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SM-P00077-A/3

4. MAINTENANCE AND INSPECTION

2020-04-15

MAINTENANCE AND INSPECTION

4.1

Periodic Inspection

WARNING

Turn off the power, stop the supply of compressed air, and make sure that there is no residual
pressure before maintenance.

Observe the condition to ensure safety.

CAUTION

Plan and perform daily and periodic inspections so that maintenance can be managed
properly.

If maintenance is not properly managed, the product's functions may deteriorate significantly and
this may lead to faults (such as short service life, damage, and malfunction) or accidents.

In order to use the product under optimum conditions, perform a periodic inspection once or twice a year.

◼

Pressure of supplied compressed air

• Is the set pressure supplied?
• Does the pressure gauge indicate the set pressure during operation of the device?

◼

Pneumatic filter

• Is drainage correctly discharged?
• Are the bowl and element clean enough to use?

◼

Leakage of compressed air from piping connections

• Are all connections, especially at movable sections, correctly connected?

◼

Operation of solenoid valves

• Is there any delay in operation?
• Are the valves exhausting properly?

◼

Operation of pneumatic actuator

•  Are operations smooth?
•  Is the actuator reaching the end stop properly?
•  Are loads connected properly?

◼

Lubricator

• Is the oil rate correctly adjusted?

◼

Lubricant

• Is the specified lubricant supplied?

◼

Screws

• Are there any loose screws?

Содержание M3GA/B R Series

Страница 1: ...SERIES M 4GA B R SERIES M 3GD E R SERIES M 4GD E R SERIES Single Valve Manifold Metal Base SM P00077 A 3 SM 358642 Read this Instruction Manual before using the product Read the safety notes carefully...

Страница 2: ...such as solenoid valves motor valves and air operated valves is intended for users who have basic knowledge about materials fluids piping and electricity CKD shall not be responsible for accidents cau...

Страница 3: ...gs and precautions described in this Instruction Manual to ensure device safety Although various safety measures have been adopted in the product customer s improper handling may lead to an accident T...

Страница 4: ...press machine brake circuit and safety measures For applications where life or properties may be adversely affected and special safety measures are required Exception is made if the customer consults...

Страница 5: ...w to mount a base piping type single valve 33 2 3 3 How to mount a manifold 34 2 4 Piping 36 2 4 1 Recommended tightening torque 36 2 4 2 Seal material 37 2 4 3 Flushing 37 2 4 4 M5 fitting 37 2 4 5 B...

Страница 6: ...lace a cartridge type fitting 4GA B R 4GD E R 71 4 2 4 How to change piping connection specifications 4GA B R 73 4 3 Adding a Valve to the Reduced Wiring Manifold 74 4 3 1 How to add to the position w...

Страница 7: ...Name Mounting plate Individual wiring manifold Reduced wiring manifold figure shown is DIN rail mount Common terminal block T10 M3 thread fastening type Common terminal block T11 Clamping type D sub...

Страница 8: ...EW 2 2020 04 15 Serial transmission T6 Serial transmission T8 DIN terminal box B Socket with cover EJ Flat cable connector T50 Flat cable connector T51 Pressure sensor G1 Pressure sensor G2 Residual p...

Страница 9: ...16 Masking plate Plate replaced by a single valve when adding a valve 17 Fitting stopper plate Plate used for securing a cartridge type fitting Not interchangeable with No 11 2 18 Electrical component...

Страница 10: ...ts green while the coil is energized 36 Coil assembly Coil assembly provided for DIN terminal box type valve Not interchangeable with No 3 37 Socket with cover Socket provided with a covered cabtyre c...

Страница 11: ...All ports closed E Side base piping 4 3 position ABR connection 5 3 position PAB connection 1 NC Normally closed 3GA 3GD 11 NO Normally open 3GA 3GD 66 Two 3 port valves integrated type NC NC 67 Two...

Страница 12: ...suppressor lamp BN DIN terminal box Pg7 without terminal box With surge suppressor E type connector top and side socket entries E0 Lead wire 300 mm E00 Lead wire 500 mm E01 Lead wire 1000 mm E02 Lead...

Страница 13: ...External pilot A Ozone cutting oil proof S Surgeless E Low heat generating energy saving circuit F Built in A B port filter G1 1 port detection type pressure sensor pressure range 0 MPa to 0 7 MPa G2...

Страница 14: ...3GD 66 Two 3 port valves integrated type NC NC 67 Two 3 port valves integrated type NC NO 76 Two 3 port valves integrated type NO NC 77 Two 3 port valves integrated type NO NO 8 Mixed f Electrical co...

Страница 15: ...L shape push in fitting downward Rc3 8 CX Mix push in fitting Rc1 8 Rc1 4 Rc3 8 M5 M5 Rc1 8 06 Rc1 8 Rc1 4 08 Rc1 4 Rc3 8 C3N 1 8 push in fitting 1 8NPT C4N 5 32 push in fitting 1 8NPT C6N 1 4 push in...

Страница 16: ...Lead wire 300 mm With surge suppressor lamp E20 Lead wire 500 mm With surge suppressor lamp E21 Lead wire 1000 mm With surge suppressor lamp E22 Lead wire 2000 mm With surge suppressor lamp E23 Lead...

Страница 17: ...Left side connection T53R Right side connection T6A0 UNI WIRE SYSTEM NPN 8 points T6A1 NPN 16 points T6C0 CompoBus S NPN 8 points T6C1 NPN 16 points T6E0 S Link NPN 8 points T6E1 NPN 16 points T6G1 CC...

Страница 18: ...ow heat generating energy saving circuit F Built in A B port filter G1 1 port detection type pressure sensor pressure range 0 MPa to 0 7 MPa G2 2 port detection type pressure sensor pressure range 0 M...

Страница 19: ...30 or more 30 58 5 48 5 25 5 17 12 R3 8 SLW 10L 30 or more 60 68 2 58 4 28 19 12 R3 8 Blanking plug Model D L d PG P2 B 1 8 20 13 5 GWP4 B 4 27 16 6 GWP6 B 6 29 11 5 8 GWP8 B 8 33 14 10 GWP10 B 10 40...

Страница 20: ...box Coil assembly for reduced wiring 4GR A2N Option COIL Rated voltage 3 24 VDC 4 12 VDC Blank Standard A Ozone proof Lead wire related parts Part name Model number E type connector socket assembly 4G...

Страница 21: ...elbow Note 1 4G2R JOINT CL6N CLL6N 5 16 inch elbow Note 1 4G2R JOINT CL8N CLL8N Plug cartridge 4G2R JOINT CPG 4G3 R 6 straight 4G3R JOINT C6 8 straight 4G3R JOINT C8 10 straight 4G3R JOINT C10 8 elbo...

Страница 22: ...G3R JNT ADAPTOR KIT C8N 1 2 C10N 4G3R JNT ADAPTOR KIT C10N 1 2 1 Specify NC for 3GA 10R NO for 3GA 110R and leave blank for models other than 3GA 10R and 3GA 110R 2 Specify F for built in A B port fil...

Страница 23: ...247 5 260 300 287 5 260 272 5 312 5 300 272 5 285 325 312 5 285 297 5 337 5 325 297 5 310 350 337 5 310 322 5 362 5 350 322 5 335 375 362 5 335 347 5 387 5 375 347 5 360 400 387 5 360 372 5 412 5 400...

Страница 24: ...del Model number 3G1 R 4G1 R 4G1R SET SCREW 3G2 R 4G2 R 4G2R SET SCREW 3G3 R 4G3 R 4G3R SET SCREW 3GA3 R 4GA3 R for 08 port size 4G3R SET SCREW L DIN rail kit Model Model number Kit contents M4G1 R 4G...

Страница 25: ...r socket assembly 4G 1R SOCKET ASSY A 2 3 4 1 Series 2 Connection specifications 3 Solenoid coil position 4 Socket row no Symbol Description Symbol Description Symbol Description Symbol Description 1...

Страница 26: ...and oil from splashing onto the product DIN terminal box is rated IP65 water jet proof provided that a cord cable with an appropriate outside diameter is used and the terminal box is secured in place...

Страница 27: ...0 70 0 34 ABR connection 1 1 0 33 0 72 0 34 PAB connection 1 3 0 61 0 72 0 36 3GA2 R 4GA2 R 3GD2 R 4GD2 R Two 3 port valves integrated type 1 8 0 29 2 3 0 32 2 position 2 4 0 33 2 8 0 30 3 position Al...

Страница 28: ...onnection 3 0 0 34 3 8 2 6 0 12 0 27 PAB connection 3 3 0 30 3 3 0 32 M3GB1 R M4GB1 R M3GE1 R M4GE1 R Two 3 port valves integrated type 0 86 0 35 1 1 0 67 0 22 0 23 2 position 1 1 0 22 1 2 0 70 0 20 0...

Страница 29: ...Solenoid position electrical connection 3GD1 R 3GD2 R 3GD3 R 4GD1 R 4GD2 R 4GD3 R 3GE1 R 4GE1 R 3GE2 R 4GE2 R 4GE3 R 2 position Single Grommet lead wire 48 41 110 80 144 102 48 41 115 85 153 111 80 38...

Страница 30: ...n 117 External pilot 36n 105 38 113 88n 135 90n 163 136n 194 138n 223 Base piping Unit g Pilot air exhaust method M3GB1 R M4GB1 R M3GE1 R M4GE1 R M3GB2 R M4GB2 R M3GE2 R M4GE2 R M4GB3 R M4GE3 R Direct...

Страница 31: ...diagram 1 P 2 B 4 A 5 R1 Energized 1 P 4 A 2 B 3 R2 4G 20R 2 position Double SOL a Energized 1 P 4 A 2 B 3 R2 SOL b Energized shown in the diagram 1 P 2 B 4 A 5 R1 After energized solenoid position i...

Страница 32: ...iagram 1 P 2 B Energized 2 B 3 R2 3G 660R 3G 670R 3G 760R 3G 770R Two 3 port valves integrated type 3G 660R De energized 4 A 5 R1 2 B 3 R2 SOL a Energized 1 P 4 A SOL b Energized 1 P 2 B 3G 670R De en...

Страница 33: ...ng cylinder connected to ABR connection valve due to the flow of back pressure caused by actuation of other cylinders Note that this option cannot be selected for valves with all ports closed and PAB...

Страница 34: ...such as sulfur dioxide gas or solvents are present Do not use the product in a humid environment Condensation may occur due to a change in the temperature Do not use the product in an explosive gas en...

Страница 35: ...use Secure sufficient space around the solenoid valve for installation removal wiring and piping 2 3 Mounting CAUTION Do not use a method of mounting that relies on support from the piping when mounti...

Страница 36: ...s When using screw holes the recommended tightening torque is 0 7 N m to 1 2 N m 4GA1 R Series has only through holes 4GA1 R Series 4GA2 R Series 4GA3 R Series Mounting hole shape 4GA2 R Series 4GA3 R...

Страница 37: ...tion Attach the valve and the mounting plate in the right direction and use correct holes since damage can occur if not mounted correctly For grommet lead wire and E type connector DC voltage connecti...

Страница 38: ...nal box and E type connector AC voltage connections 4GA1 R 4GD1 R Series 2 position single 2 position double 3 position 4GA2 R 4GD2 R Series 2 position single 2 position double 3 position 4GA3 R 4GD3...

Страница 39: ...ounting hole 2 4 4 Mounting hole 2 3 2 How to mount a base piping type single valve The base piping type single valve can be mounted using through holes in the subbase 4GB1 R 4GE1 R Series 4GB2 R 4GE2...

Страница 40: ...t intervals of 50 mm to 100 mm and make sure that there is no abnormality with the mounting condition M4G1 R Series M4G2 R M4G3 R Series Lock nut Mounting screw Make sure to tighten the lock nuts Be c...

Страница 41: ...proper tightening torque The recommended tightening torque is 1 0 N m to 1 5 N m M4G1 R Series has only through holes If not mounted correctly the threads may become damaged M4G2 R M4G3 R Series Moun...

Страница 42: ...ir for the first time after connecting the pipes tubes Sudden introduction of highly pressurized air may cause the tubes to become disconnected and jump around and an accident may occur Do not decreas...

Страница 43: ...e foreign matters 2 4 4 M5 fitting M5 fitting is sealed using a gasket Do not retighten when pressure is applied in the pneumatic circuit Design and construct the piping system in such a way that the...

Страница 44: ...e diameter mm Nylon Urethane 1 8 1 2 4 2 5 2 6 4 4 8 5 7 5 10 7 2 6 5 Minimum allowable bending radius of tubes Observe the minimum allowable bending radius of tubes Neglecting the minimum allowable b...

Страница 45: ...mmon to 4GB1 R through 4GB3 R Manifold M4GB1 R M4GB2 R M4GB3 R External pilot air supply port External pilot air exhaust port Mounting hole External pilot air supply port is located on the top surface...

Страница 46: ...he safety CAUTION Check the power supply voltage and the type of current AC or DC before supplying power Do not apply stress to the lead wires Undue stress may cause such problems as disconnection of...

Страница 47: ...b from the slot and pull it out straight Connecting the lead wires Strip the end of the lead wires by approximately 3 mm Align the end of conductors insert them into the contact terminal and crimp wit...

Страница 48: ...crew 1 to remove the connector from coil assembly 12 Pull out screw 1 from cover 2 Locate notch 9 next to the GDSN mark at the bottom of terminal block 3 Insert a compact flat blade screwdriver into n...

Страница 49: ...m into cover 2 Wire the cable to terminals 1 and 2 There is no polarity Recommended tightening torque is 0 2 N m to 0 25 N m For AC type establish a ground connection For DC type a ground connection i...

Страница 50: ...s the user refer to the figure below Voltage drop occurs when energizing solenoids at the same time or depending on the cable length Make sure that the voltage drop on the solenoid does not exceed 10...

Страница 51: ...14 13 12 11 10 9 Valve no 8b 8a 7b 7a 6b 6a 5b 5a Terminal no 8 7 6 5 4 3 2 1 Valve no 4b 4a 3b 3a 2b 2a 1b 1a Mixed both single and double solenoid valves are mounted Maximum of 16 solenoids Terminal...

Страница 52: ...9 8 7 6 5 4 3 2 1 Valve no 6b 6a 5b 5a 4b 4a 3b 3a 2b 2a 1b 1a Mixed both single and double solenoid valves are mounted Maximum of 24 solenoids Terminal no 24 23 22 21 20 19 18 17 16 15 14 13 Valve no...

Страница 53: ...nal arrays of the PLC output unit must match signal arrays on the valve side Only 24 VDC or 12 VDC power can be used Maximum number of solenoids is 24 Wiring exceeding the maximum number is unavailabl...

Страница 54: ...b 10b 11b 12b Mixed both single and double solenoid valves are mounted Maximum of 24 solenoids Pin no 1 2 3 4 5 6 7 8 9 10 11 12 13 Valve no 1a 3a 4a 5a 7a 8a 10a 11b 12b 14a 15b 17a COM Pin no 14 15...

Страница 55: ...socket HDBB 25S Hirose Electric Co Ltd Solder type D sub connector socket JAZ 25S J S T Mfg Co Ltd Crimp type D sub connector socket CDB 25S Hirose Electric Co Ltd Crimp type D sub connector socket J...

Страница 56: ...connector terminal no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Conductor identifiers Insulator color Orange Orange Yellow Yellow Green Green Gray Gray White White Orange Orange Yellow Yellow Green Mark ty...

Страница 57: ...ections with the PLC are limited Use the cable specified by the PLC manufacturer Only 24 VDC or 12 VDC power can be used When driving T50 type with a general output unit use the terminal 20 10 of the...

Страница 58: ...7 8 9 10 Valve no 1a 1b 2a 2b 3a 3b 4a 4b power power Mixed both single and double solenoid valves are mounted Maximum of 16 solenoids Pin no 11 12 13 14 15 16 17 18 19 20 Valve no 7a 7b 8a 9a 10a 10...

Страница 59: ...he terminal block Use crimp terminals for M3 screws with width of 6 4 or less and secure the screws with a tightening torque of 0 3 N m to 0 5 N m How to connect to PLC Make sure that the signal line...

Страница 60: ...o the input unit may cause damage not only to the manifold itself but also to peripheral devices Do not connect this manifold to the input unit Manifold stations are numbered in order from left to rig...

Страница 61: ...14 12 10 8 6 4 2 Valve no COM 9b 8b 7b 6b 5b 4b 3b 2b 1b Mixed both single and double solenoid valves are mounted Maximum of 18 solenoids Pin no 19 17 15 13 11 9 7 5 3 1 Valve no COM 12a 11a 10a 8a 7a...

Страница 62: ...2a Double solenoid valve Maximum of 4 stations Pin no 9 7 5 3 1 Valve no COM 4a 3a 2a 1a Pin no 10 8 6 4 2 Valve no COM 4b 3b 2b 1b Mixed both single and double solenoid valves are mounted Maximum of...

Страница 63: ...7b 6b 5b 4b 3b 2b 1b Mixed both single and double solenoid valves are mounted Maximum of 24 solenoids Pin no 25 23 21 19 17 15 13 11 9 7 5 3 1 Valve no COM 16a 15a 14a 12a 10a 9a 8a 7a 5b 4b 3a 1a Pi...

Страница 64: ...g mechanism may not be suitable In such a case secure the lock lever with a strap such as a cable tie For T50 T51 Part name Model Manufacturer Socket XG4M 2030 Omron Corporation Strain relief XG4T 200...

Страница 65: ...Cable This system in general uses flat cables or thin multi conductor cables These cables have thin conductors and must be checked that they have sufficient mechanical strength and electrical capacity...

Страница 66: ...en once it will require periodic lubrication from then on Make sure to keep it lubricated Do not use either spindle oil or machine oil They induce expansion of the rubber parts which will cause operat...

Страница 67: ...t mixes in with oxidized oil tar or carbon the sliding section of the pneumatic components will wear out Use compressed air that does not contain solid foreign matters If solid foreign matters in comp...

Страница 68: ...ay time to determine serviceability If necessary take a different measure against surge The 4G R Series solenoid valves equipped with a surge suppressor suppress the terminal to terminal reverse volta...

Страница 69: ...cannot be maintained Do not raise the voltage gradually when using this type The valve cannot be operated Solenoid valves of low heat generating energy saving circuit models have built in PWM circuit...

Страница 70: ...re live parts An electric shock may occur Do not touch live parts with bare hands An electric shock may occur Install the product and its wiring away from sources of noise such as high voltage lines a...

Страница 71: ...istics 2 FS or less Output current 0 5 mA max load resistance 10 k Wiring method Connector Wire length 1000 mm How to open and close the manual protection cover of valve with pressure sensor Open the...

Страница 72: ...Tighten the pressure sensor mounting screws Recommended tightening torque is 0 17 N m How to replace the solenoid valve 4GB1 R Series 1 Remove the pressure sensor 2 Replace the solenoid valve 3 Mount...

Страница 73: ...protection cover will not close unless the locking manual override is released Manual override has both locking and non locking overrides It is locked by pressing down and turning the lever When locki...

Страница 74: ...sidual pressure exhaust Non locking type option symbol X Push the operating tab in the direction of the arrow Residual pressure can be exhaused while the operating tab is pushed Release the tab to fin...

Страница 75: ...under optimum conditions perform a periodic inspection once or twice a year Pressure of supplied compressed air Is the set pressure supplied Does the pressure gauge indicate the set pressure during op...

Страница 76: ...id valve When replacing the solenoid valve use extreme care so that the gasket and pilot check valve do not fall off Model Screw size Tightening torque N m 4G1 R M1 7 0 18 to 0 22 4G2 R M2 5 0 35 to 0...

Страница 77: ...bottom 4 Insert the fitting stopper pin 5 Pull on the fitting and confirm that it is installed correctly 4GA1 R 4GA2 R 4GA3 R Body piping 4GD R type Remove the mounting screws Pull out the fitting st...

Страница 78: ...oove on the replacement fitting to the fitting stopper plate and assemble them temporarily Mount the fitting stopper plate and fitting at the same time and tighten the mounting screw Model Screw size...

Страница 79: ...he body piping specifications and base piping specifications or when changing the push in fitting and internal thread specifications of body piping type Insufficient tightening causes problems such as...

Страница 80: ...iring to the b side solenoid to be added is required To add the valve to where no spare wiring is equipped follow the steps below 1 Remove the electrical component cover and open the reduced wiring co...

Страница 81: ...ng the tip of a precision screw driver to the cable through hole on the cover Do not use a pointed tool so as not to damage the cable while hooking the cover How to close the reduced wiring cover Pass...

Страница 82: ...20 19 18 17 16 15 14 13 Valve no Empty Empty Empty Empty 20a 19a 18a 17a 16a 15a 14a 13a Connector no 12 11 10 9 8 7 6 5 4 3 2 1 Valve no 12a 11a 10a 9a 8a 7a 6a 5a 4a 3a 2a 1a 2 Double solenoid valv...

Страница 83: ...y maximum of 18 stations Connector no 17 15 13 11 9 7 5 3 1 Valve no 17a 15a 13a 11a 9a 7a 5a 3a 1a Connector no 18 16 14 12 10 8 6 4 2 Valve no 18a 16a 14a 12a 10a 8a 6a 4a 2a 2 Double solenoid valve...

Страница 84: ...18 16 14 12 10 8 6 4 2 Valve no Empty Empty Empty Empty Empty Empty Empty 8a 6a 5a 4a 2a T8 1 Single solenoid valves only maximum of 20 stations Connector no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Val...

Страница 85: ...w rate is insufficient Inspect and correct the piping or install a surge tank Pressure is supplied through exhaust port Inspect and correct the piping Piping is incorrect or omitted Inspect and correc...

Страница 86: ...tandard Supply port 1 P Output port 4 A Output port 2 B Exhaust port 5 R1 Exhaust port 3 R2 Pilot air supply port 12 14 PA Pilot air exhaust port 82 84 PR There is no restriction on the mounting orien...

Страница 87: ...avoided if the customer s machinery or device into which the product is incorporated had functions and structures generally provided in the industry Failure caused by reasons unforeseen at the level o...

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