AV2000/3000/4000/5000

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1 CAT.ES4-39 Soft Start-up Valve AV/3/4/5 New Series AV5 introduced! A start-up valve that gradually increases supply pressure during start up and rapidly exhausts system air when the supply air is shut off Large effective area (mm²) AV/ (ody size: /4) AV3/ 37 (ody size: 3/8) AV4/ 6 (ody size: /) AV5/3 (ody size: 3/4) AV5/ (ody size: ) Manual supply/exhaust function Low power consumption Modular with F.R.L. combinations F.R.L. combinations F.R.L. combination Soft start-up valve AV AV3 AV4 Except AC4-6 AV5 AC AC5 AC3 AC4 AC5 AC6 SMC F.R.L. combination Soft start-up valve

2 Soft Start-up Valve AV/3/4/5 How to Order E AV F G C Q Ordering source area code Nil E N Japan, Asia, Australia Europe North Ameria Soft start-up valve Manual override Nil: Non-locking push type (flush type) : Locking type (tool required) C: Locking type (lever type) ody size /4 3/8 / 3/4, Thread type Nil F N Rc G NPT Port size /4 (AV only) 3/8 (AV3 only) / (AV4 only) 3/4 (AV5 only) (AV5 only) Nil G Option None With pressure gauge Order Made Rated coil voltage * * 3* 4* Indicator light/surge voltage suppressor Nil S Z VAC (5/6Hz) VAC (5/6Hz) to VAC (5/6Hz) VAC (5/6Hz) 4VDC VDC Other * DIN type only. Contact SMC for other voltages (9). None With surge voltage suppressor (grommet type only) With indicator light/surge voltage suppressor (not possible with grommet type) Electrical entry G: Grommet (only DC voltage) D: Type D DIN terminal How to Order Pilot Valve Assemblies SF4 G 8 Q Y: Type Y DIN terminal Rated coil voltage * VAC (5/6Hz) * VAC (5/6Hz) 3* to VAC (5/6Hz) 4* VAC (5/6Hz) 5 4VDC 6 VDC 9 Other *DIN Type only Electrical entry G D Y Grommet Type D DIN terminal Type Y DIN terminal For soft start-up valve Indicator light Surge voltage suppressor Nil S Z Manual override Nil C Non-locking push type (flush type) Locking type (tool required) Locking type (lever type) None With surge voltage suppressor (grommet type only) With indicator light/surge voltage suppressor (not possible with grommet type) TÜV Rheinland AUART GEPRÜFT TYPE APPROVED Note) The grommet type can have a surge voltage suppressor (direct coupling type lead wire), but without indicator light. TÜV approved product Conforms to standards necessary to satisfy EC directives. Series AV has received approval from TÜV Rheinland, an EC Notified ody (EC authorization number 97), for conformity to DIN VDE58: 994 Standards. Consult SMC for details when ordering TÜV approved products because of restrictions regarding product model, voltage specification, and electrical entry, etc.

Soft Start-up Valve AV/3/4/5 Specifications Type D DIN terminal Model Port size Proof pressure Operating pressure range Pressure gauge port size Ambient and fluid temperature Effective area (P) (A)

3 Soft Start-up Valve AV/3/4/5 Specifications Type D DIN terminal Model Port size Proof pressure Operating pressure range Pressure gauge port size Ambient and fluid temperature Effective area (P) (A) (mm²) (A) 3(R) Weight (kg) Rated coil voltage Allowable voltage fluctuation Coil insulation type Apparent power Inrush (current AC consumption) Energized Electrical specifications Current consumption DC Electrical entry Optional specification Pilot valve manual override AV /4 AV3 3/8 AV4 /.5MPa. to MPa /8 to 6 C Note ) AV5 3/ ,, to, VAC (5/6Hz),, 4VDC 5% to +% of rated voltage Equivalent to type (3 C) 5.6VA (5Hz), 5.VA (6Hz) 3.4VA (.W)/5Hz,.3VA (.5W)/6Hz.8W Grommet, Type D DIN terminal, Type Y DIN terminal Indicator light/surge voltage suppressor Note ) Non-locking push type (flush type), Locking type (tool required), Locking type (lever type) Note ) Use dry air when operating at a low temperature. Note ) The grommet type can have a surge voltage suppressor (direct coupling type lead wire), but without indicator light. Piston switching pressure (Open Closed).5 Type Y DIN terminal Secondary pressure MPa Primary pressure MPa (P) Symbol 3(R) Accessories/Pressure gauge Description Part no. Pressure range (A) Pressure gauge G36-- MPa Needle valve flow characteristics Air flow l/min (ANR) Conditions: Primary pressure.5mpa AV5 AV4 AV3 AV Needle rotations

4 AV/3/4/5 Working Principle ON - (P) (A) 3(R) Working condition Low speed supply High speed supply Normal operation Pressure Pilot valve conditions Working description When pilot valve is turned ON by energization or manual override, the pilot air pushes piston A and main valve downward and opens main valve while / PP > R port closes simultaneously. The air from PA P port moves to needle valve, where its flow is adjusted, and flows to A port. The meter-in control of needle valve slowly moves the cylinder from A to. ON When / PP PA after the cylinder reaches, piston fully opens and PA increases rapidly as shown from C to D and / PP PA becomes the same pressure as PP. / PP = approx. PA Pressure time chart (meter-out control) example Initial operation return stroke Pressure stroke A PP PA Cylinder movement with fixed orifice Time C D PR (atmospheric pressure) Since piston holds the fully open condition, during normal operation the cylinder's speed will be controlled by the usual meter-out control. Cylinder drive circuit (meter-out control) example PP (P) 3(R) PP (P) 3(R) PA (A) PA (A) Quick exhaust When pilot valve is turned, spring pushes piston A and main valve upward and opens R port while shutting off the air supply from P port. The pressure difference generated at this time opens check valve and the residual pressure on the A port side is quickly exhausted from R port. (P) PP 3(R) PA (A) 3

5 Soft Start-up Valve AV/3/4/5 Construction ON - (P) (A) 3(R) Parts list No. 3 Description ody Cap Cover Material ADC ADC ADC Replacement parts No Description Pilot valve assembly Piston A assembly Piston assembly Main valve assembly Check valve Piston guide assembly Needle assembly Valve spring Piston spring Check spring Needle spring C type snap ring for shaft C type snap ring for hole Seal Seal O-ring Material POM, NR rass, NR (HNR) rass, NR (HNR) rass, NR (HNR) POM, NR rass, NR Steel wire Stainless steel Stainless steel Steel wire Tool steel Tool steel NR NR NR AV P444A P445A P446A P447 P448A P449A P44 P44 P443 P444 G-5-9 P44 P448 x 8 x Part no. AV3 AV4 SF4- -8 P4434A P4444A P4435A P4445A P4436A P4446A P4437 P4447 P4438A P4448A P4439A P4449A P443 P444 P443 P444 P4433 P4443 P4434 P4444 STW-5 STW-8 - RTW- P443 P444 P4435 P4445 x 9 x.5 x 9.5 x.5 AV5 P4454A P4455A P4456A P4457 P4458A P4459A P445 P445 P4453 STW- RTW-5 P445 P x.5 x Refer to page for pilot valve assembly part number designations. 4

6 AV/3/4/5 Dimensions Grommet: AV - - G, GS D DIN terminal: AV - - D, DZ DIN terminal for European use: AV - - Y, YZ D I G - A + SMC MADE IN JAPAN 3mm (lead wire length) Manual override (locking lever type) Applicable heavy duty cord O.D.: ø6, ø8 With indicator light/ surge voltage suppressor Manual override (locking lever type) - + SMC L K A G MADE IN JAPAN M Port size ON Pressure gauge mounting bore /8 ø37 P A H Q C N ø37 P ON A Indicator light H Q 36.8 E R P 4-R 36.8 E Pressure gauge mounting bore /8 R P 4-R C Model Port size A C D E G H I K L M N P Q R AV- - G AV- - GS AV- - D AV- - DZ AV- - Y AV- - YZ AV3-3- G AV3-3- GS AV3-3- D AV3-3- DZ AV3-3- Y AV3-3- YZ AV4-4- G AV4-4- GS AV4-4- D AV4-4- DZ AV4-4- Y AV4-4- YZ 6 AV5- - G 6 AV5- - GS 6 AV5- - D 6 AV5- - DZ 6 AV5- - Y 6 AV5- - YZ /4 /4 /4 3/8 3/8 3/8 / / / 3/4, 3/4, 3/4, M4 x.7 Depth 4.5 M4 x.7 Depth 4.5 M4 x.7 Depth 4.5 M5 x.8 Depth 5 M5 x.8 Depth 5 M5 x.8 Depth 5 M6 x Depth 6 M6 x Depth 6 M6 x Depth 6 M6 x Depth 7.5 M6 x Depth 7.5 M6 x Depth 7.5 5

7 ON Soft Start-up Valve AV/3/4/5 Modular F.R.L. Combination Spacer Select one of the spacers below when connecting to an F.R.L. combination unit (AC to AC6). (Spacers must be ordered separately.) IN SMC OUT 7 R Spacer L type bracket Spacer with L type bracket T type bracket Spacer with T type bracket Spacer with L type bracket L type bracket Spacer with T type bracket T type bracket Model Y Applicable model AV L type bracket L Spacer with L type bracket YL Applicable model AV T type bracket T Spacer with T type bracket YT Applicable model AV Y3 AV3 3L Y3L AV3 3T Y3T AV3 Y4 AV4 4L Y4L AV4 4T Y4T AV4 Y6 AV5 6L Y6L AV5 6T Y6T AV5 6

8 Series AV/3/4/5 Safety Instructions These safety instructions are intended to prevent a hazardous situation and/or equipment damage. These instructions indicate the level of potential hazard by a label of "", "" or "Danger". To ensure safety, be sure to observe ISO 444 Note ), JIS 837 Note ) and other safety practices. : Operator error could result in injury or equipment damage. : Operator error could result in serious injury or loss of life. Danger: In extreme conditions, there is a possible result of serious injury or loss of life. Note ) ISO 444 : Pneumatic fluid power -- Recommendations for the application of equipment to transmission and control systems. Note ) JIS 837 : General Rules for Pneumatic Equipment.. The compatibility of pneumatic equipment is the responsibility of the person who designs the pneumatic system or decides its specifications. Since the products specified here are used in various operating conditions, their compatibility for the specific pneumatic system must be based on specifications or after analysis and/or tests to meet your specific requirements.. Only trained personnel should operate pneumatically operated machinery and equipment. Compressed air can be dangerous if an operator is unfamiliar with it. Assembly, handling or repair of pneumatic systems should be performed by trained and experienced operators. 3. Do not service machinery/equipment or attempt to remove components until safety is confirmed.. Inspection and maintenance of machinery/equipment should only be performed after confirmation of safe locked-out control positions.. When equipment is to be removed, confirm the safety process as mentioned above. Cut the supply pressure for this equipment and exhaust all residual compressed air in the system. 3. efore machinery/equipment is restarted, take measures to prevent shooting-out of cylinder piston rod, etc. (leed air into the system gradually to create back pressure.) 4. Contact SMC if the product is to be used in any of the following conditions:. Conditions and environments beyond the given specifications, or if product is used outdoors.. Installation on equipment in conjunction with atomic energy, railway, air navigation, vehicles, medical equipment, food and beverages, recreation equipment, emergency stop circuits, press applications, or safety equipment. 3. An application which has the possibility of having negative effects on people, property, or animals, requiring special safety analysis. 7

9 AV/3/4/5 Specific Product Precautions e sure to read before handling. Refer to page 7 for safety instructions. Design. Actuator drive When a component such as a solenoid valve or actuator is to be driven using this product, take appropriate measures to prevent potential danger caused by actuator operation.. Holding of pressure Since the products are subject to air leakage (allowed), they cannot be used for applications such as holding pressure in a pressure vessel. 3. Maintenance space The installation should allow sufficient space for maintenance activities. Selection. Confirm the specifications. The products presented in this catalog are designed only for use in compressed air systems. Do not operate at pressures or temperatures, etc., beyond the range of specifications, as this can cause damage or malfunction. (Refer to specifications.) Contact SMC when using a fluid other than compressed air.. Extended periods of continuous energization Contact SMC if valves will be continuously energized for extended periods of time. 3. Operation of closed centre solenoid valves When closed center solenoid valves are used, or when used on an actuator with a load factor of 5% or more, jumping (lurching) cannot be prevented even if this product is used. 4. Using a regulator on the secondary side When mounting a regulator on the secondary side (A port side), use a residual pressure relief regulator (AR55 to 45) or a check type regulator (AR56 to 66). With a standard regulator (AR to 6), the secondary side pressure may not be released when this valve is exhausted. 5. Operation of secondary side solenoid valves To operate solenoid valves mounted on this product's secondary side (A port side), first confirm that the secondary side's pressure (P) has increased to become equal to the primary side's pressure (P). 6. Operation The residual pressure release function of this product is for emergency use only; therefore, avoid operation in the same manner as ordinary 3 port valves. 7. Using a lubricator If mounting a lubricator, mount it on the primary side (P port side), of this product. If mounted on the secondary side (A port side), back flow of oil will occur and may spurt out of the valve's R port. 8. Operation for air blowing This product cannot be operated for air blowing due to the mechanism that switches the main valve to be fully open after the secondary side's pressure increases to approximately / of the primary side. Selection. Leakage voltage Particularly when using a C-R element (surge voltage suppressor) for protection of the switching element, take note that leakage voltage will increase due to leakage current flowing through the C-R element, etc. Power supply Switching element Resistor Leakage current AC coil is % or less of rated voltage. DC coil is 3% or less of rated voltage. Valve. Low temperature operation Although the valve can be operated at a temperature as low as C, measures should be taken to avoid solidification or freezing of drainage and moisture, etc. Mounting. If air leakage increases or equipment does not operate properly, stop operation. After mounting or maintenance, etc., connect the compressed air and power supplies, and perform appropriate function and leakage tests to confirm that the unit is mounted properly.. Instruction manual Mount and operate the product after reading the manual carefully and understanding its contents. Also keep the manual where it can be referred to as necessary. 3. Painting and coating s or specifications printed or pasted on the product should not be erased, removed or covered up. Furthermore, contact SMC before paining resin parts, as this may cause adverse effects depending on the solvent. Leakage voltage Adjustment. To perform the initial speed adjustment of a secondary side actuator, supply air from this valve's primary side and turn ON the pilot valve. Then, rotate the needle counter clockwise from the fully closed condition. 8

10 AV/3/4/5 Specific Product Precautions e sure to read before handling. Refer to page 7 for safety instructions. Piping. Preparation before piping efore piping is connected, it should be thoroughly blown out with air (flushing) or washed to remove chips, cutting oil and other debris from inside the pipe.. Wrapping of pipe tape When connecting pipes and fittings, etc., be sure that chips from the pipe threads and sealing material do not get inside the valve. Further, when pipe tape is used, leave.5 to thread ridges exposed at the end of the threads. Winding direction Expose approx. threads Pipe tape Indicator Light/Surge Voltage Suppressor Voltage AC and VDC 4VDC or less Electrical circuit Terminal no. (+) ZNR With indicator light Terminal no. ( ) Terminal no. + ( ) +( ) (+) Electrical Connection ZNR With indicator light Terminal no. (+) Note) There is no polarity (+ or ). The internal connection of the DIN terminal is as shown below, therefore, connect to the power supply side as shown. DIN terminal 3. Tighten threads with the proper tightening torque. When screwing fittings into valves, tighten with the torques given below. Tightening torque for piping Connection threads Rc /4 Rc 3/8 Rc / Rc 3/4 Rc Proper tightening torque N m to 4 to 4 8 to 3 8 to 3 36 to Connection of piping to products When connecting piping to a product, refer to its instruction manual to avoid mistakes regarding the supply port, etc. 5. F.R.L. module combination When connecting to a modular F.R.L. combination (AC to 6), select one of the spacers, which are included. (Refer to page 6 for details.) However, modular combination with AC4-6 is not possible. Furthermore, connect soft start-up valves to the secondary side of the F.R.L. combination. 6. Primary side piping conditions The nominal size of the piping material's or equipment's bore should be equal to or larger than the soft start-up valve's port size. The composite effective area of the primary side's (P port side's) piping or equipment should be equal to or larger than the values below. Terminal DIN terminal Lubrication. The valve has been lubricated for life at the factory, and does not require any further lubrication.. In the event that it is lubricated, use Class turbine oil (without additives), ISO VG3. However, once lubrication is applied it must be continued, as the original lubricant may be eliminated leading to malfunction. Contact SMC regarding Class turbine oil (with additives), ISO VG3. + Model AV AV3 AV4 AV5 Composite effective area mm² When the piping is restricted or the supply pressure is insufficient, the main valve will not switch and air leakage may occur from the R port. 9

11 AV/3/4/5 Specific Product Precautions 3 e sure to read before handling. Refer to page 7 for safety instructions. Air Supply. Use clean air. Do not use compressed air which contains chemicals, synthetic oils containing organic solvents, salts or corrosive gases, etc., as this can cause damage or malfunction.. Install air filters. Install air filters close to valves at their upstream side. A filtration degree of 5µm or less should be selected.. Install an after-cooler, air dryer or water separator, etc. Air that includes excessive drainage may cause malfunction of valves and other pneumatic equipment. To prevent this, install an after-cooler, air dryer or water separator, etc. Operating Environment. Do not use valves in atmospheres of corrosive gases, chemicals, salt water, water or steam, or where there is direct contact with any of these.. Do not use in an explosive atmosphere. 3. Do not use in locations subject to vibration or impact. 4. A protective cover, etc., should be used to shield valves from direct sunlight. 5. Shield valves from radiated heat generated by nearby heat sources. 6. Employ suitable protective measures in locations where there is contact with water droplets, oil or welding spatter, etc. 7. In a dusty environment or when valve switching noise is intrusive, take measures for the prevention of dust entry and for noise reduction, such as mounting a silencer on the R port. Maintenance. Perform maintenance procedures as shown in the instruction manual. If handled improperly, malfunction or damage of machinery or equipment may occur.. Equipment removal and supply/exhaust of compressed air When equipment is removed, first confirm that measures are in place to prevent dropping of work pieces and run-away of equipment, etc. Then cut the supply pressure and power, and exhaust all compressed air from the system using its residual pressure release function. 3. Low frequency operation Valves should be switched at least once every 3 days to prevent malfunction. (Use caution regarding the air supply.) 4. Manual override operation When the manual override is operated, connected equipment will be actuated. Confirm safety before operating.. Drainage removal Remove drainage from air filters regularly. (Refer to specifications.) How to Find the Flow Rate (at air temperature of C) Choke flow: when (P +.)/(P +.).5 Q = x S x (P +.) x t Subsonic flow: when (P +.)/(P +.) >.5 Q = 4 x S x (P P)(P +.) x t Q: Air flow rate [l/min (ANR)] S:Effective area (mm²) P: Upstream pressure [MPa] P: Downstream pressure [MPa] t : Air temperature Note) Formulas above apply to compressed air only. Use conventional formulas for water and steam.

12 DiskArt 988 Austria SMC Pneumatik GmbH (Austria). Girakstrasse 8, A- Korneuburg Phone: 6-68, Fax: Germany SMC Pneumatik GmbH oschring 3-5, D-6339 Egelsbach Phone: 63-4, Fax: Netherlands SMC Pneumatics V Postbus 38, AH Amsterdam Phone: , Fax: Slovenia SMC Slovenia d.o.o. Grajski trg 5, 836 Zuzemberk Phone: Fax: elgium SMC Pneumatics N.V./S.A. Nijverheidsstraat, -6 Wommelgem Phone: , Fax: Greece S. Parianopoulus S.A. 9, Konstantinoupoleos Street, GR-855 Athens Phone: , Fax: Norway SMC Pneumatics (Norway) A/S Wollsveien 3 C, granfoss Noeringspark N-34 Lysaker, Norway Phone: , Fax: Spain SMC España, S.A. Zuazobidea 4, Pol. Ind. Jundiz, E-5 Vitoria Phone: , Fax: Czech SMC Czech.s.r.o. Kodanska 46, CZ- Prague Phone: , Fax: Hungary SMC Hungary Kft. udafoki ut 7-3, 7 udapest Phone: , Fax: Poland Semac Co., Ltd. PL-5-75 Wesola k/warszaway, ul. Wspolna A Phone: , Fax: Sweden SMC Pneumatics Sweden A.. Ekhagsvägen 9-3, S-45 Huddinge Phone: , Fax: Denmark SMC Pneumatik A/S Jens Juuls vej 3, DK-86 Viby J Phone: , Fax: Ireland SMC Pneumatics (Ireland) Ltd. Citywest usiness Campus, Naas Road, Saggart, Co. Dublin Phone: -43 9, Fax: Portugal SMC España (Sucursal Portugal), S.A. Rua de Engº Ferreira Dias 45, 4 Porto Phone: , Fax: Switzerland SMC Pneumatik AG Dorfstrasse 7, CH-8484 Weisslingen Phone: , Fax: Estonia Teknoma Eesti AS Mustamäe tee 5, EE-6 Tallinn, Estonia Phone: 5953, Fax: 5953 Italy SMC Italia S.p.A Via Garibaldi 6, I-6 Carugate, (Milano) Phone: -97, Fax: Romania SMC Romania srl Vasile Stroescu 9, Sector, ucharest Phone: --354, Fax: --68 Turkey Entek Pnömatik San. ve Tic Ltd. Sti. Perpa Tic. Merkezi Kat: No: 65, TR-87 Okmeydani Istanbul Phone: --5, Fax: --38 Finland SMC Pneumatiikka OY Veneentekijäntie 7, SF- Helsinki Phone: 9-68, Fax: Latvia Ottensten Latvia SIA Ciekurkalna Prima Gara Linija, LV-6 Riga, Latvia Phone: , Fax: Russia SMC Pneumatik LLC Centrako usiness Centre 3, olshoy Prospect V.O., 996 St. Petersburg Phone: 8-953, Fax: DiskArt UK SMC Pneumatics (UK) Ltd Vincent Avenue, Crownhill, Milton Keynes, MK8 AN Phone: Fax: France SMC Pneumatique, S.A., oulevard de Strasbourg, Parc Gustave Eiffel ussy Saint Georges F-7767 Marne La Vallee Cedex 3 Phone: -6476, Fax: Lithuania UA Ottensten Lietuva Savanoriu pr.8, LT-6 Vilnius, Lithuania Phone/Fax: Slovakia SMC Slovakia s.r.o. Pribinova ul. C. 5, 89 ratislava Phone: , Fax: OTHER SUSIDIARIES WORLDWIDE: ARGENTINA, AUSTRALIA, OLIVIA, RASIL, CANADA, CHILE, CHINA, HONG KONG, INDIA, MALAYSIA, MEXICO, NEW ZEALAND, PHILIPPINES, SINGAPORE, SOUTH KOREA, TAIWAN, THAILANDIA, USA, VENEZUELA For more information, please contact your local SMC Regional Centre SMC UK Contact Numbers Head Office: SMC Pneumatics (UK) Ltd, Vincent Avenue, Crownhill, Milton Keynes MK8 AN THE NATIONAL SALES CENTRE FOR ENGLAND & WALES Internal Sales (Price, Delivery Information & Order Placement) Freephone: Fax: sales@smcpneumatics.co.uk Customer Services (Post-Order Resolution) Freephone: Fax: customerservice@smcpneumatics.co.uk TECHNICAL CENTRE Freephone: Fax: technical@smcpneumatics.co.uk SMC FAST RESPONSE (Literature & Catalogue Requests) 8 66 SMC SALES CENTRE FOR SCOTLAND & N. IRELAND Tel: Fax: SMC Pneumatics (UK) Ltd, Carradale Crescent, roadwood usiness Park, Cumbernauld, Glasgow G69 9LE SMC UK Distributors irmingham JAMES LISTER Tel: 5838 Fax: lackburn LACKURN PNEUMATIC SYSTEMS LTD Tel: Fax: ristol APPLIED AUTOMATION Tel: Fax: ury St Edmunds PNEUMATIC LINES Tel: Fax: Cardiff WALES FLUID POWER Tel: Fax: Plymouth APPLIED AUTOMATION Tel: Fax: /6/ SMC CORPORATION -6-4 Shimbashi, Minato-ku, Tokio 5 JAPAN; Phone: Fax: Specifications are subject to change without prior notice and any obligation on the part of the manufacturer.

Series AV2000/3000/4000/5000

Series AV2000/3000/4000/5000 Soft Start-up Valve Series AV/3/4/5 Series introduced! A start-up valve that gradually increases supply pressure during start up and rapidly exhausts system air when the supply air is shut off AC AV AU