Pneumatic components (F.R.L. unit Separated type) Safety precautions

Transcription

1 Pressure unit Separated type 1. Common Pneumatic components ( unit Separated type) Safety precautions Always read this section before starting use. Refer to Intro 67 for general precautions for components., lubricator plastic bowl, lubricator drip window, and pressure gauge lens Material is polycarbonate. Do not use in the atmosphere with synthetic oil, organic solvent, chemical materials, coolant, screw locking adhesive, liquid soap, hot water, etc., or possible exposure to these substances. Refer to page 373 for details for chemical resistance of plastic bowl. Piping load torque Check that the piping load or torque is not applied to the body or piping sections. Max. torque N m Rc1/8, Rc1/4 Rc3/8, Rc1/2, Rc3/4 Design & Selection Rc1 and over Large drainage Install the air and drain separator before the air. Use of hot humid air causes excessive drainage from the compressor and may shorten component life or cause corrosion. Ultra dry air Rubber parts for the could deteriorate quickly, so use of a fluorine rubber valve assembly is recommended. Consult with CKD when required. Waterlubricated compressor circuit Take measures to prevent chlorinebased substances from entering the compressed air. Use the automatic drain under the following working conditions. Failure to observe this could result in operation faults. "F" NO type automatic drain (exhaust without pressurized) Applicable compressor must be used at 0.75 kw or more (discharge flow 0.09 m 3 /min. [ANR]). is purged with initial drainage until pressure reaches 0.1 MPa just after compressor operated. Set the working pressure to 0.15 MPa or more. "F1" NC type automatic drain (no exhaust without pressurized) Applicable compressor can be used at 0.75 kw or less. Set the working pressure to 0.15 MPa or more. Piston drain "D" Set the working pressure to 0.1 MPa or more. Do not use this type for devices to which impact is applied. Automatic discharge used in an intermittent flow. Drainage is not discharged under working conditions where air flows constantly. 2. Filter The miniature (A1019, B7019, A3019) bowl does not have a bowl guard. Provide a guard on the device, etc., for safety. Do not select using the port size. Use a pre before the micronaught micro alescer. Use a (5 m) or submicron as the pre. Use a micronaught micro alescer before the odor naught micro alescer air. 3.Regulator, unit Install a safety device where an output pressure exceeding the 's set pressure value could result in damage or faulty operation of secondary side devices. The cannot process residual pressure (remove secondary pressure) when primary pressure is released. Use a with a check valve when residual pressure must be processed. In some cases, the cannot be used for secondary side sealing circuits or balance circuits. Consult with CKD for these applications. 546

2 FRL unit Separated type Set secondary side pressure of the to 85% or less of the primary side. Consult with CKD when using the dial in applications where a back pressure is applied on the secondary side with a balancer, etc. After setting pressure, do not release primary pressure and repressurize. When using the, mount the seal packing and tighten the nut after setting pressure. When using the, life could be shortened markedly depending on the fluid (water quality). Use this for clean water for general industries. Remove all foreign matter and water deposits, and do not use for liquids and fluids that cause corrosion or swelling of the rubber. When using s in parallel as shown below, do not use the OUT side as a closed circuit. If a closed circuit is required, set a check valve at the 's OUT side. 1. Common Using the correctly Avoid installing this product where it is subject to direct sunlight. Set the pressure setting upward. After setting pressure, lock the handle. Check primary pressure carefully before setting pressure. Check the arrow indicating the air inlet before connecting. A reverse connection could result in improper operation. Install the air and lubricator vertically with the bowl facing downward. Failure to do so could result in a drainage discharge fault, and prevent dripping from being confirmed. Use of the automatic drain where vibration is present could cause faults and malfunctions. Pipe automatic drain piping as follows. Not doing so could cause malfunctions. Use an inner diameter of 5.7 or more and piping of 5 m or less for the drainage section. Do not use vertical piping. Pipe so that no lateral load acts on the bowl. 4. Lubricator Consult with CKD for using lubrication with an air motor or bearings. Also consult with CKD when using this unit at a high frequency such as in a press machine. If the working air rate is low for the lubricator, oil may not drip. Check the minimum air rate required for dripping oil. The economist type has a check valve that allows the oil to be supplied in the pressurized state without stopping primary pressure. (Excluding A3019) Check that the bowl is not pressurized before supplying oil. Check that the oil level in the bowl is between the upper and lower limits. 5. Relief valve Installation & Adjustment When using released to the atmosphere, restrict the pressure before releasing. Piping screwin torque Make sure that excessive torque is not applied on the body and piping when piping. Max. torque N m Rc1/8, Rc1/4 Rc3/8, Rc1/2 Rc3/4 and over Plastic bowl drain piping The drain piping for the plastic bowl has a barbed nipple, and can be directly installed. Confirm that the drain cock is closed before inserting the tube. The maximum tightening torque of the drain cock is 0.5N m. Applicable tube Bore size 5 soft vinyl tube Bore size 5.7 to 6 nylon tube (F1508) Pressure unit Drain cock Drain port 547

3 FRL unit Separated type Pressure Drain piping of metal bowl with automatic drain Fix the hexagon side of the cock before screwing the joint, etc., into the Rc1/4 female screw. When using the metal bowl with automatic drain, if the drain is piped with a tightening joint, manual operation is not possible. 2. unit Cock (hexagon head) Drain port Rc 1/4 Turn the pressure adjustment handle clockwise to increase the secondary pressure, and counterclockwise to lower the pressure. Set the pressure while checking primary pressure. If the pressure cannot be adjusted, check the valve assembly for the adherence of foreign matter, and check the Oring for damage, etc. 3. Filter When piping, remove coolant or rust proof oil. Failure to observe this obstructs initial performance of the micro naught micro alescer, and shortens life. Coolant and rustproofing agent on the inside of pipes enters compressed air and adversely affects expensive components or devices. Installation & Adjustment 4. Regulator, unit For B7019, B2019, 2419 and B6061, if the knob is forcibly rotated in the L direction, the knob could be broken, so care must be taken. When using the dial air, turn adjusting knob clockwise to increase the secondary pressure, and counterclockwise to lower pressure. Adjust pressure so the primary pressure is 0.1 MPa or more higher than set pressure. Do not turn ON and OFF frequently using the air valve. When piping the, pipe the A section shown in the drawing so matching marks on the body and cover do not deviate. Sections other than A section must not be held with a tool such as a vise. When installing or removing the bracket, fix the octagonal section of the cover with a wrench, etc., and securely tighten with the panel installation nut so the body and cover matching marks do not deviate. When changing the position of the bracket, fix the octagonal section of the cover in the same manner and tighten with the panel installation nut. Panel mount nut Matching mark Octagonal section of cover Guard A Bracket Matching mark Body Do not apply pressure exceeding the pressure gauge's full scale or the pressure gauge could break. (Pay special attention when using the full scale 0.2 or 0.4 MPa pressure gauge.) 548

4 FRL unit Separated type 5. Lubricator Adjustment of lubricator drop down Turn the adjusting screw to adjust oil drip. Check that the adjusting screw does not protrude past the unit side. Failure to observe this could cause a "hazard" such as the adjusting screw dislocating and popping out. 1. Common Oil dosing rate adjusting screw Check the air, lubricator plastic bowl, and lubricator drip window for cracks, damage, and other deterioration. Cracks, damage or other deterioration could result in breakage, so if found, replace with a new bowl, new window or with a metal bowl. Check the air, lubricator plastic bowl, and lubricator drip window periodically for contamination. If parts are heavily contaminated or if transparency has dropped, replace with a new bowl or drip window. Use a diluted neutral household detergent to wash parts, and then rinse well with clean water. Use of other agents could result in breakage. Removing the or lubricator bowl Stop the compressed air, completely discharge pressure in the bowl, and confirm that there is no residual pressure before removing the bowl. Assembling parts for maintenance For maintenance, wash up parts and avoid cutting chip or foreign matters. Check the oil drip once a day. If the oil drip is faulty, problems could occur in the unit being lubricated. During Use & Maintenance O Drain Note that the compressor may generate oil oxides such as tar and carbon, so use clean air. Release air in the bowl before checking for draining problems of After washing the drain unit, dry it with compressed air. Storage Do not leave the product in a hot or highly humid atmosphere or outside of the specified range for a long time. Resin and rubber parts could deteriorate, and the resin bowl could discolor. Consult with CKD when storing this unit outside specifications. 2. Filter Drain so that air drainage does not accumulate beyond the upper limit. Components could malfunction if drainage flows into the secondary side. S Drainage method Manual cock Flexible drain Metal bowl manual cock Drainage is started when the cock is turned to the O side, and the discharge is stopped when the cock is turned in the S direction. When the automatic drain is provided, drainage is discharged automatically when it accumulates. Drainage is also discharged manually. When using the flexible drain, the drainage can be discharged by pressing in the direction of the arrow. O S O S Metal bowl automatic drain Pressure unit 549

5 FRL unit Separated type Pressure Filter Use the differential pressure gauge GA4008P02 to measure pressure drop. Measure the pressure drop accurately. Differential pressure gauge GA4008P02 Differential pressure gauge GA4008P02 Compressed air flow direction 0.07 MPa 0.07 MPa The odor naught micro alescer air adsorbs odors with activated carbon, so life cannot be measured. When the micro naught micro alescer's pressure drops to 0.07 MPa, replace the mantle for the micro naught micro alescer at the same time. Submicron 0.3 m element This cannot be washed and reused. When the pressure drops to 0.07 MPa, replace the element. (Excluding A1019) During Use & Maintenance Regulator Pull the pressure adjustment knob and release the lock before setting the pressure shown below. The could be damaged if the pressure is set without releasing the lock. Note that the knob locks again if it is turned with force in the L direction from the setting pressure 0. For the remote control dial, attach a pressure gauge to the unit's gauge port, and adjust the pilot pressure. The water should be serviced once a year. Life could be shortened depending on the fluid (water quality) used. 4. Lubricator PULL B2019 B6061 B2419 Use Class 1 turbine oil (nonadditive) ISO VG32 for the lubricator. Other oils could cause breakage or improper operation. Removing the lubricator's filling plug To prevent the filling plug from popping out, loosen the filling plug by one turn, and then completely depressurize the bowl before removing the filling plug. The dirt around the filling plug could scatter, so completely remove it. Periodically replenish oil in the lubricator bowl so that it does not drop below the lower limit. The micro alescer (oil removing ) mantle (element) is spent when the pressure drops to 0.07 MPa. Replace the mantle when life is reached. Do not touch the urethane foam layer when replacing the mantle. 550

6 FRL unit Separated type The chemical resistance of plastic parts is shown below. Avoid using products in an atmosphere where chemicals are contained in compressed air, the atmosphere, or where they could adhere to parts. Use in the above state could lead to bowl damage and accidents. Chemical resistance of plastic bowl and body Types of chemicals Inorganic chemicals Organic chemicals Category of chemicals Acid Alkaline Inorganic salt Aromatic hydrocarbon Chlorinated aliphatic hydrocarbons Chlorinated aromatic hydrocarbon Petroleum components Alcohol Phenol Ether Ketone Carboxylic acid Ester Oxyacid Nitro compound Amine Nitrile Chemical resistance of plastic parts Avoid using these types of chemicals or in an atmosphere containing these chemicals. A metal bowl is used if these chemicals must be used. A metal bowl is available for use in an atmosphere containing the following chemicals. Check whether the testing solutions, sealing agents and adhesives contain the following chemicals. General usage Main products of chemicals examples Hydrochloric acid, sulfuric acid, hydrofluoric acid, Acid washing of metals, acidic degreasing phosphoric acid, chromic acid, etc. solution, film treatment liquid, etc. Alkalies such as caustic soda, caustic potash, calcium Alkaline degreasing of metals hydroxide, ammonium water, sodium carbonate The waterbased coolant, leakage detection agent Sodium sulfide, nitrate of soda, potassium bichromate, sodium sulfide, etc. Benzene, toluene, xylene, Contained in paint thinner ethyl benzen, stylene, etc. (benzene, toluene, xylene) Methyl chloride, ethylene chloride, methylene chloride, Organic solventbased washing solution for metals acethlene chloride, chloroform, trichlene, (Trichlene, perchlene, perchlene, carbon tetrachloride carbon tetrachloride etc.) Chlorobenzene, dichloro benzene, Agricultural chemicals benzene hexachloride (B/H/C), etc. Solvent naphtha, gasoline, kerosene. Methyl alcohol, ethyl alcohol, Used as freezing prevention agent cyclohexanol, benzyl alcohol Leakage detection agent Carbolic acid, cresol, naphthol, etc. Liquid disinfectant Methyl ether, methyl ethyl ether, Additive of brake oil ethyl ether Acetone, methyl ethyl keton, Cyclohexanone, acetophenone, etc. Formic acid, acetic acid, butyl acid, Dyes; oxalic acid for aluminum processing, acrylic acid, oxalic acid, phthalic acid, phtalic acid for paint base etc. Leakage detection solution Dimethyl phthalate (DMP), diethl Lubricant, synthetic coolant, phthalate (DEP), dibutyl phtalate (DBP), rustprevention agent additive dioctyl phthalate (DOP) plasticizer for synthetic resin. Glycol acid, lactic acid, malic acid, citric acid, tartaric acid Nitro methane, nitro ethane, nitro ethylene, nitro benzene, etc. Methylamine, diethylamine, ethylamine, Brake fluid additive aniline, acetoacetanilide, etc. Acetonitrile, acrylonitrile, benznitrile, Raw material for nitryl rubber acetoylidyne nitrile, etc. Polycarbonate bowl Nylon bowl Nylon body Pressure unit : Available, : Not available (plastic will be damaged.) 551

7 Separated type Pressure Bracket dimensions Wall bracket: 6506 Applicable model A1019/1219/B2019/A3019/B6061/6119/2419/2619 Bracket thickness 2mm Tapping screw attached Wall bracket: 65052C/3C/4C/6C Applicable model 1137/1237/3002E/3502/6167/3202/1637 Bracket thickness 2.6mm Model no C 65053C 65054C 65056C Port size Rc1/4 Rc3/8 Rc1/2 Rc3/ Wall bracket: 6503 Applicable model A2000/A7070/2400/2100/7170/6062 Bracket thickness 2.3mm Wall bracket: 65042C/3C Applicable model 1144/1244/3000E3500/1644 Bracket thickness 2.3mm Model no C 65043C Port size Rc1/4 Rc3/ Wall bracket: 6166 Applicable model B2519/B7019/B2019(P)/2419(P)/B6061 (P) Bracket thickness 2mm Wall bracket: 6502 Applicable model 2001/7080/2401 Bracket thickness 2.3mm R R (Product center)

8 Bracket dimensions Wall bracket: 6501 Applicable model 1404 Bracket thickness 2.3mm Pipe bracket (miniature): Bracket thickness 2.3mm Separated type Bracket dimensions R Model no Port size 1/8B Pipe bracket: 6132 Applicable model 1138/1238/2215/2415 Bracketpipe bracket thickness 4.5 mm Pressure unit Model no C 61323C 61324C 61326C 61328C Port size 1/4B 3/8B 1/2B 3/4B 1B

9 Separated type Many options are available for CKD air. When selecting model No. of air, atmosphere around the air and working environment are carefully considered. If an option is required, indicate an optional symbol at the end of model No. when placing an order. (E.g.) If metal bowl is installed to 11372C, use 11372CM. Pressure Bowl options table Model Applicable type Option symbol Blank E F F1 D Z EZ FZ F1Z DZ M FM F1M DM MG FMG F1MG A1019 B How to order bowl assembly (Set of bowl assembly and for sealing) 1144 A J A7070J 7170J J Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note J 1238 A1019 A * * 1238 A1019 A Model no. B Option symbol Drainage Size Bowl material A Blank E F F1 D Manual drain cock Flexible drain NO auto. drain with manual cock (exhaust w/o pressurized) NC auto. drain with manual cock (no exhaust w/o pressurized) Piston drain Blank J Standard Jumbo bowl Blank Z M MG Polycarbonate resin Transparent nylon resin Metal bowl Metal bowl with sight gauge Select in turn of drainage, size and bowl material. "J" is used only when an asterisk (*) is added to the Applicable Model field of the Bowl Option Development Table. Note 1: Do not apply F (NO automatic drain) to micro alescer. Note 2: Refer to page 547 for the automatic drain use conditions. DM Other bowl assembly model no. table Bowl material Polycarbonate resin Nylon resin Metal bowl Metal bowl with sight gauge Model 1326/5100 A A Z 5100M A1338M 5100MG A1338MG 610

10 Separated type Optional parts table Ari BBracket For model no. with port size from Rc1/4 to Rc3/4, the dedicating bracket is available. When screwing a nipple or connector, etc. into, these can be assembled together, so handling is easy. Body assembly Polycarbonate bowl Do not use this product where the ambient temperature is high, or organic solvent and chemicals etc. such as thinner, trichlene, etc. are contained. Manual or automatic drain type is available, so use these products according to usage. Metal bowl Use metal bowl where the ambient temperature is high, or organic solvent and chemicals, etc. such as thinner, trichlene, etc. are contained. 3 m element Element Baffle Bowl assembly Wall bracket Bracket installation attitude Nylon bowl Nylon resin, transparent green bowl can be used for some solvent or synthetic oil. Manual or automatic drain type is available, so use these products according to usage. M Metal bowl MG Metal bowl with side gauge E Flexible drain type (Manual type) F1 F N.O. automatic drain with manual cock (Manual, automatic type) N.C. automatic drain with manual cock (Manual, automatic type) EZ Flexible FZ drain type (Manual type) F1Z N.O. automatic drain with manual cock (Manual, automatic type) N.C. automatic drain with manual cock (Manual, automatic type) Z Manual cock type (Manual type) Rc1/4 Basic: manual cock type (Manual type) Clamp ring assembly FM F1M N.O. automatic drain metal bowl with manual cock (manual, automatic type) N.C. automatic drain metal bowl with manual cock (manual, automatic type) with 3 m element Max. flow rate table Model no CE 11443CE 11442CEJ 11443CEJ 11372CE 11373CE 11374CE 11376CE 11386CE 11388CE CE CE CE Atmospheric pressure conversion value for primary pressure 0.7MPa and pressure drop 0.034MPa Port size Rc1/4 Rc3/8 Rc1/4 Rc3/8 Rc1/4 Rc3/8 Rc1/2 Rc3/4 Rc3/4 Rc1 Rc1 1/4 Rc1 1/2 Rc2 Bowl guard Max. flow rate ( min ANR) 900 1, ,000 1,600 2,100 2,500 2,500 4,800 6,400 13,000 13,000 13,000 Pressure unit 611

11 Separated type Regulator Many options are available for CKD. When selection model No. of a, select the product according to working conditions. If an option is required, indicate an optional symbol at the end of model No. when placing an order. (E.g.) If a plastic knob is installed to 20012C, use 20012CK. K Plastic knob Synthetic resin round hand is available. Adjusting screw assembly Nut Guard Screw Spring disk Spring P Panel mount Regulator can be directly installed on panel. Hole size for panel mount is as following. B20191/2CP 24191/2CP 31 1mm A20002/3CP 24002/3CP 18 1mm 21002/3CP 20012/3/4/6CP 24012/3/4/6CP 20 1mm BBracket Mounting bracket is available. The bracket is fixed by tapping screw. L Spring for H Spring for low pressure high pressure Diaphragm assembly Disk seal Body assembly N Nonrelief type Wall bracket Valve assembly Spring Pressure Specifications Model Regulator for low pressure Relief valve for low pressure Regulator for low water pressure Regulator for high pressure Bracket installation attitude Model no. Pressure adjusting range B20191/2CL 24191/2CL A20002/3CL 0.02 to 0.34MPa 24002/3CL 20012/3/4/6CL 24012/3/4/6CL B6061L 0.04 to 0.35MPa B2519L 0.02 to 0.35MPa 20012/3/4/6CH 0.07 to 1.72MPa 22156/8/10CH 0.07 to 1.23MPa Bottom plug Attached pressure gauge Model Attached pressure gauge G LG A7070 A G59D8P10 G59D8P BA100 B2019 B B B6061 G49D6P10 G49D6P G59D8P H 2215H 2216H G59D8P20 612

12 Lubricator Many options are available for CKD lubricator. When selecting model No. of lubricator, carefully consider type of lubricant and working environment. Separated type Optional parts table Lubricator If an option is required, indicate an optional symbol at the end of model No. when placing an order. (E.g.) If metal bowl is installed to 2C, use 2CM. VZ Autofill type (Automatic lubrication) C Manual cock type Adjusting screw Filling plug Spacer tube Flow guide Flow guide screw Nylon bowl Polycarbonate bowl Nylon resin, transparent green Do not use this product where the bowl can be used for some solvent ambient temperature is high, or organic or synthetic oil. solvent and chemicals etc. such as Autofill type for automatic thinner, trichlene, etc. or spindle oil etc. lubrication is also available. are contained. (Refer to page 600 for details.) Autofill type for automatic lubrication is also available. (Refer to page 600 for details.) V Autofill type (Automatic lubrication) Sight dome Valve Body assembly Ball Adaptor Siphon tube assembly Bowl assembly basic type without cock (blank) M Metal bowl B Bracket For model no. with port size from Rc1/4 to Rc3/4, the dedicating bracket is available. When screwing a nipple or connector, etc. into, these can be assembled together, so handling is easy. Wall bracket Metal bowl Use metal bowl where the ambient temperature is high, or organic solvent and chemicals, etc. such as thinner, trichlene, etc. are contained in the atmosphere. MG Metal bowl with side gauge Bracket installation attitude MG2 Quart bowl for 2 MG8 Quart bowl for 8 MG20 Quart bowl for 20 CM Petcock type metal bowl 3003E/3503E CMG Petcock type metal bowl with sight gauge Blank A E 3000E J A J V V Bowl guard Clamp ring assembly Applicable type Polycarbonate resin bowl Transparent nylon resin bowl Manual cock Autofill Manual cock Autofill Blank A E/ EJ/3500J 3002E/ Blank A3019 Z 3000E Z 3000E JZ Z Z A1019 Z 1144 Z 1144 JZ 1137 Z 1138 Z VZ VZ 3000E M 3000E JM M M Large volume metal bowl Lubricant 2 /8 /20 can be stored. Large volume metal bowl can be quickly connected to the main body, so handling and maintenance are easy. Bowl assembly and model no. table (Set of bowl assembly and for sealing) Metal bowl Manual cock Autofill A1019 M 1144 M 1144 JM 1137 M 1138 M VM VM Bowl material Carbon steel tube Bowl weight MG2 10 MG8 20 MG20 30 Metal bowl with sight gauge Blank Manual cock Autofill E MG 3000E JMG MG MG 1144 MG 1144 JMG 1137 MG 1138 MG Note 1: Quart bowl number for 2 to 20 contains an adaptor, set screw, a gasket and a siphon tube assembly, etc. for installation. Note 2: A quart bowl for 2 to 20 is custom order. Note 3: Indicate "blank" for bowl without cock type. A blanking plug assembly applies to metal bowl without cock type "M". Note 4: Siphon tube assembly is attached for MG2/MG8/MG20. VMG VMG MG2 MG2 3004E MG2 3005E MG2 MG8 MG8 3004E MG8 3005E MG8 MG20 MG E MG E MG Pressure unit