CKD 3KA1 User manual

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．
3rdEdition

[SM-208676-A/3]
―1
―
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.
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.
①Use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.
②Useforapplicationswherelifeorassetscouldbeadverselyaffected,andspecialsafetymeasures
arerequired.
３．Observecorporatestandardsandregulations,etc.,relatedtothesafetyofdevicedesign
andcontrol,etc.
ISO4414,JISB8370(pneumaticsystemrules)
JFPS2008(principlesforpneumaticcylinderselectionanduse)
IncludingHighPressureGasMaintenanceLaw,OccupationalSafetyandSanitationLaws,othersafety
rules,standardsandregulations,etc.
４．Donothandle,pipe,orremovedevicesbeforeconfirmingsafety.
①Inspectandservicethemachineanddevicesafterconfirmingsafetyoftheentiresystemrelatedto
thisproduct.
②Notethattheremaybehotorchargedsectionsevenafteroperationisstopped.
③Wheninspectingorservicingthedevice,turnofftheenergysource(airsupplyorwatersupply),and
turn off power to the facility. Release any compressed air from the system, and pay enough
attentiontopossiblewaterleakageandleakageofelectricity.
④When starting or restarting a machine or device that incorporates pneumatic components, make
surethatsystemsafety,suchaspop-outpreventionmeasures,issecured.
WARNING

[SM-208676-A/3] −2−
５．Observewarningsandcautionsonthepagesbelowtopreventaccidents.
The safety cautions are ranked as "DANGER", "WARNING" and "CAUTION" in this
section.
FailuretopayattentiontoDANGERnoticesmaycauseasitu-
ation that results in a fatality or serious injury and that re-
quiresurgentaddressing.
Failure to pay attention to WARNING notices may result in a
fatalityorseriousinjury.
FailuretopayattentiontoWARNINGnoticesmayresultinin-
jury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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:
①Defectsresultingfromoperationunderconditionsbeyondthosestatedinthecatalogueorspecifications.
②Failureresultingfrommalfunctionoftheequipmentand/ormachinemanufacturedbyothercompanies.
③Failureresultingfromwronguseoftheproduct.
④FailureresultingfrommodificationorrepairingthatCKDCORPORATIONisnotinvolvedin.
⑤Failureresultingfromcausesthatcouldnotbeforeseenbythetechnologyavailableatthetimeofdeliv-
ery.
⑥FailureresultingfromdisasterthatCKDisnotresponsibleof.
Guaranteestatedherecoversonlythedeliveredproducts.Anyotherdamageresultingfromfailureofthedeliv-
eredproductsisnotcoveredbythisguarantee.
Confirmationofproductcompatibility
Ourcustomershallberesponsibleofconfirmingcompatibilityofourproductusedinourcustomer’ssystem,
machineryordevice.
！
 WARNING:
！
 CAUTION:
！
 DENGER :

[SM-208676-A/3]
―3
―
UNPACKING (Section 3)
Bags containing solenoid valves should be opened only
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.
INSTALLATION (Section 4)
Ifyouhavetousetheproductunderconditionsthatare
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.
ENVIRONMENT (Section 4.1)
a) Inadustyenvironment,foreignmattermayentereven
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.
b) Keep the solenoid valve system dry.  Take care to
avoiddirectcontactwithdrippingwaterorsplashesof
cuttingoil.
If the solenoid valve system is wet by a direct contact
withwaterorcuttingoil,anelectricalleakorburntsole-
noid coils may result. Protect the solenoid valve system
byusingacoverorbyinstallingitinsideapaneledcasing. 
Ifthecylinderrodissplashedwithcuttingoil,theoilmay
penetrate through the cylinder into the secondary side
piping ofthe solenoid valve.  This must be prevented to
avoidmalfunctions.  Consultusforpreventivemeasures.
c) Thecoilswillproduceheat.
Particularly if the solenoid valve system is installed in a
controlboardorifthesolenoidcoilsneedtobeenergized
foralongtime,considerprovidingsufficientventilationto
releasetheheat.  Thecoilscangetveryhot.
d) Do not use the solenoid valve system in an atmos-
pherethatincludesacorrosivegasorsolventvapors.
Do not use the solenoid valve system in an atmosphere
that includes a corrosive gas such as the sulfur dioxide
gasorinanatmospherethatincludessolventvapors.
e) Vibrationsandshocks
Do not subject the solenoid valve system to vibrations
50m/s2orstrongerorshocks300m/s2orstronger.
！
 CAUTION:
！
 CAUTION:
！
 CAUTION:

[SM-208676-A/3] −4−
f) Avoidusingthesolenoidvalvesysteminahumiden-
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).
Consultusforthe packingand gasketstobe used inan
atmospherewithahigherozonedensity.
INSTALLATION (Section 4.2)
When installing a solenoid valve unit, never attempt to
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.
！
 WARNING:
！
 CAUTION:

[SM-208676-A/3]
―5
―
PIPING (Section 4.3)
a) Observe the recommended tightening torque when
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.
If the exhaust piping of the pneumatic circuit is discon-
nected,theactuatorspeedcontrolisdisabled.
If the above happens to a chuck holding mechanism, the
chuck will open.  The inadvertent opening of the chuck
maycauseaseriousaccident.
c) When supplying the compressed air for the first time
after completing the piping, be sure to check every
jointinthepipingforairleakage.
d) When supplying the compressed air for the first time
after completing the piping, increase the air pressure
graduallybutnever introducea highly-pressurizedair
suddenly.
A sudden introduction of a highly-pressurized air may
disconnectpipesatjointsand/orcausethetubestojump
around,anyofwhichmaycauseaninjury.
e) Donotdecreasetheinsidediameterofthepipingfrom
anyofthesolenoidvalveexhaustportstoadiameter
lessthantheexhaustpipeconnectingportsize.
Normal operation of the actuator depends on the
smoothnessoftheexhaustflow.  Withamanifoldsystem,
arestrictiontotheexhaustflowmaypreventnormalop-
erationofothersolenoidvalves.
f) Removalofforeignmatter
Rust and other foreign matter in the pneumatic circuit
may cause a malfunction or leakage fromthe valveseat. 
Insert a filter (maximum allowable particle size 5μm or
less)immediatelyupstreamofthesolenoidvalve.
g) Airsupply
Donotrestricttheflowofairthroughtheairsupplypip-
ing.  Withamanifoldsystemwithmultiplestations,adrop
in the air supply pressure may cause trouble through a
delayintheoperationtiming.
！
 CAUTION:

[SM-208676-A/3] −6−
WIRING (Section 4.4)
Before wiring, read the instruction manual carefully and
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
voltageandthecurrenttype(ACorDC).
MANUAL OVERRIDE (Section 5.2)
a)Oncethemanualoperationdevicehasbeenoperated,
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.
AIR QUALITY (Section 5.3)
a) Donotsupplyanythingotherthancompressedair.
b) Supply clean compressed air without any mixture of
corrosivegas.
a)
Compressed air usually contains a large amount of 
drain, oxidized oil, tar, foreign matter, and rust from
thepiping.  Filter outthose elementsinthe supplied
air because they may cause a malfunction and de-
crease  service life.  In addition, clean the exhaust
beforeitisreleasedtotheairtominimizepollution.
b) Once you have lubricated a pre-lubricated valve, the
valveisnolongercapableofrunningwithoutbeinglu-
bricated from the outside.  Do not leave the valve
withoutlubricationbutkeepitlubricated.
c) Donotusespindleoilor machine oil.  Theymay in-
duceexpansionoftherubberparts,whichmaycause
amalfunction.
！
 WARNING:
！
 CAUTION:
！
 WARNING:
！
 WARNING:
！
 CAUTION:

[SM-208676-A/3]
―7
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ELECTRIC CIRCUITS (Section 5.4)
a) Check for the presenceofanycurrent leak fromthe
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.
b) Restrictiononcurrentleak
When controlling solenoid valves using a programmable
controlleror a similarcontroldevice, makesurethat the
current leak in the programmable controller output is
equal toor less than the level shown inthe tablebelow. 
A current leak larger than the allowable level may cause
anerroneousvalveoperation.
PERIODIC INSPECTION (Section 6.1)
Before providing a maintenance service, cut the power
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
correctlymaintainproductperformance.
If the productis not correctly maintained , product per-
formance may deteriorate dramatically, resulting in a
shorter service life, fractures of components, and mal-
functions.
DISASSEMBLING AND REASSEMBLING (Section 6.2)
Before disassembling and reassembling solenoid valves,
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.
Personnel involved ｉｎ this step must have passed the
PneumaticPressureSkillTestClass2orhigher.
！
 CAUTION:
AC100V 3.0mAorlower
AC200V 1.5mAorlower
DC24V 1.8mAorlower
CRcircuit
Leakage
current
Solenoidvalve
Contact
C
R
Programmable
controller
！
 CAUTION:
！
 WARNING:
！
 WARNING:

−8−
INDEX
3KA1,M3KA1
Manual No. SM-208676-A/3
1. PART NAME AND DESCRIPTION 9
2. INTERNATIONAL SYSTEM OF UNITS (SI)
AND PORT INDICATION
2.1 Conversion between International System
of Units (SI) and Conventional Units  10
3. UNPACKING 11
4. INSTALLATION
4.1 Environment  12
4.2 Installation 14
4.3 Piping 15
4.4 Wiring  18
5. OPERATING RECOMMENDATION
5.1 Operation 24
5.2 Manual Override 25
5.3 Air Quality  26
5.4 Electric Circuits  28
6. MAINTENANCE
6.1 Periodic Inspection  29
6.2 Disassembling and Reassembling  30
7. TROUBLE SHOOTING 33
8. PRODUCT SPECIFICATIONS AND HOW TO ORDER
8.1 Product Specifications 34
8.2 How to Order  36
8.3 Consumable parts  39

[SM-208676-A/3]
―9
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製
品
１
1. PARTNAMEANDDESCRIPTION
No. Part Name explanation
①Valve unit There are direct piping and sub plate piping
②Manual Override It uses case of manual operation. There are a non lock and a lock
formula
③Wire connection It connections to the electric circuit
④Sub plate It is a block for the piping
⑤Piping Port Port pis the supply port ; port R is the exhaust port ; port A and B is
the Output port
⑥Mounting screw There are two every individual valve and it fixes the valve unit on
the various base
Directpipingmanifold
Directpipingunit