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SMC Networks IN-777 Series Operation Manual

Air servo cylinder
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Document No. K35-OMW0030-A
PRODUCT NAME
Air servo cylinder
MODEL/ Series/ Product Number
IN-777 Series

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Summary of Contents for SMC Networks IN-777 Series

  • Page 1: Front Cover

    Document No. K35-OMW0030-A PRODUCT NAME Air servo cylinder MODEL/ Series/ Product Number IN-777 Series...

  • Page 2: Table Of Contents

    Contents Front cover................................1 Contents ................................2 Safety Instructions .............................. 3 1. Product Overview / Features ........................12 2. Names and Functions of Parts ........................13 3. How to Order ..............................14 3-1. Main Body ..............................14 3-2. Spare Parts ............................... 15 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 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. If anything is unclear, contact your nearest sales branch.
  • Page 5 Explanation of Symbols Symbol 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) This Operation Manual is intended for those who have knowledge of machinery using pneumatic equipment, and have sufficient knowledge of assembly, operation and maintenance of such equipment.
  • Page 6 ■ Handling Precautions Follow the instructions given below for selecting and handling of the air servo cylinder. ● The instructions on design and selection (installation, wiring, environment, adjustment, operation, maintenance, etc.) described below must be followed. *Product specifications Warning - Use the specified voltage. Otherwise failure or malfunction can result.
  • Page 7 Caution - Do not touch the cylinder during high speed and high frequency operation. When the cylinder is operating at high speed and high frequency, the surface temperature of the cylinder tube increases, and may cause injury to personnel. - Do not use the air cylinder as an air-hydro cylinder. If the working fluid of the air cylinder is turbine oil, oil leakage can result.
  • Page 8 * Wiring (Including connecting/disconnecting of the connectors) Warning - Wire correctly. Incorrect wiring can cause damage the product. - Do not perform wiring while the power is on. Incorrect wiring can damage the air servo cylinder and/or input/output equipment and malfunction can result.
  • Page 9 Otherwise it can cause damage or malfunction. - Do not use the product in an environment that is exposed to temperature cycle. Heat cycles other than ordinary changes in temperature can adversely affect the internal components of the product. - Do not expose the product to direct sunlight. If using in a location directly exposed to sunlight, protect the product from the sunlight.
  • Page 10 * Adjustment and Operation Caution - Set the switches using a small flat blade screwdriver. Using an unsuitable tool may lead to damage to the setting switch. - Perform settings suitable for the operating conditions. Incorrect setting can cause operation failure. For details of each setting, refer to 6.
  • Page 11 - Check items 1. Smooth operation 2. Changes in piston speed and cycle time 3. Abnormal stroke 4. Looseness of the cylinder mounting bolt 5. Looseness of cylinder mounting frame or excessive deflection 6. Internal and external leakage (Change in output) 7.

  • Page 12: Product Overview / Features

    1. Product Overview / Features Product Overview The positioning operation of this air servo cylinder can be accurately controlled. It can be used for positioning applications which require high thrust. It can be easily set up with simple interface, function and configuration.

  • Page 13: Names And Functions Of Parts

    2. Names and Functions of Parts Controller Switch cover Panel Power supply connector LED alarm display FU port FB port Residual pressure Cover tube release valve FA port Air supply port R2 port Cylinder tube R3 port R1 port Rotary switch DIP switch Pipe Flange...

  • Page 14: How To Order

    3. How to Order 3-1. Main Body (1) Air servo cylinder IN-777 - 160 Made to order Bore size 125 mm LED alarm display 160 mm With LED alarm display 200 mm 250 mm 320 mm Communication protocol 4-20mA/HART communication Port thread type Rod boot Silicone rubber material...

  • Page 15: Spare Parts

    3-2. Spare Parts (1) Controller assembly IN-777P- -410AS Communication protocol 4-20mA/HART communication LED alarm display LED alarm display With LED alarm display Servo valve (2) Valve unit IN-777P-010AS Pilot valve Valve unit (3) Servo valve XT581-V-C-X001 (One piece) (4)Pilot valve V211KT-5LOZ-X48 (5)Position sensor unit IN-777P-...
  • Page 16 (6)Rod boot Bore size (mm) Stroke (mm) Part number C96A2G-1461V-R C95A6G-471AQ-R C95B0G-472AQ-R C95B5G-533AQ-R C1SC2G-1468V-R C1SC2G-1470V-R (7)Seal kit IN-777P- -910AS Bore size (mm) (13) Tube gasket：2 pcs, (16) Piston seal：1 pc, (25) Rod seal：1 pc, (28) Wear ring：1 pc, (31) Pipe O-ring：2 pcs (13) Tube gasket：2 pcs, (16) Piston seal：1 pc, (25) Rod seal：1 pc, (28) Wear ring：1 pc, (31) Pipe O-ring：2 pcs, (35) Wiper ring：1 pc...

  • Page 17: Specification

    4. Specification 4-1. General Specification Item Specification Action Double acting, Single rod Fluid 0.3 μm or less Filtration of compressed air Proof pressure 1.2 MPa Operating pressure range 0.55 MPa to 0.8 MPa Repeated stop position accuracy +/-0.5 mm or less Ø125 to Ø250: 155 mm/sec Maximum speed Ø320: 100 mm/sec...
  • Page 18 Table 1 Weight Bore size (mm) Stroke (mm) Weight (kg) Table 2 Allowable lateral load at rod end Bore size (mm) Allowable lateral load at rod end (N) Table 3 Theoretical output・Maximum work load Theoretical output (N) Bore size (mm) Maximum work load (kg) *2 Operating pressure (MPa) Operating...

  • Page 19: Electrical Specifications

    Air exhaust port R1 *1) IN-777 series can be operated with a fail-safe mode. In order to operate the cylinder with fail-safe mode, FA, FB and FU port piping is necessary. When the fail-safe function is not used, do not remove the plugs from FA, FB and FU ports.

  • Page 20: Dimensions

    4-4. Dimensions (1) Bore size: Ø125 Product number Bore size (mm) Stroke (mm) IN-777-125TF-250F-HL...
  • Page 21 (2) Bore size: Ø160 Product number Bore size (mm) Stroke (mm) IN-777-160TF-200F*-HL IN-777-160TF-300F*-HL...
  • Page 22 (3) Bore size: Ø200 Product number Bore size (mm) Stroke (mm) IN-777-200TF-200F*-HL IN-777-200TF-300F*-HL...
  • Page 23 (4) Bore size: Ø250 Product number Bore size (mm) Stroke (mm) IN-777-250TF-350F*-HL IN-777-250TF-450F*-HL...
  • Page 24 (5) Bore size: Ø320 Bore size Dimensions (mm) Product number Stroke (mm) (mm) 233.5 612.5 IN-777-320TF-200F*-HL IN-777-320TF-350F*-HL 90.5 IN-777-320TF-530F*-HL...

  • Page 25: Construction

    4-5. Construction Back portion of ø125 to ø250 head covers (10) (11) (33) (12) Air exhaust port Air supply port Top portion of ø320 head cover (13) (27) (14) (15) (28) (16) (17) (29) (30) (33) Cross-section portion of ø320 rod end (18) (19) (20)

  • Page 26: Installation / Wiring

    5. Installation / Wiring 5-1. Installation Mount the flange on to the base and secure with screws using the screw through holes. Flange Screw through hole Caution When installing the product, do not apply an excessive external force or impact to the cover tube and piping tube.

  • Page 27: Electrical Wiring Diagram

    5-2. Electrical Wiring Diagram Perform wiring according to the connector pin numbers and the wiring diagram. (1) Connector pin numbers (Male side) Input/output Pin No. Signal name Description status 4-20 mA analog input signal (+), Sig-in+ Input HART Communication signal 4-20 mA analog input signal (-), Sig-in- Input...
  • Page 28 (2) Wiring diagram (Numbers in brackets indicates the pin numbers) (5) PWR_DC24V (6) PWR_GND Output signal (9) CTR (10) CYL (11) VAL Max. (16) RF Output current (17) PWR 100mA Input signal (3) JOG+ (4) JOG- Main circuit 10mA or less (13) CAL (14) E-STOP (12) GND_I/O...

  • Page 29: Setting

    6. Setting Perform the DIP switch setting for normal/reversed switching of the piston rod travel direction (during target position operation), cylinder bore size, and piston rod operating direction at no signal operation. By performing the rotary switch setting, the piston rod speed during target position operation can be set. With the power to the air servo cylinder disconnected, remove the hexagon socket head cap screws to remove the switch cover from the panel.

  • Page 30: Piston Rod Movement Direction (Dip Switch No. 1)

    6-1. Piston Rod Movement Direction (DIP Switch No. 1) The piston rod movement direction relative to the analogue input signal (4-20 mA) can be set, for when the target position operation is performed. Moving Relationship between the analogue input signal No.

  • Page 31: Piston Rod Movement At No Signal Operation

    6-3 Piston rod Movement at No Signal Operation Set the piston rod operation at no signal operation (refer to 6-4) using DIP switch No. 5 and No. 6. The piston rod operation setting can be selected from "Stops after moving to the retracted end", "Stops after moving to the set point", or "Current position retained".

  • Page 32: Operation Mode And Functions

    7. Operation Mode and Functions The operation modes for this product include JOG operation, Calibration, Target position operation (4-20mA), No signal operation, and Emergency stop. The functions available during operation are residual pressure release and alarm LED display. This section describes each operation mode and function. 7-1.
  • Page 33 (2) Movement to the retracted end When the JOG- signal (Pin No. 4) is ON, the piston rod moves to the retracted end. When the JOG+ signal (Pin No. 3) turns ON while the JOG- signal is ON, the JOG operation is stopped and the piston rod retains the current position.

  • Page 34: Calibration

    7-2. Calibration The piston rod movement range (set point) can be set when using the Target position operation (refer to 7-3). By performing the Calibration, the relationship between the piston rod position (from the retracted end to the set point) and the current value (4-20 mA) input to Sig-in+ and Sig-in- can be set. Once the Calibration is performed, the set point is stored in the product and will be recorded even when the power supply is OFF.
  • Page 35 7-2-1-2. Manual mode Step (1) – Turn the power supply OFF if it is not already. Ensure that all DIP switches are turned to OFF position and check that all LEDs are off. Step (2) – Turn the power supply ON. Ensure that all DIP switches remain in the OFF position and check that the LEDs begin to flash at a rate of 0.5 Hz.

  • Page 36: Target Position Operation (4-20 Ma)

    DIP switch No. 1 setting Movement direction Standard Reversed Retracted end Retracted end 4 mA 20 mA Set point Set point 20 mA 4 mA (Stop position) Extended end Calibration Relationship between the piston rod position (between the retracted end and set point) and Sig-in (+/-) input current (*1) If calibration is never performed after receiving the product from SMC, the set point is set to the retracted end.

  • Page 37: No Signal Operation

    7-4. No Signal Operation When an analog input signal of 3.9 mA or less is input, the piston rod operates according to the No signal operation setting set beforehand. The operation can be selected from 3 types of operation by switching the DIP switch No.

  • Page 38: Residual Pressure Release

    7-6. Residual Pressure Release The pressure on the head side and rod side of the air cylinder can be released from the residual pressure release valve in the head cover of the product. Rotate the exhaust screw (hexagon socket head cap screw) in the counterclockwise direction to release the valve and exhaust the air. Exhaust the air only after disconnecting the power supply and air supply.

  • Page 39: Functions Of Led Alarm Display

    7-7. Functions of LED Alarm Display The names and functions of the LED alarm display are shown in the figure and table below. PWR (Green) RF (Red) CTR (Green) VAL (Red) CYL (Red) LED Alarm LED name LED condition Description (*1) display Green LED is ON Power supply is ON.

  • Page 40: Priority Of Operation Mode

    Target position operation (4-20 mA), No signal operation 7-9. Fail-safe function The IN-777 series can be operated with a fail-safe function. Refer to ”Example of fail-safe circuit for air servo cylinder IN-777”(Document No.K35-OMX0069) for the pneumatic circuit to use when the fail-safe function is used.

  • Page 41: Operation Examples (Timing Chart)

    7-11. Operation Examples (Timing Chart) Supply power (A) Automatic calibration (B) Target position operation Setting when power is supplied. Piston rod movement direction: Standard Set point: Not set Calibration: Automatic mode Input / Signal name Signal transition Output PWR_DC24V 24 V (Power supply) E-STOP (Emergency stop)
  • Page 42 Supply power (A) JOG+ operation (B) Stop to moving and calibration (manual mode) (C) JOG- operation (D) Target position operation Setting when power is supplied. Piston rod movement direction: Standard Set point: Not set Calibration: Manual mode Input / Signal name Signal transition Output PWR_DC24V...
  • Page 43 Supply power (A) Target position operation (B) JOG+ operation (C) Target position operation (D) JOG- operation (E) Stop to moving (F) JOG- operation (G) Target position operation Setting when power is supplied. Piston rod movement direction: Standard Set point: Set Input / Signal name Signal transition...
  • Page 44 Supply power (A) Target position operation (B) No signal operation (C) Target position operation (D) No signal operation (E) Target position operation Setting when power is supplied. Piston rod movement direction: Standard No signal operation: Piston rod moves to the retracted end Set point: Set Input / Signal name...
  • Page 45 Supply power (A) Target position operation (B) Emergency stop (C) Target position operation Setting when power is supplied. Piston rod movement direction: Standard Set point: Set Input / Signal transition Signal name Output PWR_DC24V 24 V (Power supply) E-STOP (Emergency stop) 20mA Sig-in (+/-) (Analog input signal)

  • Page 46: Replacement Of Parts

    8. Replacement of parts Caution Release the residual pressure release valve (Chapter 7.6) to exhaust the residual pressure in the product. Disassembly of the cylinder should be performed in an open, dust free area. After removing the servo cylinder from the device, be sure to protect the end of the piping port and rubber hose device side with a clean cloth to prevent dust entering.

  • Page 47: Assembly Of The Controller Assembly

    (3) Remove the cable harness from the two connectors on the board mounted on the bottom surface of the controller assembly to remove the controller assembly. Connectors Board Cable harness Caution Never touch the board with bare hand. 8.1.2. Assembly of the controller assembly (1) Connect the connectors of the cable harness to the controller assembly.
  • Page 48 (2) Lower the controller assembly down over the pillars. Ensure the pillar aligns with the pillar holes, (2 places) before fully lowering until there is no gap between the controller and cover tube. Pillar hole (2 places) Pillar (Another pillar is located on the opposite side, not shown in this image)

  • Page 49: Disassembly Of The Valve Unit

    8.2.1. Disassembly of the valve unit (1) Remove the controller assembly. (Refer to 8.1.1) (2) Remove the cover tube in the arrow direction. Cover tube (3) Remove the hexagon socket head cap screws (3 pcs.). Hexagon socket head cap screw Position of Hexagon socket head cap screw (3 pcs.) Valve unit...

  • Page 50: Assembly Of The Valve Unit

    (4) Remove the valve unit. Be careful not to lose or damage the head cover O-rings (x 6 places). Valve unit Head cover O-rings (x 6 pcs.) 8.2.2. Assembly of the valve unit (1) Mount the valve unit and tighten the hexagon socket head cap screws (3 pcs.). (Tightening torque:4.2 to 6.2 N･m) Hexagon socket head cap screw...

  • Page 51: Disassembly Of The Servo Valve

    (2) Mount to the cover tube. (Mounting direction is not specified.) Be careful to ensure that the O-ring located in the head cover groove remains in place and doesn’t become twisted. Cover tube Head cover groove (3) Mount the controller assembly. (Refer to 8.1.2) 8.3.1.

  • Page 52: Assembly Of The Servo Valve

    (3) Remove the servo valve. Servo valve 8.3.2. Assembly of the servo valve (1) Mount the servo valve to the valve unit and tighten the hexagon socket head cap screws (3 pcs.). (Tightening torque:1.2 to 1.8 N･m) Valve unit (2) Mount the cover tube and controller assembly. (Refer to 8.2.2(2) and 8.1.2.)

  • Page 53: Disassembly Of The E-Stop Valve

    8.4.1. Disassembly of the E-stop valve (1) Remove the controller assembly and the cover tube. (Refer to 8.2.1(1) to (2).) (2) Remove the cable harness from the E-stop valve. Cable harness E-stop valve (3) Remove the round head combination screw. Round head combination screw...

  • Page 54: Assembly Of The E-Stop Valve

    (4) Remove the E-stop valve. E-stop valve 8.4.2. Assembly of the E-stop valve (1) Mount the E-stop valve to the valve unit and tighten round head combination screw. (Tightening torque: 0.24 to 0.36 N･m) Round head combination screw...

  • Page 55: Disassembly The Position Sensor

    (2) Connect the connectors of the cable harness to the E-stop valve. Cable harness (3) Mount the cover tube and the controller assembly. (Refer to 8.2.2(2) and 8.1.2.) 8.5.1. Disassembly the position sensor (1) Remove the controller assembly and cover tube and valve unit. (Refer to 8.3.1(1) to (2).) (2) Remove the hexagon socket head cap screws (2 pcs.) Hexagon socket head cap screws Position sensor...

  • Page 56: Assembly Of The Position Sensor

    (3) Remove the position sensor. Position sensor 8.5.2. Assembly of the position sensor (1) Mount position sensor to the head cover and tighten the hexagon socket head cap screws (2 pcs.). (Tightening torque: 0.09 to 0.12 N･m) Hexagon socket head cap screws Position sensor Head cover (2) Mount the valve unit, the cover tube and the controller assembly.

  • Page 57: Disassembly Of The Air Cylinder Parts

    8.6.1. Disassembly of the air cylinder parts Caution Open the residual pressure release valve (Chapter 7.6) to exhaust the residual pressure in the cylinder. Be careful not to scratch or dent the inner surface of the cylinder or sliding surfaces of the piston rod during assembly.
  • Page 58 (3) Remove the tie-rod from the cover. For Ø200 to Ø320, do not remove the tie-rod nut from the tie-rod. Ø125 and Ø160 Ø200 and Ø250 Rod cover Rod cover Tie-rod Tie-rod Tie-rod nut Ø320 Head cover (4) Remove the rod cover from the cylinder tube and piston rod. Cylinder tube Piston rod Rod cover...
  • Page 59 (5) Remove the pipe from the pipe block (head side). (For Ø160 to Ø320. For Ø125, remove the piping from the head cover. Pipe block (Head side) Cylinder tube Pipe (6) Hold the piston rod and remove the piston assembly from the cylinder tube. Piston rod Cylinder tube Piston assembly...

  • Page 60: Disassembly The O-Ring And The Packing

    8.6.2 Disassembly the O-ring and the Packing (1) Remove the tube gasket from the head and rod cover. Tube gasket Tube gasket Tube gasket Head cover Rod cover (2) Remove the piston seal and wear ring from the piston. The piston seal groove is deep. Do not use a precision screwdriver.
  • Page 61 (3) Remove the rod seal from the rod cover. Remove the rod seal using a flat blade screwdriver. Take care not to scratch the seal surface or bushing when removing. Ø125 to Ø250 Ø320 Wiper ring Rod seal Rod seal Rod seal Wiper ring Rod seal...

  • Page 62: Greasing For Packing, O-Ring And Parts

    8.6.3 Greasing for Packing, O-ring and parts (1) Thinly apply grease to the surface of the seals, O-rings and wear ring. (2) Apply grease to each part as shown below. * See Table 1 for guidelines for the amount of grease. (a-1) Inside of the rod cover (Ø125 to Ø250) (a-2) Inside of the rod cover (Ø320) Rod seal groove...

  • Page 63: Assembly Of The Packing And O-Ring

    8.6.4 Assembly of the Packing and O-ring (1) Mount the tube gasket into the groove of the head cover and rod cover. Tube gasket Tube gasket Tube gasket Rod cover Head cover (2) Mount the piston seal and wear ring to the piston groove. Wear ring Piston seal Piston seal...
  • Page 64 (3) Mount the rod seal to the rod cover groove. Make sure that the mounting direction is correct as shown. 125 to Ø Ø Ø Wiper ring Rod seal Rod seal Rod seal Wiper ring Rod seal Retaining plate Head cover Rod cover (4) Mount 2 pipe O-rings to the groove at the end of the pipe.

  • Page 65: Assembly Of The Air Cylinder Parts

    8.6.5 Assembly of the Air cylinder parts (1) Mount the head cover to the cylinder tube. Head cover Cylinder tube (2) Mount the piston assembly to the cylinder tube. Mount the sensor rod inserting it to the piston rod hole. Be careful not to bend or hit the sensor rod.
  • Page 66 (4) Mount the rod cover to the cylinder tube. Mount the pipe to the pipe block (rod side). Take care not to scratch the rod seal, wiper ring and bushing. Pipe Pipe block (Rod side) Rod cover (5) Mount the tie-rod. - Ø125 and Ø160 Tighten the tie rod nut to the tie rod on the side which male thread is shorter.
  • Page 67 Ø Insert the tie rod from the head cover through the tie rod through hole. Tie rod does not have orientation for insertion. Tighten the tie rod male thread part into the rod cover female thread part. Head cover Tie-rod (6) Tightening of tie-rod nut and hexagon nut - Ø125 and Ø160 Tighten the tie rod nuts to the tie rod from the rod cover side so that the tie rod tension becomes even.
  • Page 68 - Ø200 to Ø320 Mount the washer to the tie rod from the head cover side. Tighten the hexagon nuts so that the tension of the tie rod becomes even. (See Table 2 for the tightening torque) Hexagon nut Washer Head cover Tie-rod Table 2 Tightening torque...

  • Page 69: Alarm

    9. Alarm If errors occur during operation of the air servo cylinder, alarms will be output. Alarm names and the descriptions are shown below. Alarm type Target position № Error name Possible causes Countermeasures operation LED alarm display and JOG Output signal (Option) operation...

  • Page 70: Trouble Shooting

    10. Trouble Shooting Refer to the table below for troubleshooting. When none of the causes in the troubleshooting can be confirmed, it is presumed that the product is faulty and normal operation can only be recovered by the replacement of a part. It is possible that this product may be damaged due to the operating conditions (applications).
  • Page 71 Over Does the supply pressure exceed the Make sure to supply pressure within the pressure specified value (0.8 MPa)? product specification. Review the operating condition so that the Excessive Does the load exceed the upper limit of the load in the operating condition does not load maximum load of this product? exceed the maximum load of this product.

  • Page 72: Limitations Of Use

    11. Limitations of Use 11-1. Mounting Caution (1) Vibration may occur due to positioning control depending on the operating environment, load, conditions, etc. Be sure to inspect the actual machine for sufficient strength retention in regard to the amount of cylinder vibration that occurs.
  • Page 73 Revision history 4-14-1, Sotokanda, Chiyoda-ku, Tokyo 101-0021 JAPAN Tel: + 81 3 5207 8249 Fax: +81 3 5298 5362 URL https://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...

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