion pipes and nozzles
1) Generalities
The length and location of the AIRCHOC® insertion pipes are calculated by our design department in
accordance with your indications and the specific aspects of your installation. A drawing is established
for this purpose and will be given to you for installation of AIRCHOC®.
The insertion pipes installed in silos or hoppers

must in no way hamper material flow. The
end of insertion pipe must be cut according to
slope of silo and flush with the inside walls. The
insertion pipes must be solidly attached to the
wall (Fig. 3).
The insertion pipe inclination compared to the

horizontal must be at least 30°. The length of
insertion pipes must be as short as possible.
We generally recommend a length of 500 to 700
mm depending upon the type of AIRCHOC®.
FIG 3
2) Exceptional cases
However, to solve certain particular problems

and increase cleaning efficiency, we may use
elbow pieces or deflectors as well as different
insertion pipe lengths and inclinations.
(Picture)
Elbow
Examples :
■■ Very liquid product or pressurised hopper
: The insertion pipe will be longer.
■■ Cramped site for installation of
AIRCHOC® : The use of insertion
pipe with elbow piece is sometimes
unavoidable.
■■ Vibrating or crushing hopper : Placing
of rubber sleeves between the insertion
pipe and AIRCHOC® to absorb the
vibrations (Picture).
Rubber sleeve
All such instructions are indicated on our drawings to ensure that the installation is correctly carried out.
3) Preparation of the blowpipes
A nozzle is made of a tube, a standard flange PN10 (NFA 29203) and a fixing plate.
The fixing plate is to be welded in the case of a steel silo or to be riveted in the case of a concrete silo
(fig5).
The blowpipes and mounting plates can be supplied in steel NF A 49-112 (TUE 220a or 37b), in
stainless steel NF A 49-147 or designated AISI 304 L, 310, 316 L or in aluminium.
All the blowpipes are supplied with a flange PN10 pointed (not welded).
FIG 4
Flange PN
Reminder : It is compulsory to weld the flange off-axis on the tube before mounting the AIRCHOC®.
This work must be completed by a qualified and experienced welder.
Note : It is understood that the welds for the blowpipes and nozzles have to be achieved with adequate
metals, eg: stainless steel nozzle: stainless steel wand.
a) Insertion pipe without nozzle
To prepare the insertion pipe, carry out the following operations :
■■ In accordance with the drawings supplied by us, using a scriber, trace the penetration angle
around the end of pipe
■■ Take into account the position of the flange for the positioning of tank (flange off axis)
■■ Using a saw or acetylene burner, cut the pipe along the line traced
■■ Using a grinder, smooth-off end of pipe
■■ On the plate, trace the ellipse corresponding to the pipe hole
■■ Using an acetylene burner, cut-out ellipse in plate.
FIG 5
b) Insertion pipe with nozzle
To prepare the insertion pipe, carry out the following operations : (Fig. 6)
FIG 6
■■ Take into account the position of the
flange for the positioning of the tank
(flange off axis)
■■ Adjust, according to the instructions on
the drawings, the length of insertion
pipe taking into account the length of
deflector. Except for 90° angle nozzle, all
other nozzles must be installed flush with
the inside wall of silo. Unless otherwise
indicated on the drawings, the pipe must
not protrude over 500 to 700 mm outside
the silo
■■ Using a saw or acetylene burner, cut the
excess pipe
■■ Using a grinder, smooth off end of pipe
■■ On the plate, trace the ellipse
corresponding to the pipe hole. When
tracing this ellipse the inclination angle
of insertion pipe indicated in the drawing
must be respected.
■■ Using an acetylene burner, cut-out
ellipse in plate.
■■ Using a small grinder, clean away burrs
left by the acetylene burner
X-Y=a
■■ Weld the nozzle to the pipe. Only the
class 150 lbs flange is to be welded after
■■ installation. In this operation the
technician must rigorously respect the
fundamental rules of the welding trade.
In case of a stainless steel deflector,
ensure a weld in E25-20 (ISO standard)
with a minimum height of 5 mm (Fig. 7).
FIG 7
c) Tracing ellipses
AIRCHOC®
A.C. 0,4 A.C. 0,5 A.C. 1 A.C. 510 A.C. 515 A.C. 520
type
D.N. 25 50 80 100 150 200
Parameters AC V1 AC V1 AC V1 AC V1 AC V1 AC V1
Z=(X-Y)°
15° 131 50 233 87 344 129 441 165 614 230 847 318
20° 99 38 177 66 260 98 334 125 464 174 641 240
25° 80 30 143 54 211 79 270 101 376 141 519 195
30° 68 26 121 45 178 67 228 85 318 119 439 165
35° 59 23 106 40 155 58 199 75 277 104 382 143
40° 53 20 94 35 139 52 177 66 247 93 341 128
45° 48 18 86 32 126 47 161 60 225 84 310 116
50° 44 17 79 30 116 43 149 56 207 78 286 107
55° 41 16 74 28 109 41 139 52 194 73 268 100
60° 39 15 70 26 103 39 132 49 183 69 253 95
65° 37 14 67 25 98 37 126 47 175 66 242 91
70° 36 13.5 65 24 95 36 121 45 169 63 234 88
75° 35 13 63 24 92 35 118 44 164 61 227 85
80° 34.2 12.8 62 23 91 34 116 43 161 60 223 84
85° 33.8 12.6 61 23 90 34 114 43 159.6 60 220 83
90° 33.7 12.6 60.3 23 88.9 33 114.3 43 159 59 219.1 82
DB 33.7 60.3 88.9 114.3 159 219.1
V2 12 20 30 38 53 73
HOPPER
Z=(X-Y)°
Tracing of an ellipse procedure:

In this example we will take the case of an AC0.5 with an angle Z° of 30°:
Step 1 Step 2
First, draw a horizontal axis and a vertical Then, trace the points A, B,C and D using
axis. This gives us the point O. the table. Here the value AC is equal to
120mm and DB to 61mm.
DO=OB=1/2 DB
AO=OC=1/2 AC
Step 3 Step 4
V2 V2
P
V1
V1
P
Identify the points P (here V1=90mm) then

Now we can trace the ellipse
draw a horizontal line through the points.
Finally, draw the points Q (here V2=40mm).
OP=3/4 OA=3/4 OC
Note : The worksheet « Ellipses tracing » has been created in order to make an approach to tracing. The
values given on the dimensions of the ellipses are valid for silos and hoppers with thin sheet (<3mm).
For sheets having a thickness greater, then the lower edge of the ellipse will require chamfering.
Example :
Ellipse traced thanks to the worksheet
Lower edge of the ellipse

to be chamfered.
Chamfer to complete depending on the

sheet thickness and the angle.
4) Preparation of holes in silo or hopper
The installation of one or several insertion pipes may be carried out on a full silo or on a furnace in
operation in the case of a cement furnace for example. However, this solution should only be adopted
as a last resort. For certain materials it is not absolutely necessary to clean the silo before installation
of insertion pipes.
Except in the following cases:

■■ Storage of inflammable material
■■ Storage of dangerous material
■■ Storage of toxic material
■■ Storage of foodstuff
a) On steel silo or hopper
The first operation consists of boring a hole in the FIG 8

silo wall for installation of insertion pipe.
The following operations are carried out :

■■ Where possible, clean the inside wall of the
silo in the places where insertion pipes are to
be installed. In the case where inflammable
material is stored, all imposing safety measures
must be respected.
■■ Trace out the exact location on the silo where the
insertion pipe is to be installed. For this operation,
we repeat that it is highly recommended to refer
to our drawings in order to respect the positions
calculated by our engineering department as
well as the insertion pipe penetration angle.
■■ The ellipse traced corresponds, in the case of
insertion pipe without nozzle, to that obtained in
the previous operation «preparation of insertion
pipes» (Fig. 8).
■■ In the case of a steel hopper, cut out ellipse
using an acetylene burner or a PLASMA or ARC
AIR cutter or possibly a jig saw.
a) On concrete silo or hopper
When an AIRCHOC® is to be installed on

a concrete silo or a hopper or on a chimney
with heat resistant inner lining, the opening
for penetration of insertion pipe must be core
drilled.
This method must be given preference to all

other methods of drilling. In the case of core
drilling, the following operations are to be
respected :
1
■■ Determine the exact drilling location in
accordance with information obtained
from the drawings
■■ Fix the core drill support frame (picture 1)
■■ Set the cutting angle B° (picture 2)
■■ In the case of a cement works tower, it is
preferable to cut the steel frame with an
acetylene burner
■■ Protect surrounding installations from
water used during the core drilling
operation (picture 3) 2
■■ Carry out the core drill
D - Locating the insertion pipes
1) Insertion pipes without deflector
Take the flange into account (off axis). For installation of insertion pipe without nozzle, the following
operations are to be respected :
In case of steel silo :
■■ If the class 150 lbs flange has not

already been welded to the pipe, begin
by welding the flange to the pipe end not
yet cut in the elliptical form (picture 1)
■■ Pass the pipe through the plate and

place it on the elliptical hole made in the
hopper wall (picture 2) 1 2
■■ Weld the pipe to the hopper wall while

stringently respecting the inclination
angle indicated in the drawing (picture 3)
■■ Then bring the plate flat against the wall
■■ Weld the plate to the silo wall as well

as to the pipe. These welds must be
perfectly air tight (picture 4 and 5).
3 4
■■ Grind and clean welds
■■ Apply a coat of anti-corrosion paint
■■ When dry, apply at least one coat of

finish paint
5
In case of concrete silo (Fig. 10)
Once the pipe has been positioned flush with the inside wall of the silo, maintain it in order to allow
space between the pipe and the silo wall to be blocked using fast-setting cement or sealing compound.
This operation must ensure the perfect sealing of the insertion pipe and eliminate all dust ejection
during AIRCHOC® triggering.
Once this operation is complete :
■■ Place the plate against the silo wall and fix

it by means of expansion dowels
■■ Weld the plate to the pipe then the flange to

the other end of pipe
■■ Grind and clean all welds
FIG 10
■■ When dry, apply at least one coat of finish

paint
2) Insertion pipes with nozzles
When an insertion pipe with nozzle is to be installed, the following operations are to be respected :
a) In case of steel silo
Straight or inclined nozzle (Fig.11)
■■ Weld the nozzle to the pipe while paying attentionto the location of the flange
■■ Prepare hole in wall for installation of the nozzle
■■ The nozzle must be flush with the inside wall of the silo
■■ Weld the nozzle + pipe to the wall of the silo
■■ The welds must be accurate and air tight
■■ Grind all welds
■■ Apply a coat of anti-corrosion paint to the insertion pipe assembly
■■ When dry, apply at least one coat of finish paint
FIG 11
90° nozzle (Two solutions) :
Entry in hopper (or shaft) possible (Fig. 12)
■■ Trace diameter of hole by taking

measurements of 90° nozzle and cut
passage using acetylene burner
■■ Position nozzle in hole from the inside
■■ Tack weld nozzle in position indicated on

the drawings
■■ Adjust nozzle support plate
■■ Weld support plate to the nozzle and hopper
■■ Weld insertion pipe to the nozzle while

paying attention to location of the flange.
For cosmetic reasons, once the AIRCHOC®
has been installed, this insertion pipe flange
should be positioned off-axis.
■■ Apply a coat of anti-corrosion paint to the

insertion pipe assembly
FIG 12
paint
If it is not possible to enter the hopper (Fig. 13)
■■ Prepare hole in a way as to enter nozzle into

the hopper
■■ Tack weld nozzle in location indicated in

drawing
■■ Adjust the nozzle support plate
■■ Weld support plate to the nozzle and hopper
■■ Weld insertion pipe to the nozzle while paying

attention to the location of the flange. For
cosmetic reasons, once the AIRCHOC® has
been installed, this insertion pipe flange
should be positioned off-axis.
■■ Apply a coat of anti-corrosion paint to the

insertion pipe assembly

paint FIG 13
b) In case of concrete silo (concrete or fire brick)
Straight or inclined nozzle (Fig. 14 et 15)
■■ Weld the nozzle to the insertion pipe, ensure not to weld the class 150
lbs flange to the insertion pipe
■■ To locate the exact position of the nozzle from the inside of the silo,
drill a small hole from outside in traced position thus enabling location
of the nozzle from inside
■■ Cut outside steel wall, in a cement preheater, using an acetylene
burner or other according to the material
■■ Cut through concrete or fire brick from inside or outside according to
simplicity, using, with preference, a core drill
■■ Adjust hole in order to position deflector correctly. It should be flush
with inside wall. Locate it in order to allow space between the nozzle
and wall to be blocked using fast-setting cement, sealing compound
or refractory cement.
This operation must ensure perfect sealing of insertion pipe and eliminate
all dust ejection during AIRCHOC® triggering.
■■ Locate and weld support plate to pipe and in refractory wall
■■ Locate and weld support plate to pipe and dowel it to concrete silo FIG 14
wall (or refractory)
■■ Weld the class 150 lbs flange respecting the position of the holes
being off-axis
■■ Apply a coat of anti-corrosion paint to the insertion pipe assembly
FIG 15
90° nozzle (Fig. 16)
■■ Weld the nozzle to the insertion pipe, ensure not

to weld the class 150 lbs flange to the insertion
pipe
■■ Locate the insertion pipe + nozzle assembly from
inside into the hole previously core-drilled
■■ Locate nozzle in accordance with indications
given on the drawings. Fix the nozzle.
■■ Locate it in order to allow space between
nozzle and wall to be blocked using fast-setting
cement, sealing compound or refractory cement.
This operation must ensure perfect sealing of
insertion pipe and eliminate all dust ejection
during AIRCHOC® triggering.
■■ Locate and weld support plate to pipe and to
the steel structure when existent or place plate
against wall and fix with expandable dowels and
weld support plate to pipe
■■ Weld support plate to pipe
FIG 16
■■ Weld class 150 lbs flange to the insertion pipe
ensuring that the holes are off-axis
■■ In certain cases it is recommended to protect the
nozzle by covering it with concrete (e.g. cement
works) (Fig. 17)
FIG 17
Note : if the blowpipe is facing up, it is imperative to put an elbow + a complete flange to deport the
head of the AIRCHOC® in order to prevent a blockage of the mechanism due to product accumulation
(Fig.18).
Elbow
Blowpipe + flange +
FIG 18 complete flange
Elbow
Blowpipe + flange +
complete flange
3) Blowpipe installation with interchangeable nozzles
a) Interior interchangeable nozzle
Presentation
4
7
6
3
2
5
Item Quantity Description

1 1 90° elbow nozzle
2 2 Tightening rods
3 1 Bushr
4 2 Wedge
5 1 Plate
6 4 Star washer
7 4 Screw H
Installation
■■ Break the refractory concrete around the installation area.

■■ Cut the metalic part following a diamond shape. (Fig 19)
Templates of the diamonds in attachment
FIG 19
■■ Install the bush (Rep. 3) in order to place Oustise

the opening of the nozzle (Rep.1) against measurement
the inside wall of the refractory.
■■ Adjust the depth based on the thickness of

the refractory (see below formula)
Outside measurment = Lf + I - E 1
E = total thickness of the refractory

(outer sheet included)
DN 100 DN150
Lf = sleeve length 215 300
I = installation measurment 115 160
■■ Insert the tightening rods (Rep 2) into the

nozzle slots (Fig. 20)
■■ Place the nozzle in the bush
■■ Place the plate letting the rods pass through

the holes.
■■ Screw the reinforcing plate (Rep.5) to the

bush.
■■ Push the wedges (Rep.4) into the slots

of the rods (Fig. 21) in order to clamp the
nozzle on the bush.
■■ Place the steel pipe in the deflector
■■ Weld the pipe on the plate
1 2 5
FIG 20 FIG 21
■■ Place the steel blowpipe into the nozzle.
■■ Weld the blowpipe to the plate
■■ Remake the refractory concrete around the nozzle according to the rules
Blowpipe
b) Interchangeable nozzle interior/exterior
Presentation
4
5
3
6
Item Quantity Description

1 1 90° elbow nozzle
2 2 Tightening rod
3 1 Bush
4 6 Wedge
5 1 Plate
6 4 Screw H + washers
Installation
■■ Break the refractory around the installation area.

■■ Cut the metallic wall following a semi-circle shape. (Fig.22)
Tracing dimensions in attachment.
FIG 22
■■ Install the bush (Rep.3) in order to place

the opening of the nozzle (Rep.1) against Outside measurement
the inside wall of the refractory.
■■ Adjust the depth based on the thickness of

1
the refractory (see below formula)
Outside measurment = Lf + I - E
E = total thickness of the refractory

(outer sheet included)
DN 100 DN150
Lf = length of the sleeve 220 330
I = installation dimension 80 120
2
■■ Then weld the bush to the metalic surface (Fig 1
24)
■■ Put the 2 tightening rods (Rep.2) in the slots

(Fig 23)
■■ Put the nozzle in the bush (either from the

inside or the outside) (Fig 25)
■■ Tighten the plate (Rep.5) (Fig 26)
FIG 23
FIG 24 FIG 25 FIG 26
■■ Inster the wedges (Rep.4) to fix the nozzle on the sleeve.
■■ Place the steel blowpipe in the nozzle.
■■ Weld the blowpipe on the plate (Fig 27)
■■ Remake the refractory around the nozzle following the rules. (Fig 28)
Blowpipe
FIG 27 FIG 28
4) On hopper with inside coating.
When the AIRCHOC® units are installed on a hopper, a chute (etc...) whose inner wall is lined with
a coating (eg: rubber, plastic, etc...), the following must be respected according to the following
assumptions:
a) Possibility to enter the silo :
■■ Take all necessary safety measures before entering the silo,

■■ Trace on the external wall of the ellipse corresponding to the entry hole of the blowpipe (see figure
and table page 17),
■■ Carry out the cutting of the wall and the coating using tools adapted to the problems (chainsaw, core
drill, fret saw, etc...),
■■ Insert the blow pipe in the reinforcing plate,
■■ Adjust the blowpipe so thst its end extends a little bit beyond the coating inside the silo (Fig 29).
Carefully position the flange PN10 with the holes off-axis,
■■ If it is possible to weld on the silo: weld the plate on the blowpipe and on the external wall.
■■ If it is impossible to weld on the silo, weld the plate on the blowpipe, insert the blowpipe, place an
against lock inside and fix the whole with bolts.,
■■ Provide the installation of additional fasteners around the blowpipe (similar to those already in
place) to reinforce the strength of the coating,
■■ Grind the weldings smoots,
■■ Apply a coat of anti-rust paint,
■■ After drying, apply at least one coat of finishing paint.
Inside
coating
FIG 29
b) Impossibility to enter the silo
■■ Trace on the external wall the ellipse corresponding to the penetration hole of the blowpipe,
■■ Carry out the cutting of the wall and coating using tools adapted to the problems (chainsaw, core
drill, fret saw, etc...),
■■ Insert the blow pipe in the reinforcing plate,
■■ Adjust the blowpipe in order to leave a little bit of the end of it overlapping the inner lining (Fig 29).
Carefully position the flange PN10 with the holes off-axis,
■■ If it is possible to weld on the silo: weld the plate on the blowpipe and on the outer wall.
■■ If it is impossible to weld on the silo, weld the plate on the blowpipe, insert the blowpipe, place an
against lock inside and fix the whole with bolts.,
■■ Provide the installation of additional fasteners around the blowpipe (similar to those already in
place) to reinforce the strength of the coating,
■■ Grind the weldings smooth,
■■ Apply a coat of anti-rust paint,
■■ After drying, apply at least one coat of finishing paint.
■■ If it is impossible to weld the blowpipe, then insert a system in the hole ( fig 30) that will ensure the
connection of the coating with the blowpipe.
FIG 30
5) Specific applications
Any installation of a blowpipe on a fiberglass silo

(HERMEX type, see beside picture) must be
done under the responsibilty of the manufacturer
and be subcontracted to him in the case of an
AIRCHOC® installation completed by us.
6) Risky installations
Any installation in a dangerous environment (explosive environments, chemical products, etc…) needs
to be carried out following the safety measures relative to each company.
Earthing :
Bonding strips
7) Blowpipe with isolation device:
To reduce risks and particularly projections and sources of heat (in the case of a cement plant for
example) during maintenance operations, we offer blowpipes that can be equipped with a guillotine to
isolate an aircannon. The operator inserts the guillotine through the slot insulator casing which isolates
the cannon from production, he will previously have released the locking device (rep1). To put the
cannon back into function it will simply need to be put into back the open position.
Important note: do not fire the airchoc :

1. When the guillotine is in closed position (Fig 31). Indeed there is a risk of damage to the airchoc
because of the return of air.
2. As long as the locking device is not set and secured.
Guillotine
2
FIG 31
Blockage axis
1
Do not forget to put back in place

the safety pins to prevent the axis
from moving.
E- Installation of AIRCHOC® type SD - standard model (Fig. 32)
Once the blow pipe is installed, fit the AIRCHOC® on to the blow pipe flange while not forgetting to fit
the flat seal between the blow pipe flange and the flange of the AIRCHOC® head. Check that one of the
openings in the tank is situated at the low point. Bolt the AIRCHOC® to the BLOW PIPE flange.
Fit the high temperature AIRCHOC®, only

when the plant is on stop. Under exceptional
circumstances, for urgent reasons, it is possible
to install an AIRCHOC® when the plant is
operational. In this case, please to consult us.
FIG 32
Nuts and bolts used :
AIRCHOC® models AC510, AC515, AC520 and

Dimensions Numbers
AC5 are equipped with a hook on the
head for ease of handling. AC 0.4 Tapping 1’’
AC 0.41/12 Tapping 1’’½

The insertion pipe of the AIRCHOC® type AC 0.4
is threaded for the AIRCHOC® to be screwed into AC 0.5 M 16 8
it. Teflon must not be forgotten during assembly. AC 1 M 16 8
AC 510 M 16 8
AC 515 M 20 8
AC 520 M 20 8
AC 5 M 20 12
F- Fitting the hanging device
The AIRCHOC® hanging device is designed to compensate and to soften the recoil force which occurs
during each firing, as well as support the overhand represented by the weight of the AIRCHOC®,
blowpipe and accessories.
The hanging device is essential to avoid any fatigue in the weld seams ans to safeguard any deformation
of the AIRCHOC® body during firing. The device must be fitted on the same wall as the AIRCHOC®.
The hanging device consists of :
■■ 2 collars, Rep.1 ■■ 4 cable eye stiffeners, Rep.5

■■ 2 cables, Rep.2 ■■ 2 hanging hooks, Rep. 6
■■ 2 tensioners, Rep.3 ■■ 2 x 10 mm tighteming bolts for the collars, Rep. 7
■■ 8 cable clamps and accessories, Rep. 4
5
6
1
6
However, the hanging device can be replaced by a fixing cradle.
In this case, this fixing cradle must be correctly dimensioned to take into account the points raised
above ( see pictures below).
G - Fitting the control device
The control device is the unit which makes it possible to start firing the AIRCHOC®. If several cannons
are installed, each AIRCHOC® has its own control device. Triggering the firing of an AIRCHOC® can be
made by :
■■ Either a pneumatic manual command.
■■ Or an electro-pneumatic command .
■■ Or both
In this case, triggering can be brought about by means of a pushbutton or else with a cyclical control
panel. Where large installations are concerned, triggering the firing can be managed by our control
panel which can control up to 240 AIRCHOC®.
a) Pneumatic manual command device

AC0.4 – AC0.41/12 – AC0.5 – AC1 – AC 5
This device consists of a manual control
by means of an off-set lever
AC510 - AC515 - AC520

This device consists of a manual control
by means of an off-set lever
b) Electro-pneumatic control device
AC0.4 –AC0.41/12 – AC0.5 – AC1 – AC5 AC510 – AC515 – AC520
This device consists of a 3/2 way solenoid valve, and a quick

This device is fitted as original equipment, except on the
exhaust valve (QEV), a non return valve, boss and connectors.
AC520 version. The HT version as in addition a metal hose.
The HT version as in addition a metal hose.
STANDARD VERSION STANDARD VERSION
AC520 VERSION
HT VERSION HT VERSION
Air inlet
Electric power
Operation : A 3/2 solenoid valve has three openings and two positions P : Pressure A : Admission R :
exhaust Openings P and A are in communication In the stand-by position (solenoid valve not activated)
the opening A and the opening P are in communication the pendulum blocks the opening R In the
operating position (solenoid valve electrically activated) the pendulum changes position, blocks the
opening P and puts the openings A and R in communication.
See explanation on page 9
H - Fitting the safety control-unit or safety control unit + valve
Safety control units : The pressure gauge and the safety valve should
■■ Check the pressurization of the AIRCHOC®, be fitted with the t-piece on one of the openings
■■ Show the exact pressure reached in the of the AIRCHOC®. tank. (Two ratings exist for the
AIRCHOC®, valve: 8 bar or 10 bar, the maximum pressure
■■ Check the operation of the AIRCHOC®, of the network must be specified at the time of
■■ Put the AIRCHOC® in the purge position the order). A valve should be fitted to one of the
when the cannon is being worked on or openings of the tank. This valve will serve as
during installation after the compressed air a purge for the tank and will make it possible if
feed has been cut off to purge the tank. necessary to drain off any water coming from the
compressed air circuit and which could remain
there. Thus, the choice of the opening on which
The safety control unit (CONAC or CONACH)
this valve will be fitted is significant and should
consists of :
be, as far as possible, the low point of the tank.
■■ 1 pressure gauge (rep. 3),
■■ 2 valves (rep. 1),
The other valve will be fitted in the compressed
■■ connectors, nipples
air feed circuit. This valve can be several meters
from the AIRCHOC®. In all cases, this valve should
It becomes a safety control unit + valve
be fitted so as to be accessible to any person in
(CONACSOU) if the following options are added :
order to cut off the air supply of the AIRCHOC®.
■■ 1 safety valve (rep. 7)
■■ 1 t-piece (rep. 5)
Branch air pipe are not supplied
Air inlet
4
2
Purge vessel
AC510SD
I - Fitting the consafe device
This device has been designed to permit the AIRCHOC® to be isolated in total safety when empty,
(ie. When there is no compressed air) And whenever there needs to be human presence near any
installation equipped with AIRCHOC®.
The CONSAFE is a total safety device for the men working close to installations equipped with
AIRCHOC® Naturally, it is advisable to fit the device to ensure the safe operation of the installation.
The CONSAFE allows :
■■ The fast and automatic draining of any AIRCHOC® connected to the network by operating only
one single valve,
■■ The avoidance of any danger from accident which could result from forgetting the presence of an
AIRCHOC®,
■■ The choice to drain one or more AIRCHOC®.
a) The CONSAFE Device consists of :

■■ 1 x QEV 1/2» (rep. 6) Pay attention to the direction of
the decompression valve
■■ 1 x metal hose, 2m long (rep. 5)
■■ 1 x 1/4» decompression valve (rep. 2) Air
■■ 1 pressure gauge (rep. 1) Inlet
■■ 1 x 1/4» safety valve (rep. 3)
■■ 2 x T-pieces (rep. 4)
■■ Connectors, nipples, reductions
Hole side
Airchoc supply
Metallic flexible delivered with

the AIRCHOC®
2 1
Air inlet
3
5
6 Purge vessel
AC510HT
The 1/2” QEV is fitted by means of a connector to an opening of the AIRCHOC® tank. The metal
hose provided is connected to the QEV and joined to the T-piece connected to the air inlet. For safety
reasons it is important to direct the QEV purge downwards.
The decompression valve is fitted just upstream of the T-piece on the compressed air arrival circuit.
This valve must be accessible, sometimes from several meters away. The pressure gauge and safety
valve are fitted with the T-piece on one of the openings of the AIRCHOC® tank.
b) CONSAFE operating principle
The pressure gauge fitted on the tank gives the user all the information necessary concerning the
pressure in the AIRCHOC®. Thanks to the quality - approved safety valve there is no risk of increase in
accidental pressure, thus avoiding any serious risk for the personnel or the equipment
The CONSAFE makes it possible to drain the AIRCHOC® completely and safely. If a complete CONSAFE
installation is being considered, it is recommended to fit a lockable 3 way valve on the main air network
for all the AIRCHOC®. (if a lubricator filter unit is used, fit the 3 way valve downstream from the unit).
Action :
■■ Working on one AIRCHOC® only, close the decompression valve, ref 3.
■■ Shutting down all the AIRCHOC®, close the 3-way safety valve + lock.
Advantages :
■■ Safety
Disadvantages :
■■ Fall of pressure in the tanks
■■ Incompatible with booster
■■ Poor lubrication of the mechanismscausing the pneumatic control drain valve membrane to
retract, as well as draining the tank and air contained in conic head and pneumatic control block.
J - Lubricator filter regulator unit
To ensure the correct functioning of AIRCHOC® unit, avoid freezing of solenoid valve and clogging of
AIRCHOC® supply pipes, clean and well-lubricated air must be used.
The FRL unit supplied by STANDARD INDUSTRIE comprises of two stop valves, one of which with
exhaust to atmosphere, a safety valve, a water filter, a lubricator and a pressure regulating valve with
pressure gauge. The use of lubricated air (3 drops of oil/Nm3 of air) is recommended for the correct
functioning of moving parts in the AIRCHOC® as well as to reduce the freezing point of water present
in the compressed air. We advise the use of an oil, low viscosity VG32 (example : Mobil DTE 24).
Under severely cold conditions, install the FRL unit in a room or sheltered spot to protect it from low
temperatures.
In extreme cases, the pneumatic circuit (filter and SV included) should be lagged ( filter unit and
solenoid valve included).
K - Startup ans use of a filter-lubricador unit (G.F.L)
1) Filter
The filter is equipped with automatic purging set off by the ball-cock when the level of water and
impurities is reached.
2) Lubricator
The oil flow can be regulated using the screw located on the top of the lubricator close to the drop by
drop display system. Turn this screw clockwise to decrease the flow and vice versa. The oil flows only
when the lubricant is subjected to an air flow, thus when the AIRCHOC® is being filled.
Minimum flow recommended for an AIRCHOC® installation: 3 drops / Nm3.
3) Adjustment
■■ Depressurise one or more of the units located located downstream from the filter lubricator unit.
Cutt off the compressed air supply to each AIRCHOC® using the isolating valves. Drain each
AIRCHOC® by using the purging valve or by causing the cannon to fire.
■■ Make sure in advance that there are no leaks in the air network, as that could distort the calculation.
■■ As the volume, as well as the operating pressure of each unit is known, we can calculate the
volume of air necessary to put the AIRCHOC® under pressure, and thus the number of drops of
oil which must be used. Open the valves from the closed position and observe the number of
oil drops through the sight glass. Adjust if necessary the number of oil drops via the adjustment
screw.
Example :
Say 5 AIRCHOC® Type AC515 (100L) downstream from the same lubricator filter unit. If the operating
pressure is 8 bar, the volume recessary to fill the AIRCHOC® is :
5 x 100L x 8 bars = 4000L soit 4 m3
The number of drops required during the filling of these 5 units is:
3 gouttes / Nm3 x 4 m3 = 12 gouttes
The installation of a Filter Unit is recommended for all the AIRCHOC®, but the installation of a lubricator
is essential for the AIRCHOC® type AC515, AC520, AC5 Standard and for the full AIRCHOC® Haute
Température range.
4) Maintenace of the GFL

The filter is equipped with 5 μm filter cartridge. Check it every two months and clean it with soapy water
or replace it every six months in order to avoid pressure loss, and in the long term, the bursting of the
cartridge which could allow impurities to interfere with the operation of the non-return valve and the
penumatic circuit of the AIRCHOC®.
It is also enssential to keep the oil tank filled in order to ensure the correct operation of the AIRCHOC®.
Example of calculation of the filling ferquancy of the oil tank
Volume of an oil drop: 20 mm3

Volume of a standard tank: 1000 cm3
The tank contains: 1000 / 0.02 = 50000 drops
Number of drops by normo cubic meter : 3
AIRCHOC® reservoir of an AC515 : 100 litres.

Volume of air with 6 bars : 0.6 Nm3
0.6 x 3 = 1.8 drops forthe filling of one AC515.
50000 / 1.8 = 27777 fillings.
If we feed 10 AC515 with a frequancy of de 4 firings/ hour:
27777 / ( 4x10 ) = 694.4 hours, soit 28.9 days.
Il will thus be necessary to fill the tank of the lubricant every 28.9 days.
Number of drops recommended per Normo cubic meter of air:

■■ In continuous operation : 3 drops/minute
■■ Before starting up an installation or before a prolonged stop : 7 drops/minute
■■ During one week is recommended.
III - PNEUMATIC NETWORK (Fig. 33)
FIG 33
General :
Compressed air being the source of energy of the AIRCHOC®, it is essential to take care of it, during
the design stage, production, and then maintenance. An air network adapted to your installation will
enable you to get the maximum benefit from your AIRCHOC®.
Our pneumatic installation consists of 3 important components:

■■ The compressor
■■ The line ( the network)
■■ The oiler filter unit.
Legend
1 Oiler filter unit (regulator)
2 AIRCHOC®
3 Safety device
4 Control panel
*option
The filling time of the AIRCHOC® varies depending on the following criteria :
■■ Air flow from the compressor
■■ Capacity of the pneumatic network and accessories (lubricator filter ) which feeds each AIRCHOC®,
■■ Consumption of the AIRCHOC® and other equipment connected to the same air circuit (hydraulic
ram, air spray gun ,etc…).
A - Required delivery-rate of pneumatic supply
The efficiency of the AIRCHOC® depends upon the pressure available in the circuit. The consumption
of the AIRCHOC® is relatively low but may increase rapidly during continuous triggering cycles. The
compressed air required is calculated as follows :
n x L x pü x X
Air required per hour : ----------------- = (Nm3/h)
1000
n = number of AIRCHOC® pü = air supply pressure

L = volumein litres of AIRCHOC® tank X = number of triggers per hour
B - Capacity of the pneumatique network
It is recommended to use galvanized piping to avoid problems which develop in time such as those
linked to condensation (rust). It is important to adapt the diameter of your blowpipe to number and type
of AIRCHOC® (see table page 60)
The blow pipe calculation is made only for the AIRCHOC® installation. It is clearly understood that your
air network is close to the installation (maximum 10 meters), that your network is at leaqst of the same
diameter, if not larger.
If it is not the case, i twill be necessary to link a more significant air duct to the main network, or to
put a buffer capacitiy close to the installation at least equal to the air requirments for your AIRCHOC®
installation to compensate for falls of pressure due to a sudden instantaneous surge.
This phenomenon is increasingly frequent in « cement kiln » type installations, or efficiency reasons.
We are frequently required to fire a large number AIRCHOC® at the same time, which brings about a
sudden drop in pressure in the network due to the simultaneous filling of many AIRCHOC® units.
In order to ensure that the AIRCHOC® are quickly filled, the plant network compressed air supply
equipment should have the following capacities
AIRCHOC® type Vessel Number of AIRCHOC® Drain
1 1/4”
AC 0.4 5 1/4”
4 Liters
AC 0.41/12 10 1/4”
15 1/2”
1 1/4”
5 1/2”
AC 0.5 9 Liters
10 1/2”
15 3/4”
1 1/4”
AC 1
5 1/2”
25 Liters
10 3/4”
AC510
15 1”
AC515 5 3/4”
50 Liters 10 1”
AC51010 D version
15 1”
AC51010 J version 10 1”
100 Liters
AC515 J version 15 1 ½”
AC5 400 Liters 1 2”
On certain installations equipped with many AIRCHOC® (ex Pre-heater tower, Lepol grate) where the
frequency of firing and air consumption can be significant, it is advised to fit a buffer tank or install a 2”
or 4” duct to be kept in reserve.
C - Rating of hoses connecting AIRCHOC® to pneumatic supply
The supplies of AIRCHOC® with exception of AC 5 model are connected either using rilsan 8/10 or
metal braided hose pipes. For High Temperature AIRCHOC® (AC0.4 HT to AC520 HT), the distance
between the solenoïd valve and quick exhaust valve should not exceed 5’. For SD AIRCHOC® (AC0.4
SD to AC520 SD), the quick exhaust valve is mounted right onto the solenoïd valve.
The solenoid valves and other pneumatic elements have been chosen for their quality of resistance
and are designed for intense use («heavy duty»).
D - Filter-lubricator unit
The installation of a filter is recommended for the whole AIRCHOC® range, however for certain types,
the filter lubricator unit is essential.
AIRCHOC ® ACC0.4 ACC0.5 ACC1 AC510 AC515 AC520 ACC5

SD X X X X
HT X X X X X X X
X = essential
Simply starting up the filter lubricator unit is not sufficient in itself. It is also necessary to respect certain
assembly instructions to ensure the perfect lubrication of the whole of your installation.
Please find below the instructions that have to be followed:
The filter lubricator unit must be equipped with two isolating valves and be located as close as possible
to, and at the highest point of, your AIRCHOC® installation. It must be accessible so that the maintenance
can be carried out in total safety ( maiontenance of the filter, draining the filter and filling the oil tank).
TO ENSURE THE EVEN LUBRICATION OF ALL YOUR AIRCHOC®
The blowpipe must be installed according to certain basic rules:

■■ Never position the pipe downwards ( see below). You are certain to give preferenance to lubrication
of the lower duct.
■■ All the AIRCHOC® isolating valves must be located on the higher part of the blow pipe.
E - Installation rules
The feed tubes must never be directed downwards (fig 34). If it is absolutely necessary to do so, it is
essential to fit a horizontal or vertical off set pipe to ensure that the lubricated air circulates correctly.
OK OK
FIG 34
What should not be done
The same rules apply for the isolating valves of each AIRCHOC® , they must be located above the unit
(fig.35) even if the hose is directed downwards.
OK
FIG 35 OK
F - Installation examples
1) Air network on silo
Air inlet hose
Piping
Ring
2) Air network on a hopper
Air inlet hose
Rigid tube
3) Air network in a cement plant
IV - ELECTRICAL SUPPLY NETWORK

The electrical supply network is used to feed the coils of the solenoid valves or the solenoid valve
solenoid valve. These solenoid valves or coils of the solenoid valve solenoid valve are part of the
electrical control unit. The operating voltage of the solenoid valves is determined at the time of placing
the sales order for the supply of the material.
From the table below please check the relationship between the Control Box and the solenoid valves.
CONTROL BOX SOLENOID VALVE

CONTROL BOX DESCRIPTION
VOLTAGE (AC) VOLTAGE
24 VDC
COF4 Control panel 4 outlets 110/240 V – 50/60 Hz
50/60Hz
Control box 8 outlets
COFS8024 without pressure 24 V – 50/60 Hz 24 V - 50 Hz
switch option
switch option
switch option
switch option
COFFP8024 with pressure switch 24 V – 50/60 Hz 24 V - 50 Hz
option
COFP8048 with pressure switch 48 V – 50/60 Hz 48 V - 50 Hz
option
option
option
The installation of electrical power supply must be carried out in accordance with the regulations
currently applicable and should be carried out by a qualified electrical specialist.
A - Connecting up the AIRCHOC® 5 (AC510, AC515)
METHOD OF CONNECTION
TO THE AIRCHOC® SOLENOID
VALVE SOLENOID VALVE.
Feed inlet pin to the

coil of the solenoid
Connector
dismantling screw
Connector
Tightening nut for

INSERT THE CONNECTING the packing piece
CABLE 3XG 0,75mm²
OR 3 x G 1 mm²
THROUGH THE PACKING
Earth
Connector’s
detail
TO LEAVE THE CABLE
1 : Phase
2 : Neutral P N
: Earth
A - Connection of the AIRCHOC® AC0.4, AC0.5, AC1, AC5 and AC520

Standard solenoid valve
Air inlet
Airchoc AC520
Towards the
AIRCHOC®
Towards the
Air inlet
AIRCHOC®
Connector
dismantling screw
TO LEAVE THE CABLE
1 : Phase
2 : Neutral
Connector : Earth
Tightening nut for

the packing piece Earth
P N
INSERT THE CONNECTING
CABLE 3XG 0,75mm²
OR 3 x G 1 mm²
THROUGH THE PACKING PIECE
V - CONTROL BOX
The control box makes it possible for the AIRCHOC® to be triggered and fired
The control box sends an electric signal to the solenoid coil.
There are two types of control box currently on offer :
■■ Manual control box
■■ Automatic, cyclical control box
A - Manual control box
This box makes it possible to fire the AIRCHOC® manually and by remote control.
This box includes :
■■ An on/off switch .
■■ A pushbutton to fire the AIRCHOC®.
The manual control box is to be fed according to the supply voltage of the solenoid valve
Connecting method : see instructions manual.
B - Automatic, cyclical control box (COF4)
The automatic, cyclical control box enables triggering of AIRCHOC® at adjustable time intervals.
Furthermore, this cabinet is equipped with a remote control facility which authorizes or prevents the
triggering process.
After a stop, this remote control offers two cycle restart modes:
■■ Cycle restart with starting over of the cycle
■■ Cycle restart at point where cycle was stopped
The automatic, cyclical control box is equipped with three timers :

■■ T 1 : Impulse duration
■■ T 2 : Interval between two impulses
■■ T 3 : Interval between two cycles
■■ T 4 : Interval between two cycles (sequential) (on 8 AIRCHOC® control box).
There are two types of boxes : to control 4 AIRCHOC® or 8 AIRCHOC®
4 AIRCHOC® control box :

T1 = 0.5 s
T2 = 0 to 32 mn
T3 = 0 to 16 h 03 mn
CAUTION: the control panel supply will be 110-240V 50-60Hz but can only drive 24VDC
solenoid valves.
The 8 AIRCHOC® control box:
Inputs
■■ 4 TOR interlocks
■■ 8 TOR (or OPTIONAL analogue) pressure switch entries
■■ Emergency stop
Outputs
■■ 1 emergency stop output
■■ 1 fault report output
■■ 1 operating report output
■■ 8 outputs for the control of the solenoid valves
Use
■■ Possibility of networking (CAN bus) up to 30 control box, in master / slave
■■ 3 levels of access; choice of different languages (French, English, Germany, Italian, Spanish)
■■ Management of electrical, pneumatic, mechanical faults, maintenance management (firing
counter)
■■ Management of the firings per sequence or super-sequence (16 firing sequences and 8 super
sequences of 30 steps.)
Display : built-in 4-line backlit display of 80 characters.
Possibility to program the control box from a PC via an optial software package.
Connection : see instructions manual.
The Wireless control panel
This control panel powered in 230V or 115V communicates with the solenoid valves wireless and only
by transmission. This control panel has the same options as the hard wired one. It is a transmitter and
receivers have to be connected to the AIRCHOC®’s solenoid valves. The solenoid valves in 6V dc are
operated by 2 batteries which are in the receivers.
- 16 digital servo
Long distance transmission

With a 300 meter-range (984 feet) -up to 1km
(0,62mi) in open spaces-, the wireless system
enables you to operate the AIRCHOC® Wireless
over large distances across any terrain and
regardless of any obstacles.
Up to 128 AIRCHOC® Wireless units with a

single transmitter.
Installed in your control room, the transmitter
can be connected to your automaton or to a
computer in order to manage all your AIRCHOC®
Wireless units from a single point.
VI - STARTUP
A - General
Before putting your AIRCHOC® installation into operation, it is imperative the AIR circuit be drained of all
impurities resulting from installation work. Only after this should the AIRCHOC® be tested empty. Once
this draining operation has been effectuated: begin tests - silo empty - on your AIRCHOC® installation.
B- Safety instructions
To ensure correct functioning, the following safety measures should be observed :
a) During the initial tests, the plant safety officer f) If the AIRCHOC® is to be used on an
must ensure that no-one is inside the area fitted installation storing products which could self-
with AIRCHOC®. ignite such as oil, coal or certain chemical
products, it is strongly recommended to use an
b) The compressed air contained in the inert gas e.g. CO2 and nitrogen. The risk of dust
AIRCHOC® will be released instantaneously explosion is thus eliminated.
into the production unit on which it is fitted. The
extremely powerful compressed air flow blows g) During operation of the AIRCHOC® all
away everything in its path. openings, man-holes and poke holes must be
closed and sealed to prohibit unauthorized
c) The high kinetic energy contained in the opening. All such opening must be foreseen with
AIRCHOC® could be fatal for any person standing a safety instructions notice. We can supply these
in front of the AIRCHOC®C discharge. notices.
d) All persons working regularly around an h) Observation holes, man-holes and poke
installation fitted with an AIRCHOC® must holes in an installation fitted with an AIRCHOC®
receive specific training concerning handling may only be opened after the safety officer has
of AIRCHOC® before starting up and during verified that the AIRCHOC® has been drained
operation. and the control cabinet power isolated.
e) AIRCHOC® are not to be transported, i) The hanging devices, supplied with the rest of
installed, modified or dismantled unless all air our AIRCHOC® equipment must be systematically
has been evacuated. fitted. In a case where the buyer has not fitted
this hanging device : a support frame or other
form of suspension must be designed and fitted
before starting-up the AIRCHOC®.
C- Testing and start-up
■■ Respect the safety instructions given in paragraph VI b

■■ Fill the AIRCHOC® with compressed air one after the other
■■ Close the isolation valve of each AIRCHOC®
ATTENTION. In the case of an CONSAFE facility, the tank content is released to air automatically.
■■ Drain by means of drain valve on tank
■■ Repeat this operation twice at a pressure of 4 bar
Once the AIRCHOC® have been tested

■■ Put the AIRCHOC® under pressure, cut off the supply by closing the isolator valve
■■ Next, carry out the AIRCHOC® firing tests by operating the manual control of the solenoid valve
■■ Then carry out the adjustments to the electronic control box (see instructions for control box).
These tests must be carried out on an empty silo with extraction point open.
According to the options chosen, refer to the following tests:
1 - Filling and triggering with mushroom type manual override

To fill the AIRCHOC®, open the isolator valve, the AIRCHOC® fills until reaching the pressure regulated
behind manual control
To activate the AIRCHOC® cannon, press the control button and block off the opening of the solenoid
valve; the AIRCHOC® fires and fills up again after the manual control button is released.
2 - Filling and firing manually using the solenoid valve

Each solenoid valve has a manual switch.
The solenoid valves are usually activated by the electronic control box. To activate the cannon manually,
move the switch to the AIRCHOC® firing position, then move it back to its original position so that the
AIRCHOC® can again fill.
VII - MAINTENANCE INSTRUCTIONS

A - General
To ensure the AIRCHOC® installation functions correctly, we recommend you proceed with an overhaul
every year or every 25 000 trigger operations.
B - Safety requirements
■■ During an intervention on an installation fitted with AIRCHOC® ensure that:

■■ The isolation or decompression (CONSAFE) valve is closed.
■■ The tank is drained and the drain valve held in the open position.
■■ The electrical power supply of the solenoid valve control cabinet is isolated and protected against
accidental power-up.
C - Visual inspection (equipment not under pressure)
1 - This inspection consists of :

■■ Check general condition of AIRCHOC®
■■ Check condition of accessories
■■ Check condition of tank and welds
■■ Check condition of pressure gauge, various taps and valves
■■ Check that quick exhaust valve is pointing down
■■ Visually examine condition of welds around flange and insertion pipe support plate
■■ Put AIRCHOC® under pressure again
■■ Check condition of hanging device
2 - Faults can appear during this inspection

■■ Wear, breakage or defect of various accessories. In which case, replace the defective part.
■■ Cracks, weak spots on welds around insertion pipe. In this case, remove the AIRCHOC® and
carry out welding repairs.
■■ The hanging device must be tensioned and tight
■■ Dents and bulges in the tank. Replace immediately
■■ Electrical cables and pneumatic hoses defective. Repair or replace the defective elements
■■ Whistling coming from solenoid valve, quick exhaust valve or AC mechanism. In this case :
-- Locate leak
-- Remove solenoid valve, quick exhaust valve or head
-- Inspect gaskets and pistons
-- Replace worn parts.
D - Confirmation that the AIRCHOC® is working correctly
This inspection is carried out once a year or once every 25,000 triggering operations.
To do so :
■■ Isolate the AIRCHOC® by closing the isolation or decompression (CONSAFE1/2) valve

■■ Drain tank :
-- * Either manually by opening drain valve
-- * Or automatically by means of the CONSAFE1/2
■■ Reopen the pneumatic supply and check that pressure increases correctly (pressure gauge)
■■ Trigger the AIRCHOC® by manually activating the solenoid valve or by pressing the mushroom
type button
■■ A fter filling, activate the solenoid again, this time electronically, either via the control box or via the
electronic control cabinet.
The Air Network :

■■ Check that the compressor is providing sufficient air flow .
■■ Check that the diameter of the duct for the air line air is adequate
This problem has already been noticed on installations equipped with CONSAFE1/2. The problem was
solved by increasing the diameters of the air ducts and by adding a buffer tank
VIII - TROUBLE SHOOTING ON AIRCHOC® 5 V5
Does the AIRCHOC® 5 V5 shows external leakages?
no
yes See next page
1. Leaking reservoir :
Check the tightness and the presence of Teflon on the reservoir accessories.
2. Leakage at the flange level between the head and the reservoir :
Check the tightness of the flange, the flange gasket. Replace the seal if necessary.
3. Leakage on the plate level :
Check the tightness of the plate. Replace the seal if necessary.
4. Leakage on the base of the QEV:
Check the tightness of the base. Replace the seals if necessary.
5. Leakage on the solenoid valve :
Check the state and the presence of the 3 seals.
Tight the solenoid valve well to 2Nm.
6. A large amount of air escapes through the base elbow and the silencers :
Check the position of the manual control of the solenoid valve
Check the position of the QEV piston.
Manual control blocked

if pressure switch pushed and turned
Is the AIRCHOC® 5 V5 under pressure ?
yes no
When you active the AIRCHOC® manual
control is the AIRCHOC® firing?
yes no
Electrical problem Mechanical Problem Pneumatic problem
How operate the Manual control
push and
release
Pneumatic problem
When you open the drain valve, is the reservoir emptying ?
yes no
Replace the manometer Check the pneumatic connection
Check the compressed air network:

1. The main isolation valve.
2. The oil filter unit.
3. The individual isolation valve
4. The installation orientation of the valve if CONSAFE
device.
5. The orientation of the non-return valve.
Blocked piston in closed position

Poor sealing of the piston
Control the scope
Piston blocked in an intermediate position

4 lobes seal too tightening in the plate
Replace the seal by a lip seal
OR
Damaged guiding ring
No longer ensure the translation of the
piston
Replace the ring
Model SD Model HT
MECHANICAL problem
The AIRCHOC® no longer fire or intermittently
When you operate the manual control of the pilot, is the

air release from the QEV?
yes Check
1. The state of the silencers

Dismantle the silencers and do a manual firing. If the firing is
OK, clean the silencers, replace if necessary.
2. 4 lobes seal
Dismantle the rear plate and check the 4 lobes seal. If it is
damaged or does not work properly, replace it with a lip seal.
Attention to the direction of the lip seal
3. The QEV piston

Dismantle the base and control the position and the state
of the QEV piston. Depending on its state put it back into
position or replace it.
MECHANICAL PRO-
The AIRCHOC® is no longer firing
When you activate the manual control of the

pilote (rep1) (or when it is electrically triggered)
Nothing happens
yes Check the mechanism of the pilot (rep 2)
Electrical Problem
Check
if the control panel is correctly connected
yes
If there is a pulse on the connecting terminal of the

AIRCHOC®
yes no
Check Check
1. If the voltage is identical to the voltage 1. The output fuses on the control panel
of the pilots
2. The electrical connection of the pilot. Replace them if necessary
3. The electrical continuity of the pilot If the problem persists after replacing the
4. The coil of the pilot fuses, control the operation of the control
panel.
ANNEXE 1 : Cutting template for rhombus :
Scale 1/1
Annexe 2 : Cutting template for the semi-circles:
Scale 1/2
EC Conformity
Manufacturer : Standard Industrie international

139-141 rue du Luxembourg
CS50207
59054 ROUBAIX Cedex 1
The material describe below respond to community harmonization legislation in effect following:
Directive 2006/42/CE of European parliament and of council of 17 may 2006 relative to machinery and
changing the directive 95/16/CE
Manufacturer : AIRCHOC® 5
AC510, AC515, AC520, AC510SD, AC510HD, AC515SE, AC515HE, AC520SF, AC520HF,

AC510SDEVD5, AC510HDEVD5, AC515SEEVD5, AC515HEEVD5, AC520SFEVD5,
AC520HFEVD5, ACW510SDEVD, ACW510HDEVS, ACW515SEEVD, ACW515HEEVD,
ACW520SFEVD, ACW520HFEVD, AC510SDPNE5, AC510HDPNE5, AC515SEPNE5,
AC515HEPNE5, AC520SFPNE5, AC520HFPNE5.
If modification of material without approval, this certificate loses its validity.
Roubaix, le 11/03/2013
Jean-François Duhautois, Quality Manager

Airchoc5 (16.6.16)

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TECHNICAL MANUAL NOT AIRCHOC5

INSTALLATION OPERATION AND MAINTENANCE

STANDARD INDUSTRIE International Tél : +33 (0)3 20 28 32 32

Revision Date Reason Amended pages

III - PNEUMATIC NETWORK 57

IV - ELECTRICAL SUPPLY NETWORK 69

VII - MAINTENANCE INSTRUCTIONS 78

VIII - TROUBLE SHOOTING ON AIRCHOC 5 V5 80

The operating principle of the AIRCHOC®

AC510 DN100 / 25 liters

AC0.4 DN25 / 4 liters

Models big volume

AC510 DN100 / 50 liters

B - Operating principle of AIRCHOC®

POUR LES MODELES AC0.4 /AC0.41/12/ AC0.5 / AC1 / AC5

■■ The solenoid valve 3/2 is in reception

■■ The air enters the QEV

■■ Stand by position: the reservoir is full.

■■ The solenoid valve is activated and puts the

■■ The QEV piston changes position.

Step 6 : FIRING THE L’AIRCHOC®

■■ The AIRCHOC® head piston changes

Description of the parts

Piston Elbow of exhaust

QEV Return spring

Operating principle of solenoid valve 3/2

A 3/2 solenoid valve has three openings and two R

Chamber C1 and C2 are in communication

Stage 1 : FILLING OF THE CANNON (under pressure)

R QEV (PEA) piston

Air supply of the vessel

Stage 2 : ACTIVATION OF THE PILOT

QEV in open position

Stage 3 : AIRCHOC® FIRING

Piston moves back

Vessel : Air exhaust

D - Ratification of tank under pressure and

C - Preparation of insertion pipes and nozzles

The insertion pipes installed in silos or hoppers

The insertion pipe inclination compared to the

However, to solve certain particular problems

3) Preparation of the blowpipes

a) Insertion pipe without nozzle

To prepare the insertion pipe, carry out the following operations :

b) Insertion pipe with nozzle

Tracing of an ellipse procedure:

Identify the points P (here V1=90mm) then

Lower edge of the ellipse

Chamfer to complete depending on the

4) Preparation of holes in silo or hopper

Except in the following cases:

a) On steel silo or hopper

The first operation consists of boring a hole in the FIG 8

The following operations are carried out :

a) On concrete silo or hopper

When an AIRCHOC® is to be installed on

This method must be given preference to all

D - Locating the insertion pipes

1) Insertion pipes without deflector

In case of steel silo :

■■ If the class 150 lbs flange has not

■■ Pass the pipe through the plate and

■■ Weld the pipe to the hopper wall while

III - PNEUMATIC NETWORK 57

IV - ELECTRICAL SUPPLY NETWORK 69

VII - MAINTENANCE INSTRUCTIONS 78

VIII - TROUBLE SHOOTING ON AIRCHOC 5 V5 80