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Summary of Contents for CKD 4KA2
- Page 1 ＳＭ−２０６７９０-A ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ ＰＮＥＵＭＡＴＩＣ ＶＡＬＶＥ ４ＫＡ２, ４ＫＢ２ Ｍ４ＫＡ２, Ｍ４ＫＢ２ 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． 5 Edition ...
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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 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 ！ CAUTION : voltage and the current type (AC or DC). MANUAL (Section 5.2) OPERATING DEVICE a) Once the manual operating device has been operated, ...
- 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 4KA2, 4KB2 M4KA2, M4KB2 Manual No. SM-206790-A/5 1. PART NAME AND DESCRIPTION 2. INTERNATIONAL SYSTEM OF UNITS (SI) 3. UNPACKING 4. INSTALLATION Environment Installation Piping Wiring 5. OPERATING RECOMMENDATION Operation Manual Operating Device Air Quality Electric Circuits 6. MAINTENANCE...
- Page 10 １ PART NAME AND DESCRIPTION 1. PART NAME AND DESCRIPTION Direct piping unit Direct piping manifold Subplate piping unit Subplate piping manifold Part Name explanation Valve unit There are direct pipng and sub plate piping ① It uses in case of manual operation. There are a non lock and a lock Manual Override ②...
- Page 11 ２ 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 12 ３ UNPACKING 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. ...
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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 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 ...
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Page 16: 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 17: Pipe Connections
４ INSTALLATION 4.3.6 Pipe connections (1) Tubes to be used For use with solenoid 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 18 ４ INSTALLATION (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. The tension applied sideways through the tube should not exceed 40N.
- Page 19 ４ INSTALLATION 4.3.7 External pilot (K) piping port Pilot air is individual supply in the external pilot (K) type. Supply port is M5, so pay attention to piping connecting position not to mistake. If it isn’t correctly piped, it causes the malfunc- tion.
- Page 20 ４ INSTALLATION 1) Caution for wiring (1) When using the small terminal box and water-proof is required, use cab-tire cords φ4 to φ6.5 in outer diameter (water-resistance is improved, but not for outdoor use). (2) The connector type (C, C1, C2, C3, D, D1, D2, D3) should be used in a place with little dust and not directly exposed to water and oil.
- Page 21 ４ INSTALLATION Plug-in connector D type Plug-in connector D type with lead wire, without leadwire, Plug-in connector D type Plug-in connector D type Name surge suppressor and surge suppressor and with lead wire without lead wire indicator light indicator light Option code Lead wire 300mm...
- 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 indicator light (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...
- 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 Crimp terminal (Socket ＋ Crimp terminal) (made by CKD) Caulking tool (made by CKD) ② Terminal caulking ⑥ Tightening screw ①...
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Page 25: Operating Recommendation
５ OPERATION 5. OPERATING RECOMMENDATION 5.1 Function 1) 4KA series 4KA210 No signal current (Illustrated) → A → R2 (R1 port is closed.) When actuated → B → R1 (R2 port is closed.) PR is an exhaust port of the pilot pressure line. ... - Page 26 ５ OPERATION 2) 4KBseries 4KB210 No signal current (Illustrated) → A → R2 (R1 port is closed.) When actuated → B → R 4KB220 When Sol is actuated (Illustrated) → A → R When Sol is actuated → B → ...
- Page 27 ５ OPERATION 5.2 Manual Operating Device a) After using the manual override, be sure to reset the ！ WARNING : manual override to the original (OFF) position before resuming the operation of the device. After a non-lock type operation (push and release), be sure to check that the manual override is automati- cally reset. After a lock-type operation (push and lock), ...
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Page 28: Air Quality
5.3.1 Lubrication The 4KA2、 4KB2 Series solenoid valve systems use pre-lubricated valves that usually 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 29 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.
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Page 30: 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 31: 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 32: 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. A person who disassembles and reassembles a solenoid valve system needs to have a knowledge for safely per- forming such operation based on the understanding about the mechanisms and operating principles of solenoid valves. ... - Page 33 ６ MAINTENANCE 6.2.2 Disassembling drawing and parts list 1) 4KA210･4KB210 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 M2.5×24 ④ Coil Gasket Fluore rubber ⑤ Pilot valve ass’y ⑥...
- Page 34 ６ MAINTENANCE 4KA220・4KB220 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 M2.5×24 ④ Coil Gasket Fluore rubber ⑤ Pilot valve ass’y ⑥ Pilot valve Gasket Nitrile rubber ⑦...
- Page 35 ６ MAINTENANCE 4KA230・4KA240・4KA250 4KB230・4KB240・4KB250 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 M2.5×24 ④ Coil Gasket Fluore rubber ⑤ Pilot valve ass’y ⑥ Pilot valve Gasket Nitrile rubber ⑦...
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Page 36: Troubleshooting
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 37: Product Specifications
８ SPECIFICATIONS 8. PRODUCT SPECIFICATIONS AND HOW TO ORDER 8.1 Product Specifications 1) Specifications 4KA240 4KA250 4KA230 4KA210 4KA220 3-pos. Load 3-pos. Load Model code 3pos. All ports 2-pos. Single 2-pos. Double ports open to ports open to blocked exhaust ports supply ports JIS Symbol A B Item R1 P R2... - Page 38 SPECIFICATION Model code M4KA2 Item Manifold structure Manifold integrated Applicable solenoid valve 4KA2 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 39 ８ SPECIFICATIONS 4KB240 4KB250 4KB230 4KB210 4KB220 3-pos. Load 3-pos. Load Model code 3pos. All ports 2-pos. Single 2-pos. Double ports open to ports open to blocked exhaust ports supply ports JIS Symbol A B Item Working fluid Compressed air Valve type and operation Pilot operated soft spool valve Min.
- Page 40 ８ SPECIFICATION Model code M4KB2 Item Manifold system Manifold integrated Applicable solenoid valve 4KB2 series Nos. of station 2〜20 stations Manifold type Common supply, common exhaust Grommet with lead wire Electrical connections (Option : Small terminal box, Plug-in connectors) Supply port Side (Rc1/8) Port Cylinder ports...
- Page 41 ８ HOW TO ORDER 8.2 How to Order 4KA2 4KA2 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 on-locking type man- 2-pos. single operator...
- Page 42 ８ HOW TO ORDER NOTE: Following options are available as a custom order. ・Ozone-proof specifications Available in ozone-proof specifications by adding -P11 to the end of model number. Model number: ※※-Voltage-P11 ・Coolant proof specifications Selectable with option symbol A. Model number: ※※-A-Voltage ・Copper and PTFE free (Copper and PTFE materials are not used for flow path) Available in copper and PTFE free by adding -P6 to the end of model number.
- Page 43 ８ HOW TO ORDER M4KA2 4KA2 ※ Solenoid valve AC100V for manifold ※ Gasket, mounting screws are attached M4KA2 Manifold AC100V Operator type Solenoid valve (a) Position/Operator type (b) Port size (c) Manual operation device Code Description Code P･ A ･ B ports R1 ･...
- Page 44 Available in copper and PTFE free by adding -P6 to the end of model number. Model number: ※※-Voltage-P6 Example of same model Manifold M4KA210-06-5-AC100V Indicates 4KA2 manifold, 2-position single solenoid, A ･ B ports Rc1/8 top porting, 5 stations, 100 V AC 50/60 Hz. Example of mixed manifold Method of coding the contents of combination : Indicate the number of the function-wise solenoid valves (simplex) after the normal Model No.
- Page 45 3000mm DC12V DC12V No option 300mm 500mm Consult with CKD about vacuuming of external 1000mm Plug-in connector D type pilot (K). 2000mm When attached surge suppressor is DC24V or less, sup- 3000mm pression connector type (diode) is provided.
- Page 46 ８ HOW TO ORDER NOTE: Following options are available as a custom order. ・Ozone-proof specifications Available in ozone-proof specifications by adding -P11 to the end of model number. Model number: ※※-Voltage-P11 ・Coolant proof specifications Selectable with option symbol A. Model number: ※※-A-Voltage ・Copper and PTFE free (Copper and PTFE materials are not used for flow path) Available in copper and PTFE free by adding -P6 to the end of model number.
- Page 47 ８ HOW TO ORDER M4KB2 ※ Gasket, mounting screws are attached ※ Solenoid valve 4KB2 M1 B AC100V for manifold M4KB2 M1 B AC100V Manifold Operation classification Solenoid valve (a) Operator type (b) Port size (c) Manual operating device P ･ R1 ･ R2 Code Description Code...
- Page 48 ８ HOW TO ORDER NOTE: Following options are available as a custom order. ・Ozone-proof specifications Available in ozone-proof specifications by adding -P11 to the end of model number. Model number: ※※-Voltage-P11 ・Coolant proof specifications Selectable with option symbol A. Model number: ※※-A-Number of stations-Voltage ・Copper and PTFE free (Copper and PTFE materials are not used for flow path) Available in copper and PTFE free by adding -P6 to the end of model number.
- Page 49 ８ HOW TO ORDER ８．３ Consumable parts 2) Piston assembly Spool assembly Function Model example Function Model example 4KA210 4KA210, 4KB210 4K9-150 4K9-153 4KB210 4KA220, 4KB220 4KA220 4KA230, 4KB230 4K9-126 4KB220 4KA240, 4KB240 4K9-154 4KA230 4KA250, 4KB250 4K9-127 4KB230 4KA240 4K9-128 4KB240 4KA250 4K9-129 4KB250 Coil assembly Function Model example...
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