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SMC Networks ZK2 Series Operation Manual

Ejector / vacuum pump system
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No. ZK2-OM00201
PRODUCT NAME
Vacuum Unit
Ejector / Vacuum Pump System
MODEL / Series / Product Number
ZK2 Series

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Summary of Contents for SMC Networks ZK2 Series

  • Page 1 No. ZK2-OM00201 PRODUCT NAME Vacuum Unit Ejector / Vacuum Pump System MODEL / Series / Product Number ZK2 Series...

  • Page 2: Table Of Contents

    Contents Safety Instructions 1. How to Order 2. Summary of Product Parts 3. Installation 3.1. Installation 3.2. Air Supply 3.3. Piping 4. Solenoid Valve 5. Pressure Sensor/Pressure Switch 6. Construction/Replacement Parts 6.1. Construction for Single Unit 6.2. Component Parts 6.3. Replacement Parts 6.4.

  • Page 3: Safety Instructions

    Safety Instructions These safety instructions are intended to prevent hazardous situations and/or equipment damage. These instructions indicate the level of potential hazard with the labels of “Caution,” “Warning” or “Danger.” They are all important notes for safety and must be followed in addition to International Standards (ISO/IEC) and other safety regulations.
  • Page 4 Safety Instructions Caution 1. The product is provided for use in manufacturing industries. The product herein described is basically provided for peaceful use in manufacturing industries. If considering using the product in other industries, consult SMC beforehand and exchange specifications or a contract if necessary.

  • Page 5: Explanation Of Symbols

    ■Explanation of Symbols S ym b o l Definition Things you must not do. Instructions are provided as a drawing or sentence next to the symbol. Things you must do Instructions are provided as a drawing or sentence next to the symbol. ■Operator 1.
  • Page 6 ■Safety Instructions Warning Do not disassemble, modify (including the replacement of board) or repair other than instructed in this manual. Otherwise, an injury or failure can result. Disassembly prohibited Do not operate the product outside of the specifications. Do not use for flammable or harmful fluids. Fire, malfunction, or damage to the product can result.

  • Page 7: Product Specifications

    Caution Do not touch the terminals and connectors while the power is on. Otherwise electric shock, malfunction or damage to the switch can result. Do not touch Perform sufficient trial run. Otherwise, injury or damage to the system can result due to suction failure depending on the conditions of the suction of the workpiece or the pressure switch settings.
  • Page 8 ● Product handling  Installation - Tighten to the specified tightening torque. If the tightening torque is exceeded, the product, the mounting screws, brackets and the pressure switch can be broken. Insufficient torque can cause displacement of the product and the pressure switch from each proper position and loosening of the mounting screws.
  • Page 9  Operating environment - Do not use in an environment where corrosive gases, chemicals, sea water, water or steam are present. These may cause failure or malfunction. - Do not use the product in a place where the product could be splashed by oil or chemicals. If the product is to be used in an environment containing oils or chemicals such as coolant or cleaning solvent, even for a short time, the solenoid valve or pressure switch/sensor may be adversely affected (damage, malfunction, or hardening of the lead wires).
  • Page 10  Piping - Preparation before piping Before piping, perform air blow (flushing) or cleaning to remove any cutting chips, cutting oil, dust, etc. from the piping. - Wrapping of pipe tape When installing piping or a tube fitting into a port, prevent cutting chips and sealant material from getting inside the product. If a sealant tape is used, leave 1 thread exposed at the end of threads.

  • Page 11: How To Order

    1. How to Order ■Single Unit Ejector System ZK2 A 12 K 5 A L - 08 - Vacuum Pump System ZK2 P 00 K 5 A L - 08 - (1) (2) (3) (4) (5) (6) Remains blank when no potion is selected.
  • Page 12 (5) Pressure Sensor/Pressure Switch for Vacuum Symbol Type Pressure range [kPa] Specifications 0 to -101 Analog output 1 to 5V Note 10) Pressure sensor -100 to 100 Analog output 1 to 5V Note 12) Unit selection function 2 outputs Note 13) SI unit only 0 to -101 Note 12)
  • Page 13 Note 16) (7) Vacuum (V) port Symbol Standard Port size ø6 One-touch fitting Metric size ø8 One-touch fitting ø1/4” One-touch fitting Inch size ø5/16” One-touch fitting Note 16) Supply port (PV) size of single unit: ø6 (mm), ø1/4” (inch) Note 17) (8) Options Symbol Type...
  • Page 14 ■Manifold ZZK2 04 - A 1 L - (2) (3) (4) Remains blank when no potion is selected. Note 1) (1) Number of stations Symbol Stations 1 station 2 stations 10 stations Note 1) In the case of an ejector, for an adequate performance, the number of stations when operated simultaneously depends on the nozzle diameter.
  • Page 15 Note 8) (4) Wiring Symbol Type Note 9) Individual wiring Note 10) D-sub connector (25 pins) Note 10) Flat ribbon cable connector (26 pins) No wiring (No valve) Note 8) Common wiring is available only solenoid valve wiring. Individual wiring is specified for vacuum switches and sensors. Note 9) Select “L”, “L#”, or “W”...

  • Page 16: Summary Of Product Parts

    2. Summary of Product Parts ■Single unit (Ejector system) Supply valve manual override Valve Assembly Release valve manual override Pressure switch for vacuum Air pressure supply (PV) port 2 x ø4.5 Mounting hole Vacuum break flow adjusting needle Silencer exhaust port Exhaust port (nozzle size 1.2, 1.5 only) Vacuum (V) port Filter case...
  • Page 17 ■Pressure switch for vacuum Name Function Output (OUT1) LED LED (Green) is ON when the switch output (OUT1) is ON. (Green) Pressure switch for vacuum: Output (OUT2) LED LED (Red) is ON when the switch output (OUT2) is ON. (Red) Pressure switch for vacuum with energy saving function: supply valve is energized.

  • Page 18: Installation

    3. Installation 3.1. Installation ■ Single Unit 1. DIN rail mounting 1) Insert a precision screwdriver into the groove of the release lever and push in direction (1), and slide the filter case in direction (2). 2) Hook the ejector onto the DIN rail from direction (3) and mount the ejector onto the DIN rail by pushing it down in direction (4).
  • Page 19 3. Bracket mounting 1) Fix the body with the brackets before mounting, using the holes in the body (2 x ø4.5). 2) Mount the body using the holes in the brackets. Note) Mounting bracket for single unit (Option) [Nuts and bolts are included.] Part number: ZK2-BK1-A ■...

  • Page 20: Air Supply

    3.2. Air Supply ■Use clean air (1) Using compressed air which contains chemicals, synthetic oils containing organic solvents, salts or corrosive gases, etc. can cause damage or malfunction. Do not use compressed air containing toxic impurities. (2) If the compressed air contains excessive drainage or carbon powder, it can stick to the vacuum generating part (the nozzle diffuser) or inside of the solenoid valve or the pressure switch for vacuum and cause deterioration of the performance or operation failure.

  • Page 21: Piping

    3.3. Piping ■ Single unit The sizes of the each port are as follows. (Refer to Application and Operating Pressure Range on page 21.) Size Vacuum Pump System Port Ejector System Metric Inch Metric Inch ø1/4” ø6 ø6 ø1/4” ø6, ø8 1/4”, 5/16”...
  • Page 22 ■ Application and Operating Pressure Range Port Description Ejector System Vacuum Pump System Air pressure supply port Compressed air supply for operating ejector Note 1) (Operating pressure range) 0.3 to 0.6 MPa Vacuum pressure supply port Vacuum source (vacuum pump) (Operating pressure range) 0 to -100 kPa Pilot pressure supply port...
  • Page 23 2. Removal of the tube (1) Push the release button flange evenly and sufficiently to release the tube. Do not push in the tubing before pressing the release button. (2) Hold down the release button while pulling out the tube. If the release button is not held down fully, it will be more difficult to pull out the tube.

  • Page 24: Solenoid Valve

    4. Solenoid Valve ■ Manual override operation Manual override is non-locking push type. Push the manual override with a screwdriver of a diameter smaller than indicated in the diagram until it reaches the end. Confirm that the product operates safety before the manual override is operated. Note) When valve type R is selected, the supply valve can hold the position and will not switch off even if the supply valve manual override operation is finished unless the release valve manual override is pressed.
  • Page 25 ■ Electrical wiring 1. Wiring (1) Individual wiring To install the connector, hold the cover and insert the connector straight pushing the connector lever with your finger. Ensure that the connector lever clip is properly inserted onto mating part. To remove the connector, hold the cover and pull out the connector straight pushing the connector lever clip. Note) Do not pull the lead wire excessively, as this damage the connector or cover.
  • Page 26 2. Internal Circuit Wiring should be connected as shown below. Connect with the power supply respectively. Light/surge voltage suppressor circuit is equipped for the valve type J, K and R. Solenoid valve is non-polar type. (1) Individual wiring Valve type: J Valve type: K, R (With supply valve, Without release valve) (With supply valve, With release valve)
  • Page 27 2-2) Flat ribbon cable connector A flat ribbon cable connector conforming to MIL standards is used. 3. LED indication Red LED turns on when supply valve is energized. Green LED turns on when release valve is energized. (1) Individual wiring (2) Common wiring -26- No.
  • Page 28 4. Cable assembly for common wiring D-sub connector cable assembly (1) Assembly part number AXT100-DS25-□ Symbol(□) Cable length L (m) Note Cable 0.3mm x 25 cores For other commercial connectors, use a 25-pin type with female connector conforming to MIL-C-24308. Cannot be used for movable wiring.
  • Page 29 Flat ribbon cable connector assembly (1) Assembly part number AXT100-FC26-□ Symbol(□) Cable length L (m) For other commercial connectors, use a 26-pin type with strain relief conforming to MIL-C-83503. Cannot be used movable wiring. (2) Terminal number Connector manufacturers’ example HIROSE ELECTRIC CO., LTD.

  • Page 30: Pressure Sensor/Pressure Switch

    5. Pressure Sensor/Pressure Switch ■Internal circuit and wiring examples Pressure sensor ZK2-PS□-A Pressure switch for vacuum ZK2-ZS□A□□-A ZK2-ZS□B□□-A (NPN 2 outputs) (PNP 2 outputs) The FUNC terminal is connected when using the copy function. (Refer to the ZSE10/ISE10 Operation Manual) Pressure switch for vacuum with energy saving function ZK2-ZSVA□□-A ZK2-ZSVB□□-A...

  • Page 31: Construction/Replacement Parts

    6. Construction/Replacement Parts 6.1. Construction for Single Unit (Including single unit for manifold) Pressure switch with energy saving function Pressure switch for vacuum Pressure sensor High-noise reduction silencer 6.2. Component Parts Item Material Remarks Valve body assembly Resin HNBR, NBR and steel are also used Needle assembly Brass Electroless nickel plated brass, resin, steel and NBR are used...

  • Page 32: Replacement Parts

    6.3. Replacement Parts Item Remarks Valve assembly Connector for solenoid valve 3 wires (For valve type K, R), Connector assembly 2 wires (For valve type J) One-touch fitting assembly Standard supply (PV) port: ø6, ø1/4” Sound absorbing material 10 pcs. per set With One-touch fitting and filter element Vacuum port adapter assembly (Case material: Polycarbonate)
  • Page 33 (7) Connector assembly ZK2 - LV W Valve type: K, R Valve type: J Applicable valve type Lead wire length 300 mm Valve type K, R (With supply valve 600 mm and release valve) 1000 mm 2000 mm Valve type J (Supply valve only) 3000 mm (8) One-touch fitting assembly...
  • Page 34 (11) Filter element (10 pcs. per set) ZK2 - FE1 - 3 - A Nominal filtration rating μm Note) (12) Check valve (10 pcs. per set) ZK2 - CV - A Note) When mounting a check valve additionally, the workpiece may not be removed unless vacuum release pressure is applied. (13) Pressure switch for vacuum assembly ZK2-ZS E A M G [1] [2] [3] [4] [5]...
  • Page 35 (14) Lead wire with connector (When individual lead wire is necessary, order with the part number below.) Lead wire with connector for pressure switch for vacuum ZS - 39 - 5G Lead wire with connector for pressure switch with energy saving function ZK2 - LW A 20 - A Output specifications NPN open collector...

  • Page 36: Exploded View Of Manifold/Replacement Parts

    7. Exploded View of Manifold/Replacement Parts 7.1. Exploded View of Manifold Individual wiring Common wiring 7.2. How to Increase Manifold Stations 7.2.1 Individual wiring specifications 1) Remove two tension bolts. 2) Remove the end plate U. (Be careful not to drop the gasket.) 3) Mount a single unit to the end surface of U side.
  • Page 37 7.2.2 Common wiring specifications ■ To increase the number of stations from odd number (1, 3, 5, 7, 9) to even number (2, 4, 6, 8, 10) (Common wiring of odd number station has a vacant connector for one station. Easy to add a station.) 1) Remove the tension bolt.
  • Page 38 ■ To increase the number of stations from even number to odd number, or increase two stations or more 1) Remove the valve assembly for all stations. (Single unit for extra station is also removed.) 2) Remove the switch assembly if it is present. (Be careful not to drop the O-ring. Refer to Fig.1) 3) Remove the junction box B (top) for all stations using a precision screwdriver.

  • Page 39: Component Parts

    7.3. Component Parts Item Material Remarks End plate D assembly Resin HNBR, NBR and steel are also used End plate U assembly Resin Electroless nickel plated brass, steel and NBR are also used 7.4. Replacement Parts Item Remarks Tension bolt assembly 2 pcs.
  • Page 40 (4) Port plug assembly (5) Port plug assembly (Purchasing order is available in units of 1 piece.) (Purchasing order is available in units of 1 piece.) VVQZ2000 - CP ZK2 - MP1C6 - A (6) One-touch fitting assembly (Purchasing order is available in units of 10 pieces.) VVQ1000 - 51A - C8 One-touch fitting size ø8 One-touch fitting...
  • Page 41 (9) Connector housing assembly ZK2 - CH 2 04 - A Connector type Applicable stations D-sub connector (25 pins) For 2 stations manifold Flat ribbon cable connector (26 pins) For 4 stations manifold For 6 stations manifold For 8 stations manifold For 10 stations manifold *Plug (For One-touch fitting) (Purchasing order is available in units of 10 pieces.)

  • Page 42: Maintenance

    8. Maintenance 8.1. Maintenance Implement the maintenance and check shown below in order to use the ejector and the vacuum pump system safely and in an appropriate way for a long period of time. 1 Maintenance should be performed according to the procedure indicated in the Operation Manual. Improper handling can cause damage and malfunction of equipment and machinery.

  • Page 43: Replacement Procedure

    9) Be sure to ground the frame ground (FG) terminal when using a commercially available switching power supply. 10) Eliminate any dust left in the piping by using a blast of air before connecting the piping to the product. Otherwise, failure or malfunction may occur. 11) If the fluid contains foreign matter, install and connect a filter or mist separator to the inlet.
  • Page 44 4) Put the filter back into the filter case following this procedure in reverse. To mount the vacuum port adapter into the filter case, turn the adapter so that the mating mark of the adapter and the case are aligned. (Rotation stops there.) If it is difficult to remove the vacuum port adapter, you can remove the adapter with a hexagon wrench using the hexagonal hole in V port.
  • Page 45 3) To remove the clip that holds the port plug, insert a precision screwdriver from the release lever notch. Move the screwdriver in direction (1) to pull out the clip in direction (2). 4) Remove the port plug. Slide back the release lever. 5) Remove the sound absorbing material from the slit (hole) at the side of the body by using a precision screwdriver.
  • Page 46 8.2.3. Replacement procedure for High-noise Reduction Silencer Case Assembly Refer to Replacement procedure for Sound Absorbing Material (for Silencer Exhaust) on page 43 to replace the assembly. Note) When a high-noise reduction silencer case assembly is attached to System/Body Type “A” (silencer exhaust), the silencing effect cannot be acquired.
  • Page 47 8.2.5. Filter case maintenance 1) When the filter case is dirty, it can be removed and cleaned. To remove the filter case, insert a precision screwdriver into the groove of the release lever and push in direction (1), and slide the filter case in direction (2). Note) Surface A of the filter case is the sealing surface when vacuum is generated.

  • Page 48: Specifications

    9. Specifications ■General Specifications -5 to 50 C (Without pressure sensor and pressure switch, With pressure switch) 0 to 50 C (With pressure sensor) Ambient temperature range 5 to 50 C (With pressure switch with energy saving function) (No condensation) Fluid 30m/s (Without pressure sensor and pressure switch, With pressure sensor)
  • Page 49 ■Ejector Specifications Model ZK2□07 ZK2□10 ZK2□12 ZK2□15 Nozzle diameter (mm) (L/min(ANR)) Port exhaust Max. suction Silencer exhaust/Complex exhaust (L/min(ANR)) Note 6) flow High-noise reduction silencer exhaust (L/min(ANR)) Note 6) Air consumption (L/min(ANR)) Note 6) Max. vacuum pressure (kPa) Note 7) Supply pressure range (MPa) 0.3 to 0.6 (0.1 to 0.6)
  • Page 50 ■Pressure Switch for Vacuum (For details, refer to the ZSE10/ISE10 series in the Best Pneumatics No. 8 catalog, and the Operation Manual.) Model ZK2-ZSE□□□-A ZK2-ZSF□□□-A (Switch unit: Standard model number) (ZSE10) (ZSE10F) Rated pressure range 0 to -101 kPa -100 to 100 kPa Set/Display pressure range 10 to -105 kPa -105 to 105 kPa...
  • Page 51 ■Pressure Switch for Vacuum with energy saving function (For details, refer to the ZK2-ZSV□□□-A Operation Manual.) Model ZK2-ZSV□□□-A Rated pressure range -100 to 100 kPa Set/Display pressure range -105 to 105 kPa Proof pressure 500 kPa Minimum setting unit 0.1 kPa 12 to 24 VDC ±10%, Ripple (P-P) 10% or less Power supply voltage (Protected against reverse connection)
  • Page 52 ■Weight Single Unit Model of a single unit Weight (g) ZK2P00K□N□ (Vacuum pump, without pressure sensor and pressure switch) ZK2A□K□N□ (Ejector, without pressure sensor and pressure switch) ZK2A□N0NN (Ejector, without valve) ZK2C□K□N□ (Ejector for manifold, without pressure sensor and pressure switch) Pressure Sensor, Pressure switch for vacuum Model of pressure sensor and pressure switch for vacuum Weight (g)

  • Page 53: Port Layout

    10. Port Layout ■Standard products (No Option) Port Port combination: PV  PS = PD Layout No. Single unit: ZK2P00□□□□-□ System Vacuum pump Body type Single unit Exhaust type Without silencer Application Vacuum pressure Exhaust purpose Release pressure Same pressure as PS Port Port combination: Common PV ...
  • Page 54 Port Port combination: PV = PS = PD Layout No. Single unit: ZK2A□□□□□□-□ System Ejector Body type Single unit Exhaust type Silencer exhaust Application Vacuum pressure Exhaust Released in operating environment purpose Release pressure Same pressure as PV Port Port combination: PV = PS = PD Layout No.
  • Page 55 Port Port combination: PV = PS = PD Layout No. Single unit: ZK2G□□□□□-□ System Ejector Body type Single unit Exhaust type High-noise reduction silencer exhaust Application Vacuum pressure Exhaust Released in operating environment purpose Release pressure Same pressure as PV Port Port combination: Common PV = Common PS = Common PD Layout No.
  • Page 56 Port Port combination: Common PV = Common PS = Common PD Layout No. Single unit: ZK2F□□□□□-□ Manifold: ZZK2□□-A2□ System Ejector Body type Manifold Exhaust type Individual port exhaust Vacuum pressure Common for each station Application After piping, individual exhaust Exhaust is necessary.
  • Page 57 ■Option -D (With individual release pressure supply(PD) port) Port Port combination: PV  PS  PD Layout No. Single unit: ZK2P00□□□□-□-D System Vacuum pump Body type Single unit Exhaust type Without silencer Application Vacuum pressure Exhaust purpose Release pressure PD pressure has to be supplied with PS pressure. Port Port combination: Common PV ...
  • Page 58 Port Port combination: PV = PS  PD Layout No. Single unit: ZK2A□□□□□□-□-D System Ejector Body type Single unit Exhaust type Silencer exhaust Application Vacuum pressure Exhaust Released in operating environment purpose Release pressure PD pressure has to be supplied with PV pressure. Port Port combination: PV = PS ...
  • Page 59 Port Port combination: PV = PS  PD Layout No. Single unit: ZK2G□□□□□-□-D System Ejector Body type Single unit Exhaust type High-noise reduction silencer exhaust Application Vacuum pressure Exhaust Released in operating environment purpose Release pressure PD pressure has to be supplied with PV pressure. Port Port combination: Common PV = Common PS ...
  • Page 60 Port Port combination: Common PV = Common PS  Common PD Layout No. Single unit: ZK2F□□□□□□-□-P Manifold: ZZK2□□-A2□-D System Ejector Body type Manifold Exhaust type Individual port exhaust Vacuum pressure Common for each station Application After piping, individual exhaust is Exhaust necessary.
  • Page 61 ■Option -L (Manifold individual supply specification) Port Port combination: Individual PV  Common PS = Common PD Layout No. Single unit: ZK2C□□□□□□-□-L Manifold: ZZK2□□-A1□-L System Ejector Body type Manifold Exhaust type Complex exhaust Application Vacuum pressure PV pressure can be changed per station. Exhaust Released in operating environment purpose...
  • Page 62 Port Port combination: Individual PV  Common PS = Common PD Layout No. Single unit: ZK2H□□□□□-□-L Manifold: ZZK2□□-A2□-L System Ejector Body type Manifold Exhaust type High-noise reduction silencer exhaust Application Vacuum pressure PV pressure can be changed per station. Exhaust Released in operating environment purpose Release pressure...

  • Page 63: Exhaust/Flow Rate Characteristics

    11. Exhaust/Flow Rate Characteristics 11.1. Ejector Exhaust Characteristics/Flow Rate Characteristics The flow rate characteristics correspond to the standard supply pressure. ■ZK2□07 ■ZK2□10 -62- No. ZK2-OM00201...
  • Page 64 ■ZK2□12 ■ZK2□15 The following graphs show the characteristics of the ejector with valve. (Please contact SMC for models without valve.) -63- No. ZK2-OM00201...

  • Page 65: Vacuum Pump Flow Rate Characteristics

    11.2. Vacuum Pump Flow Rate Characteristics The graph shows the suction flow rate characteristics of the vacuum pump system at different vacuum pressure. ■ZK2P00 The actual suction flow at the point of suction varies depending on the piping conditions to the vacuum port. (The above graph shows the value when V port is ø8.) Port size Flow rate characteristics of V to PV (Vacuum side)
  • Page 66 ■ZK2□□□ (Vacuum Pump) The actual suction flow at the point of suction varies depending on the piping conditions to the vacuum port. Note) Port size Flow rate characteristics of PS to V (Vacuum release side) PV port V port C[dm /(s·bar)] ø6 ø8...

  • Page 67: Limitations Of Use

    12. Limitations of Use ■Exhaust from Ejector The exhaust resistance should be as small as possible to obtain the full ejector performance. There should be no shield around the exhaust slit for silencer exhaust type. When the product is installed, one of the ports should be open to atmosphere.

  • Page 68: Troubleshooting

    13. Troubleshooting ■Troubleshooting chart When any malfunction is observed, it is recommended to perform the following troubleshooting. Failure phenomenon Possible causes Countermeasures Vacuum is not Clogging by foreign matter or particles Refer to (1) and (2) generated Decline in the power Refer to (3) and (4) supply voltage Electrical wire failure...
  • Page 69 ■Countermeasure Countermeasure Oil mist in the supply air or particles in the piping cause clogging if they enter into the ejector. This may cause operation failure. Blow the air piping with air to eliminate particles. It is recommended installing the mist separator and air filter for cleaner supply air. Perform regular maintenance for mist separator and filter.
  • Page 70 Countermeasure When the ejector vacuums the workpiece, high speed air coming out of the nozzle collides into the diffuser I.D. and bounces back, generating vibration in the exhaust air. Because of this, the vacuum pressure fluctuates slightly and is not stabilized. There should be no functional problem with the ejector.
  • Page 71 Revision history 4-14-1, Sotokanda, Chiyoda-ku, Tokyo 101-0021 JAPAN Tel: + 81 3 5207 8249 Fax: +81 3 5298 5362 http://www.smcworld.com Note: Specifications are subject to change without prior notice and any obligation on the part of the manufacturer. © 2019 SMC Corporation All Rights Reserved -70- No.

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