CKD 3KA1 Instruction Manual Download Page 1

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ＳＭ−２０６７９２-A

ＩＮＳＴＲＵＣＴＩＯＮＭＡＮＵＡＬ

ＭＡＳＴＥＲＶＡＬＶＥ

３ＫＡ１，４ＫＡ１，４ＫＢ１
Ｍ３ＫＡ１，Ｍ４ＫＡ１，Ｍ４ＫＢ１

●

Please

read

this

instruction

manual

carefully before using this product, par-
ticularly the section describing safety

．

●

Retain this instruction manual with the
product for further consultation whenever
necessary

．

３

Edition

Summary of Contents for 3KA1

Page 1: ...１４ＫＡ１４ＫＢ１Ｍ３ＫＡ１Ｍ４ＫＡ１Ｍ４ＫＢ１ Please read this instruction manual carefully before using this product par ticularly the section describing safety Retain this instruction manual with the product for further consultation whenever necessary ３rd Edition ...

Page 2: ...ons Use for special applications requiring safety including nuclear energy railroad aviation ship vehicle medical equipment equipment or applications coming into contact with beverage or food amusement equipment emergency shutoff circuits press machine brake circuits or for safeguard Use for applications where life or assets could be adversely affected and special safety measures are required ３ Ob...

Page 3: ...be responsible occurs within the above war ranty period a substitute or necessary replacement parts shall be provided free of charge or the product shall be repaired free of charge at the plant of CKD CORPORATION However the guarantee excludes following cases Defects resulting from operation under conditions beyond those stated in the catalogue or specifications Failure resulting from malfunction ...

Page 4: ...ter valve which may cause inhalation of foreign matter near the exhaust port This potential sit uation would be worse if the exhaust port is facing up ward Attach a silencer to the exhaust port or have the exhaust port face downward b Keep the master valve system dry Take care to avoid direct contact with dripping water or splashes of cutting oil If the cylinder rod is splashed with cutting oil th...

Page 5: ...igher than normal density of ozone for example the atmosphere near a beach or in an area with frequent thunder storms Consult us for the packing and gaskets to be used in an atmosphere with a higher ozone density INSTALLATION Section 4 2 When installing a master valve unit never attempt to hold it in position by means of the pipes connected to it Mount the master valve by applying the mounting scr...

Page 6: ...r air leakage d When supplying the compressed air for the first time after completing the piping increase the air pressure gradually but never introduce a highly pressurized air suddenly A sudden introduction of a highly pressurized air may disconnect pipes at joints and or cause the tubes to jump around any of which may cause an injury e Do not decrease the inside diameter of the piping from any ...

Page 7: ...on PERIODIC INSPECTION Section 6 1 Before providing a maintenance service cut and the sup ply of compressed air and confirm the absence of residu al pressure The above is required to ensure safety Regularly perform the daily and periodic inspections to correctly maintain product performance If the product is not correctly maintained product per formance may deteriorate dramatically resulting in a ...

Page 8: ...KING 10 4 INSTALLATION 4 1 Environment 11 4 2 Installation 12 4 3 Piping 13 5 OPERATING RECOMMENDATION 5 1 Operation 17 5 2 Air Quality 20 6 MAINTENANCE 6 1 Periodic Inspection 22 6 2 Disassembling and Reassembling 23 7 TROUBLE SHOOTING 27 8 PRODUCT SPECIFICATIONS AND HOW TO ORDER 8 1 Product Specifications 28 8 2 How to Order 31 8 3 Consumable parts 37 ...

Page 9: ...anation Master valve unit There are direct pipng and subplaate piping Sub plate It is a block for the piping Piping Port Port pis the supply port port R is the exhaust port port A and B is the Output port Pilot air piping port It is pilot air a supply port PA PB Mounting screw There are two every individual valve and it fixes the valve unit on the Various base ...

Page 10: ...04 9 80665 10 2 1 10 2 1 Note 1Pa 1N m2 1MPa 1N mm2 Pressure Pa kPa MPa bar kgf cm2 atm mmH2O mmHg or Torr 1 1 10 3 1 10 6 1 10 5 1 01972 10 5 9 86923 10 6 1 01972 10 1 7 50062 10 3 1 103 1 1 10 3 1 10 2 1 01972 10 2 9 86923 10 3 1 01972 102 7 50062 1 106 1 103 1 1 10 1 01972 10 9 86923 1 01972 105 7 50062 103 1 105 1 102 1 10 1 1 1 01972 9 86923 10 1 1 01972 104 7 50062 102 9 80665 104 9 80665 10...

Page 11: ...he valves are ready to be con nected to the pipes the entry of foreign matter from the piping ports could cause the master valves to fail or mal function a Check the model number imprinted on the product to make sure that the product you received is exactly the product you ordered b Check the exterior of the product for any damage c Before using the product read the supplied documentation CAUTION ...

Page 12: ...eep the master valve system dry Take care to avoid direct contact with dripping water or splashes of cutting oil If the cylinder rod is splashed with cutting oil the oil may penetrate through the cylinder into the secondary side piping of the master valve This must be prevented to avoid malfunctions Consult us for preventive measures hot c Do not use the master valve system in an atmosphere that i...

Page 13: ...y 4 2 Installation When installing a master valve unit never attempt to hold it in position by means of the pipes connected to it Mount the master valve by applying the mounting screws and or mounting plate to the master valve 4 2 1 A work space for installation removal wiring and piping opera tions should be provided around the installed master valve sys tem 4 2 2 Direct mounting 1 Direct piping ...

Page 14: ...iping increase the air pressure gradually but never introduce a highly pressurized air suddenly A sudden introduction of a highly pressurized air may disconnect pipes at joints and or cause the tubes to jump around any of which may cause an injury e Do not decrease the inside diameter of the piping from any of the master valve exhaust ports to a diameter less than the exhaust pipe connecting port ...

Page 15: ...apply the sealant to the female screw parts of the machine 4 3 2 Flushing Before connecting pipes flush the interiors of the tubes master valves and connected devices to remove foreign matter 4 3 3 About M5 joint M5 seal it with gasket model FGS Don t tight while increasing Pressure Consider a trouble of emergency Design and enforce to be Possible to remore and mount of a valve 4 3 4 Blow circuit ...

Page 16: ...n selecting from tubes commercially available carefully study the accu racy of the outside diameter as well as the wall thickness and the hardness The hardness of an urethane tube should be 93 C or more as measured by a rubber hardness meter With a tube that does not have a sufficient accuracy of the outside diameter or the specified hardness a decrease in the chucking force may cause dis connecti...

Page 17: ...e connections Do not bend a tube immediately at where it is connected to the joint but lead it out straight from the end of the joint for a length equal to or greater than the outside diameter of the tube The tension applied sideways through the tube should not exceed 40N 8 Blank plug to be used For use with a master valve with a one touch joint select the blank plug specified by us Blank plug GWP...

Page 18: ...PB When PB pressurization P B R2 port is closed P R2 3KA1111 When PB no pressurization See the right figure P A R1 port is closed When PB pressurization A PB A R1 P port is closed R1 P 3KA121 When PA pressurization See the right figure B R2 When PB pressurization P B PA B PB Even if air is cut off after press urization it maintaing the chan ging by the self P R2 ...

Page 19: ... B PB When PB pressurization P B A R1 R2 port is closed Even if air is cut off after pressuri zation it maintaing the changing by the self R1 P R2 4KA131 4KA141 4KA151 When 4KA131 is PA PB no pressurization See the right figure P A B R1 R2 are closed When 4KA141 is PA PB no pressurization PA A B PB P Closed A R1 B R2 When 4KA151 is PA PB no pre ssurization P A B R1 R2 Closed R1 P R2 Refer to the f...

Page 20: ...ressurization P B A R Even if air is cut off after press urization it maintaing the chan ging by the self A P B R 4KB131 4KB141 4KB151 When 4KA131 is PA PB no pressurization See the right figure P A B R are closed When 4KA141 is PA PB no pressurization P Closed A B R PA PB When 4KA151 is PA PB no pressurization P A B R Closed Refer to the function of 4KB121 concerning the caseof PA or PB which is ...

Page 21: ...ce expansion of the rubber parts which may cause a malfunction 5 2 1 Lubrication The 4KA1 4KB1 Series master valve systems use pre lubricated valves that usually do not require lubrication from the outside If you have to lubricate a valve use Type 1 turbine oil ISO VG32 without additives Excessive lubrication and extremely low pressure may cause a longer re sponse time 5 2 2 Ultra dry compressed a...

Page 22: ... oil wear of the sliding components of the pneumatic device may be acceler ated 2 Supply clean compressed air that does not include solid foreign matter 1 Solid foreign matter in the compressed air may cause wear of the sliding components of the pneumatic device or stick to such components and cause hydraulic lock 5 2 5 Cleaning the supplied air Compressed air usually contains a large amount of dr...

Page 23: ...m the air filters 1 Checking the compressed air supply pressure Is the supply pressure at the specified level Does the pressure gauge indicate the specified pressure when the system is operating 2 Checking the air filters Is the drain normally discharged Is the amount of dirt attached to the bowl and element at a normal level 3 Checking joints in the piping for the leakage of compressed air Are th...

Page 24: ...needs to have a knowledge for safely performing such operation based on the understand ing about the mechanisms and operating principles of master valves 6 2 1 Master valve mounting and detaching When replacing the master valve pay special attention so that no gaskets are fallen down Additionally carefully check the orientation of the gasket and the master valve The proper tightening torque of the...

Page 25: ...B111 No Parts Material Qty Remarks Pilot cap mounting screw Steel 2 M2 5 17 with Spring washer Pilot cap Resin 1 Piston ass y 1 Body Aluminum alloy die casting 1 Spool ass y 1 Spool spring Stainless steel 1 Cap Gasket Nitrile rubber 1 Cap Resin 1 Cap mounting screw Steel 2 M2 5 12 6 with Spring washer ...

Page 26: ... 3 25 MAINTENANCE ６ 2 3KA121 4KA121 4KB121 No Parts Material Qty Remarks Pilot cap mounting screw Steel 4 M2 5 17 with Spring washer Pilot cap Resin 2 Piston ass y 2 Body Aluminum alloy die casting 1 Spool ass y 1 ...

Page 27: ...141 4KB151 No Parts Material Qty Remarks Pilot cap mounting screw Steel 4 M2 5 22 with Spring washer Pilot cap Resin 2 Piston ass y 2 Body Aluminum alloy die casting 1 Spool ass y 1 Body block Resin 1 Pilot cap mounting screw 3pozi Steel 2 M2 5 30 with Spring washer ...

Page 28: ... an open air Install pipe joints to A and B ports with diame ter equal to or smaller than that of to P port joint Valve is frozen Add remedies of avoiding freezing Heating system or dehumidifying system etc Clogged up exhausting port with dust Install a cover or silencer and clean it regularly High actuating pressure is required Bulged or decomposed packings Check the quality of the lubricant Turb...

Page 29: ... Lubrication Not required Use turbine oil type 1 ISO VG32 when required Vibration resistance m s2 50 or less Shock resistance m s2 300 or less Atmosphere No corrosive gas should exist Working pressure MPa 0 15to0 7 0to0 7 Pilot pressure MPa 0 6 working pressure 0 06 to0 7 0 15to0 7 Pressure is converted as 1MPa 10 1972kgf cm2 10 2kgf cm2 Note 1 Ambient temperature applies when stored or sitting an...

Page 30: ...ine oil type 1 ISO VG32 when required Vibration resistance m s2 50 or less Shock resistance m s2 300 or less Atmosphere No corrosive gas should exist Working pressure MPa 0 15to0 7 0to0 7 Pilot pressure MPa 0 6 working pressure 0 06 to0 7 0 15to0 7 0 2to0 7 Pressure is converted as 1MPa 10 1972kgf cm2 10 2kgf cm2 Note 1 Ambient temperature applies when stored or sitting and does not apply to the f...

Page 31: ...2 when required Vibration resistance m s2 50 or less Shock resistance m s2 300 or less Atmosphere No corrosive gas should exist Working pressure MPa 0 15 to 0 7 0 to 0 7 Pilot pressure MPa 0 6 working presure 0 06 to 0 7 0 15 to 0 7 0 2to0 7 Pressure is converted as 1MPa 10 1972kgf cm2 10 2kgf cm2 Note 1 Ambient temperature applies when stored or sitting and does not apply to the fluid temperature...

Page 32: ... GS4 and GS6 are assembled by screwing push in joints GWS4 M5 S or GWS6 M5 S to P A B ports 2 M3KA1 a b c Operator type master valve a Position Operator type b Port size c No of stations Code Description Code P A B ports R1 R2 ports PA PB ports Co de Description 1 2 pos single normal close M5 M5 Rc1 8 M5 2 2 station 11 2 pos single normal open GS4 φ4 push in joint 2 2 pos double GS6 φ6 push in joi...

Page 33: ... close S10 S10 2 pos single normal close 2 2 position single normal close S10 S11 2 pos single normal open 3 2 position single normal close S10 S20 2 pos double 4 2 position double S20 MP Masking plate 5 2 position double S20 6 2 position double S20 7 2 position single normal close S10 8 2 position single normal close S10 9 2 position single normal open S11 The method of indicating the manifold co...

Page 34: ...S6 are assembled by screwing push in joints GWS4 M5 S or GWS6 M5 S to A B port 5 3 pos load ports open to supply ports 4 M4KA1 a b c Operation classification master valve a Operator type b Port size c No of stations Code Description Code A B ports P R1 R2 ports PA PB ports Code Description 1 2 pos single operator M5 M5 Rc1 8 M5 2 2 station 2 2 pos double operator GS4 φ4 push in joint 3 3 pos all p...

Page 35: ...ngle operator 2 2 position double S2 S2 2 pos double operator 3 3 position all ports blocked S3 S3 3 pos all ports blocked 4 3 position all ports blocked S3 S4 3 pos load ports open to exhaust ports 5 2 position double S2 S5 3 pos load ports open to supply ports 6 2 position single S1 MP Masking plate 7 3 position load ports open to supply ports S5 The method of indicating the manifold combination...

Page 36: ...d a b c Operation classification master valve a Operator type b Port size c No of stations Code Description Code A B ports P R1 R2 ports PA PB ports Code Description 1 2 pos single operator 06 Rc1 8 Rc1 8 M5 2 2 station 2 2 pos double operator M5 M5 3 3 pos all ports blocked M5Y M5 Rear 20 20 stations 4 3 pos load ports open to exhaust ports H6 φ6 push in joint 5 3 pos load ports open to supply po...

Page 37: ...ngle operator 2 2 position double S2 S2 2 pos double operator 3 3 position all ports blocked S3 S3 3 pos all ports blocked 4 3 position all ports blocked S3 S4 3 pos load ports open to exhaust ports 5 2 position double S2 S5 3 pos load ports open to supply ports 6 2 position single S1 MP Masking plate 7 3 position load ports open to supply ports S5 The method of indicating the manifold combination...

Page 38: ...9 118 4KA141 4KB141 4KA121 4KA151 4KB151 4KB121 3KA131 4K9 111 4KA131 4KB131 4KA141 4K9 112 4KB141 4KA151 4K9 113 4KB151 3 Sub plate kit Individual Function Model example 4KB1 4KB110 06 SUB BASE KIT 4 Sub plate kit Manifold Function Model example M3KA1 M4KA110 M5 SUB BASE KIT M4KA1 M4KB1 M4KB110 SUB BASE KIT 5 Gasket kit Function Model example M3KA1 M4KA110 GASKET KIT M4KA1 4KB1 M4KB1 M4KB110 GASK...

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