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CKD 3KA1 Instruction Manual

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ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ
ＳＥＬＥＸ    ＶＡＬＶＥ
３ＫＡ１，Ｍ３ＫＡ１ 
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．
ＳＭ−２０８６７６-A
rd
                3
 Edition 

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  • Page 1 ＳＭ−２０８６７６-A ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ ＳＥＬＥＸ    ＶＡＬＶＥ ３ＫＡ１，Ｍ３ＫＡ１  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 ...

  • Page 2: Safety Precautions

    SAFETY PRECAUTIONS When designing and manufacturing a device using CKD products, the manufacturer is obli- gated to manufacture a safe product by confirming safety of the system comprising the fol- lowing items:  ・Device mechanism  ・Pneumatic or water control circuit  ・Electric control that controls the above  It is important to select, use, handle, and maintain the product appropriately to ensure that  the CKD product is used safely.  Observe warnings and precautions to ensure device safety.  Check that device safety is ensured, and manufacture a safe device.  WARNING １．This product is designed and manufactured as a general industrial machine part. It must  be handled by someone having sufficient knowledge and experience.    ２．Use this product within its specifications.  This product cannot be used beyond its specifications. Additionally, the product must not be modified  or machined.  This product is intended for use in general industrial devices and parts. Use beyond such conditions is  not considered. Consult with CKD for details when using the product beyond the unique specification  range, outdoors, or in the following conditions or environments. In any case, measures for safety shall  be provided when the vavle malfunctions.  ① 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.  ② Use for applications where life or assets could be adversely affected, and special safety measures  are required. ...
  • Page 3 Precautions with regard to guarantee   Guarantee period  The  guarantee  period  of  our  product  shall  be  one  (1)  year  after  it  is  delivered  to  the  place  specified  by  the  customer.   Guarantee coverage  If any failure for which CKD CORPORATION is recognized to be responsible occurs within the above warranty  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:  ① Defects resulting from operation under conditions beyond those stated in the catalogue or specifications.  ② Failure resulting from malfunction of the equipment and/or machine manufactured by other companies.  ③ Failure resulting from wrong use of the product.  ④...
  • Page 4 UNPACKING (Section 3) Bags  containing  solenoid  valves  should  be  opened  only  ！   CAUTION  :  when  you  are  ready  to  connect  the  valves  to  the  pipes  immediately afterward.   If bags are opened before the valves are ready to be con- nected to the pipes, the entry of foreign matter from the  piping  ports  could  cause  the  solenoid  valves  to  fail  or  malfunction. ...
  • Page 5 f)  Avoid using the solenoid valve system in a humid en-   ！ CAUTION  :  vironment  because  the  humidity  is  likely  to  cause  condensation with a change in the temperature.  g)  Do not use the normal type solenoid valves for an ap- plication that requires conformity with explosion-proof  specifications.    Choose  explosion-proof  solenoid  valves instead.  h)  The packing and gaskets may deteriorate sooner than  usual  if  used  in  an  atmosphere  with  a  higher  than  normal density of ozone (for example, the atmosphere  near  a  beach  or  in  an  area  with  frequent  thunder- storms). ...
  • Page 6 PIPING (Section 4.3) a)  Observe  the  recommended  tightening  torque  when  ！   CAUTION  :  connecting pipes.   Observing  the  recommended  tightening  torque  prevents  air leakage and damage to the screw threads.    To prevent  damage to the screw threads, first use your hand to lightly  tighten the screw and then use a tool to tighten the screw  to the recommended torque.  b)  Make  sure  that  the  pipes  will  not  be  disconnected  at  the  joints  by  mechanical  movements,  vibrations  or  tension. ...
  • Page 7 WIRING (Section 4.4) Before  wiring,  read  the  instruction  manual  carefully  and  ！   WARNING  :  understand the instructions.   A  person  who  wires  needs  to  have  knowledge  for  safely  performing  such  operation  based  on  the  understanding  about the mechanisms and operating principles of solenoid  valves.  Before  supplying  the  power,  check  the  power  supply  ！...
  • Page 8 ELECTRIC CIRCUITS (Section 5.4) a)  Check  for  the  presence  of  any  current  leak  from  the  ！   CAUTION  :  external  control  device  because  it  may  cause  an  er- roneous valve operation.   When  a  programmable  controller  or  a  similar  control  de- vice  is  used,  a  current  leak  may  prevent  the  normal  re- turning of the valve when the solenoid is de-energized. ...
  • Page 9 INDEX 3KA1,M3KA1 Manual No. SM-208676-A/3 1. PART NAME AND DESCRIPTION 2. INTERNATIONAL SYSTEM OF UNITS (SI) AND PORT INDICATION Conversion between International System of Units (SI) and Conventional Units 3. UNPACKING 4. INSTALLATION Environment Installation Piping Wiring 5. OPERATING RECOMMENDATION...
  • Page 10 １ 製 品 1.  PART NAME AND DESCRIPTION  Direct piping unit  Direct piping manifold  Part Name explanation Valve unit There are direct piping and sub plate piping ① It uses case of manual operation. There are a non lock and a lock Manual Override ② formula Wire connection It connections to the electric circuit ③...
  • Page 11 ２ SI 単位 2.  INTERNATIONAL SYSTEM OF UNITS (SI) AND PORT INDICATION  2.1 Conversion between International System of Units (SI) and Conventional Units In this manual, values are expressed using the International System of Units (SI). Use the table below to convert them into values expressed in conventional units.
  • Page 12 ３ 操 作 3.  UNPACKING  Bags  containing  solenoid  valves  should  be  opened  only    ！ CAUTION  :  when  you  are  ready  to  connect  the  valves  to  the  pipes  immediately afterward.   If bags are opened before the valves are ready to be con- nected to the pipes, the entry of foreign matter from the  piping  ports  could  cause  the  solenoid  valves  to  fail  or  malfunction. ...

  • Page 13: Installation

    ４ INSTALLATION 4.  INSTALLATION  If you have to use the product under conditions that are    ！ CAUTION  :  different from the specified conditions or if you intend to  use the product for a special application, be sure to con- sult us about the product specifications before using the  product. 4.1 Environment a)  In a dusty environment, foreign matter may enter even    ！ CAUTION  :  through the exhaust port.   The movement of the exhaust valve causes a respiratory  action at the exhaust 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. ...
  • Page 14 ４ INSTALLATION g)  Do not use the normal type solenoid valves for an ap-   ！ CAUTION  :  plication that requires conformity with explosion-proof  specifications.    Choose  explosion-proof  solenoid  valves instead.  h)  The packing and gaskets may deteriorate sooner than  usual  if  used  in  an  atmosphere  with  a  higher  than  normal density of ozone (for example, the atmosphere  near  a  beach  or  in  an  area  with  frequent  thunder- storms).   Consult us ...

  • Page 15: Direct Mounting

    ４ INSTALLATION 4.2 Installation When  installing  a  solenoid  valve  unit,  never  attempt  to    ！ WARNING  :  hold it in position by means of the pipes connected to it.   Mount the solenoid valve by applying the mounting screws  and/or mounting plate to the solenoid valve.  4.2.1 A work space for installation, removal, wiring, and piping opera- tions should be provided around the installed solenoid valve sys- tem.
  • Page 16 ４ INSTALLATION 4.3 Piping a)  Observe  the  recommended  tightening  torque  when  ！   CAUTION  :  connecting pipes.   Observing  the  recommended  tightening  torque  prevents  air leakage and damage to the screw threads.    To prevent  damage to the screw threads, first use your hand to lightly  tighten the screw and then use a tool to tighten the screw  to the recommended torque.  b)  Make  sure  that  the  pipes  will  not  be  disconnected  at  the ...

  • Page 17: Exhaust Port

    ４ INSTALLATION 4.3.1 Sealant Refrain applying sealant or seal tape approx.two pitches of thread from the tip of pipe to avoid some of the sealing substances from falling into piping system. ●Seal Tape ●Sealant(Paste or liquid) （Right）  （False）  （Right）  （False）  4.3.2 Flushing Before connecting pipes, flush the interiors of the tubes, solenoid valves, and connected devices to remove foreign matter.
  • Page 18 ４ INSTALLATION (3) For a piping used for both hydraulic and pneumatic controls, select a hydrau- lic hose. When combining a spiral tube with a standard one-touch joint, fix the tube origin using a hose band. Otherwise the rotation of the tube will decrease the efficiency of the clamping.
  • Page 19 ４ INSTALLATION 4.4 Wiring Before  wiring,  read  the  instruction  manual  carefully  and  ！   WARNING  :  understand the instructions.   A  person  who  wires  needs  to  have  knowledge  for  safely  performing  such  operation  based  on  the  understanding  about the mechanisms and operating principles of solenoid  valves.  Before  supplying  the  power,  check  the  power  supply  ！...
  • Page 20 ４ INSTALLATION 2) Wire connection Small terminal box Small terminal box Name Grommet (standard) Small terminal box with lamp with lamp surge absorber Option No code code Lead wire 300mm (20/0.18) 90° Shape (〜) (〜) (〜) Circuit (〜) Black Plug-in connector C type Plug-in connector C type Plug-in connector C type Plug-in connector C type...
  • Page 21 ４ INSTALLATION Plug-in connector D type Plug-in connector D type Plug-in connector D type Plug-in connector D type Name with lead wire, without leadwire, with lead wire without lead wire lamp surge absorber lamp surge absorber Option code Lead wire 300mm Lead wire 300mm (11/0.16) (11/0.16)
  • Page 22 ４ INSTALLATION 3) Wiring of the small terminal box (B) Wire the terminal box by following ① to ⑥ in the illustration. ④ Slide the gasket and pin support over live terminals and earth terminal. Earth terminal ② Terminal caulking Crimp terminal (Parts No.
  • Page 23 ４ INSTALLATION 4) Wiring of the small terminal box with lamp (L・LS) Wire the terminal box by following ① to ⑤ in the illustration. ③ Slide the gasket and terminal block over live terminals and earth terminal. Earth terminal ② Connect element wire with screw. It may be necessary to provide a small standard driver (Eliminate connecting surge absorber together.) Gasket...
  • Page 24 5) Wiring of the C-type, D-type connectors Wire the terminal box by following ① to ⑥ in the illustration. Socket ass’y (Socket ＋ Crimp terminal) Crimp terminal(made by CKD) Caulking tool(made by CKD) ② Terminal caulking ⑥ Tightening screw ① Lead wire AWG22 to 25 0.16 to 0.38mm...

  • Page 25: Operating Recommendation

    ５ OPERATION 5.  OPERATING RECOMMENDATION  5.1 Function  3KA110 No signal current (Illustrated) →  R2 (P port is closed.) When actuated →  B (R2 port is closed.) PR is an exhaust port of the pilot pressure line.  3KA1110 No signal current (Illustrated) → ...

  • Page 26: Manual Override

    ５ OPERATION 5.2 Manual Override a)  Once the manual operation device has been operated,  ！   WARNING  :  always return it to its origin (initial position), and then  start the operation of the device.  b)  Before using the manual override, make sure that no- body is present near the cylinder to be activated.  Name Non-lock type manual override Lock type manual override Option code No code ON  OFF  PUSH  Shape Activates when Keeps on activation during the time normally this button is pushed.

  • Page 27: Air Quality

    5.3.1 Lubrication The 3KA1 Series solenoid valve systems use pre-lubricated valves that usu- ally 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.
  • Page 28 ５ OPERATION 5.3.4 Foreign matter in the compressed air 1) Supply clean compressed air that does not include oxidized oil, tar, carbon, or other foreign matter from the air compressor. (1) If oxidized oil, tar, carbon, or the like enters a pneumatic device and sticks to its components, an increase in the resistance at sliding portions may cause a malfunction.

  • Page 29: Electric Circuits

    ５ OPERATION 5.4 Electric Circuits a)  Check  for  the  presence  of  any  current  leak  from  the  ！   CAUTION  :  external  control  device  because  it  may  cause  an  er- roneous valve operation.   When  a  programmable  controller  or  a  similar  control  de- vice ...

  • Page 30: Maintenance

    ６ MAINTENANCE 6.  MAINTENANCE  6.1 Periodic Inspection Before  providing  a  maintenance  service,  cut  the  power  ！   WARNING  :  and  the  supply  of  compressed  air  and  confirm  the  ab- sence of residual pressure.   The above is required to ensure safety.  Regularly  perform  the  daily  and  periodic  inspections  to   ...

  • Page 31: Disassembling And Reassembling

    ６ MAINTENANCE 6.2 Disassembling and Reassembling Before  disassembling  and  reassembling  solenoid  valves,  ！   WARNING  :  read the instruction manual carefully and understand the  instructions.   reassembles a solenoid  A person who disassembles and  valve  system  needs  to  have  a  knowledge  for  safely  performing  such  operation  based  on the  understand- ing about the mechanisms and operating principles of  solenoid valves. 6.2.1 Solenoid valve mounting and detaching When replacing the solenoid valve, pay special attention so that no gaskets are fallen down.

  • Page 32: Assembly And Disassembly

    ６ MAINTENANCE 6.2.2 Assembly and Disassembly 1) 3KA110・3KA1110 Parts Material Remarks M2.5 × 26 (with Spring Coil mounting screw Steel ① washer ) Coil ass’y ② Plunger ass’y ③ Pilot valve mounting screw Steel M2.5×22 ④ Coil Gasket Fluore rubber ⑤...
  • Page 33 ６ MAINTENANCE 3KA120 Parts Material Remarks M2.5 × 26 (with Spring Coil mounting screw Steel ① washer) Coil ass’y ② Plunger ass’y ③ Pilot valve mounting screw Steel M2.5×22 ④ Coil Gasket Fluore rubber ⑤ Pilot valve ass’y ⑥ Pilot valve Gasket Nitrile rubber ⑦...
  • Page 34 ７ TROUBLE SHOOTING  7.  TROUBLE SHOOTING  TROUBLE SHOOTING Motion troubles Suspected cause Remedies No electric signals Turn on the power Damage to signal wiring system Repair the control circuit Does not actuate Excessive fluctuating range of current or volt- Reaffirm the power capacity. (within ±10% of voltage fluctuation) Correct control circuit and / or set a bleed cir- Excessive leaking current...

  • Page 35: Product Specifications

    ８ HOW TO ORDER 8.  PRODUCT SPECIFICATIONS AND HOW TO ORDER  8.1 Product Specifications 1) Specifications 3KA110 3KA1110 3KA120 Model code 2-pos.Single 2-pos.Single 2-pos Normal close Normal open Double JIS Symbol Item P R P R P R Working fluid Compressed air Valve and solenoid type Pilot operated soft spool valve Min.
  • Page 36 HOW TO ORDER Model code M3KA1 Item Manifold structure Manifold integrated Applicable solenoid valve 3KA1 series Nos. of station 2 to 20 stations Manifold type Common supply, common exhaust Grommet with lead wire Electrical connections (Option : Small terminal box, Plug-in connectors)
  • Page 37 ８ HOW TO ORDER 8.2    HOW TO ORDER  3KA1 3KA1 AC100V Operator type Solenoid valve (a) Position/Operator type (b) Port size (c) Manual operation device Code Description Code P･A･B ports R1･R2 ports Code Description No code Non-lock type manual override 2-pos single, Normal close φ4 push-in joint...
  • Page 38 ８ HOW TO ORDER 2) M3KA1 ※Solenoid valve 3KA1 AC100V for manifold ※Gasket, mounting screws are attached M3KA1 AC100V M1 B Manifold (ｇ) Operation classification Solenoid valve (a) Operator type (b) Port size (c) Manual override Code Description Code A･B ports P･R1･R2 ports...
  • Page 39 ８ HOW TO ORDER Example of single model Manifold  M3KA110-M5-7-AC100V Indicates 3KA1 manifold, 2-Position single normal close solenoid, B port M5 top porting, 7 stations, AC100V50/60Hz. Example of mixed manifold   Method of entering the contents of combination: Write the number of the type-wise solenoid valves (simplex) after the nor- mal Model No.
  • Page 40 ８ HOW TO ORDER ８．３ Consumable parts Spool assembly 2) Piston assembly Function Model example Function Model example 4K9-151 3KA110 3KA1※ 4K9-110 3KA1110 3KA120 4K9-118 Coil assembly Function Model example 4K1L- Electrical connection option -COIL - Nos.of station All model common 4) Sub plate kit (Manifold)

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