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CKD 3KA1 Instruction Manual

Master valve
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ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ
ＭＡＳＴＥＲ  ＶＡＬＶＥ 
３ＫＡ１，    ４ＫＡ１，    ４ＫＢ１ 
Ｍ３ＫＡ１，Ｍ４ＫＡ１，Ｍ４ＫＢ１ 
Please
read
●
carefully before using this product, par-
ticularly the section describing safety．
Retain this instruction manual with the
●
product for further consultation whenever
necessary．
ＳＭ−２０６７９２-A
this
instruction
      ３
manual
rd 
Edition

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  • Page 1 ＳＭ−２０６７９２-A ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ ＭＡＳＴＥＲ  ＶＡＬＶＥ  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．...

  • Page 2: Safety Precautions

    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, ...
  • Page 3   CAUTION  : or damage to equipment or facilities. Note  that  some  items  described  as  "CAUTION" may  lead  to  serious  results  depending on  the  situation. In any case, important information that must be observed is explained.  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 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:  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 Failure resulting from modification or repairing that CKD CORPORATION is not involved in.  ⑤ Failure resulting from causes that could not be foreseen by the technology available at the time of deliv- ery. ...
  • Page 4 UNPACKING (Section 3) Bags  containing  master  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 master valves to fail or mal- function.  INSTALLATION (Section 4) If you have to use the product under conditions that are  ！   CAUTION  :  different from the specified conditions or if you intend to ...
  • Page 5 e)  Avoid using the master valve system in a humid envi-   ！ CAUTION  :  ronment because the humidity is likely to cause con- densation with a change in the temperature.  f)  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  for  the  packing  and  gaskets  to  be  used  in  an  atmosphere with a higher ozone density.
  • 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 AIR QUALITY (Section 5.2) a)  Do not supply anything other than compressed air.   ！ WARNING  :  b)  Supply  clean  compressed  air  without  any  mixture  of  corrosive gas. a)  Compressed  air  usually  contains  a  large  amount  of      ！ CAUTION  :  drain,  oxidized  oil,  tar,  foreign  matter,  and  rust  from  the ...
  • Page 8 INDEX 3KA1,4KA1, 4KB1 M3KA1, M4KA1, M4KB1 MASTER VALVE Manual No. SM-206792-A/3 1. PART NAME AND DESCRIPTION 2. INTERNATIONAL SYSTEM OF UNITS (SI) 3. UNPACKING 4. INSTALLATION Environment Installation Piping 5. OPERATING RECOMMENDATION Operation Air Quality 6. MAINTENANCE Periodic Inspection Disassembling and Reassembling 7.
  • Page 9 １ PRODUCT 1.  PART NAME AND DESCRIPTION  Direct piping unit Direct piping manifold Subplate piping unit Subplate piping manifold Part Name explanation Master valve unit There are direct pipng and subplaate piping ① Sub plate It is a block for the piping ② Port pis the supply port;port R is the exhaust port ;...
  • Page 10 SI UNIT 2.  INTERNATIONAL SYSTEM OF UNITS (SI)    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. Table of conversion between SI units and conventional units (The values printed in Bolds fonts are values given in the International System of Units (SI)): Example (converting a pressure value): 0.0980665MPa 1MPa...
  • Page 11 ３ UNPACKING 3.  UNPACKING  Bags  containing  master  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 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.

  • Page 12: 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 13 ４ INSTALLATION f)  The packing and gaskets may deteriorate sooner than  ！   CAUTION  :  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  for  the  packing  and  gaskets  to  be  used  in  an  atmosphere with a higher ozone density.
  • Page 14 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 15: 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） When winding the fluororesin seal tape on the screw part, wind the seal tape two or three times where one or two screw threads remain at the top end of the screw, and then push the tape by tip of the nail to make the tape tightly in contact with the screw.

  • Page 16: Pipe Connections

    ４ INSTALLATION 4.3.6 Pipe connections (1) Tubes to be used For use with master valves with one-touch joints, select tubes of the type specified by us: Soft nylon tubes (F-1500 Series) Urethane tubes (U-9500 Series) (2) For installation at a site that has spatters in the air, select incombustible tubes or metal pipes.
  • Page 17 ４ INSTALLATION (6) Cutting a tube To cut a tube, use a tube cutter to cut the tube perpendicularly to the length of the tube. Inserting an obliquely cut end of a tube may cause air leakage. (7) Tube 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.

  • Page 18: Operating Recommendation

    ５ OPERATION 5.  OPERATING RECOMMENDATION  5.1 OPERATION １）3KA series  3KA111 When PB no pressurization (See the right figure) →  R2 (P port is closed.) When PB pressurization →  B (R2 port is closed.)  3KA1111 When PB no pressurization (See the right figure) → ...
  • Page 19 OPERATION ２）4KA series  ４KA111 When PB no pressurization (See the right figure) →  A →  R2 (R1 port is closed.) When PB pressurization →  B →  R1 (R2 port is closed.)  4KA121 When PA pressurization (See the right figure) → ...
  • Page 20 ５ OPERATION 2) 4KBseries  4KB111 When PB no pressurization (See the right figure) →  A →  R When PB pressurization →  B →  R  4KB121 When PA pressurization (See the right figure) →  A →  R When PB pressurization → ...

  • Page 21: Air Quality

    OPERATION 5.2 Air Quality a)  Do not supply anything other than compressed air.  ！   WARNING  :  b)  Supply  clean  compressed  air  without  any  mixture  of  corrosive gas.  a)  Compressed  air  usually  contains  a  large  amount  of   ！ CAUTION  :  drain,  oxidized  oil,  tar,  foreign  matter,  and  rust  from  the ...
  • Page 22 ５ OPERATION 5.2.4 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 23: Maintenance

    ６ MAINTENANCE 6.  MAINTENANCE  6.1 Periodic Inspection Before providing a maintenance service, cut and the sup- ！   WARNING  :  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    ！ CAUTION  :  correctly maintain product performance.   If  the  product  is  not  correctly  maintained  ,  product  per- formance ...

  • Page 24: Disassembling And Reassembling

    ６ MAINTENANCE 6.2 Disassembling and Reassembling Before  disassembling  and  reassembling  master  valves,  ！   WARNING  :  read the instruction manual carefully and understand the  instructions.   reassembles  a  master  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 ...
  • Page 25 ６ MAINTENANCE 6.2.2 Disassembling drawing and parts list 3KA111･3KA1111 4KA111･4KB111 Parts Material Remarks M2.5 × 17(with Spring Pilot cap mounting screw Steel ① washer) Pilot cap Resin ② Piston ass’y ③ Body Aluminum alloy die casting ④ Spool ass’y ⑤ Spool spring Stainless steel ⑥...
  • Page 26 ６ MAINTENANCE 3KA121・4KA121・4KB121 Parts Material Remarks M2.5 × 17(with Spring Pilot cap mounting screw Steel ① washer) Pilot cap Resin ② Piston ass’y ③ Body Aluminum alloy die casting ④ Spool ass’y ⑤ [SM-206792-A/3] ―25―...
  • Page 27 ６ MAINTENANCE 4KA131・4KA141・4KA151 4KB131・4KB141・4KB151 Parts Material Remarks M2.5 × 22(with Spring Pilot cap mounting screw Steel ① washer) Pilot cap Resin ② Piston ass’y ③ Aluminum alloy die Body ④ casting Spool ass’y ⑤ Body block Resin ⑥ Pilot mounting M2.5 ×...
  • Page 28 ７ TROUBLE SHOOTING 7.  TROUBLE SHOOTING  TROUBLE SHOOTING Motion troubles Suspected cause Remedies Pilot signal doesn’t come Correction of the air circuit Does not actuate Pilot pressure is low Adjustment of the pilot pressure Erroneous shut off pressure source Turn on the power source Reset the pressure reducer valve or install a Insufficient pressure pressure raising valve...

  • Page 29: Product Specifications

    Note 1) Ambient temperature applies when stored or sitting, and does not apply to the fluid temperature in operation. Model code M3KA1 Item Manifold system Manifold integrated Applicable master valve 3KA1 series Nos. of station 2〜20 stations Manifold type Common supply, common exhaust Supply port Side (Rc1/8) Cylinder ports A・B...
  • Page 30 ８ SPECIFICATION 4KA141 4KA151 4KA131 4KA111 4KA121 3-pos. load ports 3-pos. load Model code 3pos. all ports 2-pos. single 2-pos. double open to exhaust ports open to blocked ports supply ports JIS Symbol Item R1PR2 Working fluid Compressed air Valve type and operation Pilot operated soft spool valve Proof pressure 1.05...
  • Page 31 ８ SPECIFICATION 4KB141 4KB151 4KB131 4KB111 4KB121 3-pos. load ports 3-pos. load Model code 3pos. all ports 2-pos. single 2-pos. double open to exhaust ports open to blocked ports supply ports JIS Symbol Item R1PR2 Working fluid Compressed air Valve type and operation Pilot operated soft spool valve 1.05 Proof pressure...
  • Page 32 ８ SPECIFICATION 8.2 How to Order 1) 3KA1 3KA1 Operator type master valve (a) Position/Operator type (b) Port size (c) Other option PA・PB R1･R2 Code Description Code P･A･B ports Code Description ports ports 2-pos. single normal close No option code With mounting 2-pos.
  • Page 33 ８ SPECIFICATION Example of same model Manifold  M3KA111-M5-7 Indicates 3KA1 manifold, 2-position single normal close B ports M5 top porting, 7 stations, Example of mixed manifold   Method of coding the contents of combination : Indicate the number of the function-wise master valves (simplex) after the normal Model No. indication when selecting the mixed manifold (code 8 in -).
  • Page 34 ８ SPECIFICATION 4KA1 4KA1 Operator type master valve (a) Operator type (b) Port size (c) Other option R1・R2 PA・PB Code Description Code P・A・B ports Code Description ports ports 2-pos. single operator No option code Rc1/8 With 2-pos. double operator φ4 push-in joint mounting plate ●...
  • Page 35 ８ SPECIFICATION Example of same model Manifold  M4KA111-M5-7 Indicates 4KA1 manifold, 2-position single A ･ B ports M5 side porting 7 stations, Example of mixed manifold   Method of coding the contents of combination : Indicate the number of the function-wise master valves (simplex) after the normal Model No. indication when selecting the mixed manifold (code 8 in -). After the Model No., clearly indicate the code of the required function (see Table below) and the arrangement no.
  • Page 36 ８ SPECIFICATION 4KB1 ※Without a sub-base 4KB1 1 ※Gasket,mounting screws are attached 4KB1 Operator type master valve (a) Operator type (b) Port size Code Description Code P・A・B ports PA・PB ports 2-pos. single operator Rc1/8 2-pos. double operator 3-pos. all ports blocked 3-pos.
  • Page 37 ８ SPECIFICATION Example of same model Manifold  M4KB111-06-7 Indicates 4KB1 manifold, 2-position single A ･ B ports Rc1/8 side porting 7 stations, Example of mixed manifold   Method of coding the contents of combination : Indicate the number of the function-wise master valves (simplex) after the normal Model No. indication when selecting the mixed manifold (code 8 in -). After the Model No., clearly indicate the code of the required function (see Table below) and the arrangement no.
  • Page 38 ８ SPECIFICATION ８．３ Consumable parts Spool assembly 2) Piston assembly Function Model example Function Model example 3KA111 3KA1※ 3KA1111 4KA111, 4KB111 4K9-15１ 4K9-110 4KA111 4KA121, 4KB121 4KB111 4KA131, 4KB131 3KA121 4KA141, 4KB141 4K9-152 4KA121 4K9-118 4KA151, 4KB151 4KB121 3KA131 4KA131...

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