CKD M3GA/B R Series User manual

INSTRUCTION MANUAL
INSTRUCTION MANUAL
3, 5-PORT PNEUMATIC SOLENOID VALVE
(M)3GA/B R SERIES
(M)4GA/B R SERIES
(M)3GD/E R SERIES
(M)4GD/E R SERIES
・Single Valve
・Manifold (Metal Base)
SM-P00077-A/3
SM-358642
•Read this Instruction Manual before using the product.
•Read the safety notes carefully.
•Keep this Instruction Manual in a safe and convenient place for future reference.

SM-P00077-A/3 PREFACE
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PREFACE
Thank you for purchasing CKD's 3, 5-port pneumatic solenoid valve.
This Instruction Manual contains basic matters such as installation and usage instructions in order to
ensure optimal performance of the product. Please read this Instruction Manual thoroughly and use the
product properly.
Keep this Instruction Manual in a safe place and be careful not to lose it.
Product specifications and appearances presented in this Instruction Manual are subject to change
without notice.
•The product, which uses control valves such as solenoid valves, motor valves, and air operated
valves, is intended for users who have basic knowledge about materials, fluids, piping, and
electricity. CKD shall not be responsible for accidents caused by persons who selected or used the
product without knowledge or sufficient training with respect to control valves.
•Since there are a wide variety of customer applications, it is impossible for CKD to be aware of all of
them. Depending on the application or usage, the product may not be able to exercise its full
performance or an accident may occur due to fluid, piping, or other conditions. It is the responsibility
of the customer to check the product specifications and decide how the product shall be used in
accordance with the application and usage.

SM-P00077-A/3 SAFETY INFORMATION
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SAFETY INFORMATION
When designing and manufacturing any device incorporating the product, the manufacturer has an
obligation to ensure that the device is safe. To that end, make sure that the safety of the machine
mechanism of the device, the pneumatic or water control circuit, and the electric system that controls
such mechanism is ensured.
To ensure the safety of device design and control, observe organization standards, relevant laws and
regulations, which include the following:
ISO 4414, JIS B 8370, JFPS 2008 (the latest edition of each standard), the High Pressure Gas Safety
Act, the Industrial Safety and Health Act, other safety rules, organization standards, relevant laws and
regulations
In order to use our products safely, it is important to select, use, handle, and maintain the products
properly.
Observe the warnings and precautions described in this Instruction Manual to ensure device safety.
Although various safety measures have been adopted in the product, customer's improper handling may
lead to an accident. To avoid this:
Thoroughly read and understand this Instruction Manual
before using the product.
To explicitly indicate the severity and likelihood of a potential harm or damage, precautions are classified
into three categories: "DANGER", "WARNING", and "CAUTION".
DANGER
Indicates an imminent hazard. Improper handling will cause death or serious
injury to people.
WARNING
Indicates a potential hazard. Improper handling may cause death or serious
injury to people.
CAUTION
Indicates a potential hazard. Improper handling may cause injury to people or
damage to property.
Precautions classified as "CAUTION" may still lead to serious results depending on the situation.
All precautions are equally important and must be observed.
Other general precautions and tips on using the product are indicated by the following icon.
Indicates general precautions and tips on using the product.

SM-P00077-A/3 SAFETY INFORMATION
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Precautions on Product Use
WARNING
The product must be handled by a qualified person who has extensive knowledge and
experience.
The product is designed and manufactured as a device or part for general industrial machinery.
Use the product within the specifications.
The product must not be used beyond its specifications. Also, the product must not be modified
and additional work on the product must not be performed.
The product is intended for use in devices or parts for general industrial machinery. It is not
intended for use outdoors or in the conditions or environment listed below.
•In applications for nuclear power, railroad system, aviation, ship, vehicle, medical equipment,
and equipment that directly touches beverage or food.
•For special applications that require safety including amusement equipment, emergency
shut-off circuit, press machine, brake circuit, and safety measures.
•For applications where life or properties may be adversely affected and special safety measures
are required.
(Exception is made if the customer consults with CKD prior to use and understands the
specifications of the product. However, even in that case, safety measures must be taken to avoid
danger in case of a possible failure.)
Do not handle the product or remove pipes and devices until confirming safety.
•Inspect and service the machine and devices after confirming the safety of the entire system.
Also, turn off the energy source (air supply or water supply) and power to the relevant facility.
Release compressed air from the system and use extreme care to avoid water or electric
leakage.
•Since there may be hot or live parts even after operation has stopped, use extreme care when
handling the product or removing pipes and devices.
•When starting or restarting a machine or device that incorporates pneumatic components, make
sure that a safety measure (such as a pop-out prevention mechanism) is in place and system
safety is secured.

SM-P00077-A/3 CONTENTS
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CONTENTS
PREFACE........................................................................................................................... i
SAFETY INFORMATION .................................................................................................. ii
Precautions on Product Use..........................................................................................iii
CONTENTS...................................................................................................................... iv
1. PRODUCT OVERVIEW............................................................................................. 1
1.1 Part Name........................................................................................................... 1
1.2 Model Number Indication....................................................................................5
1.2.1 Single valve .................................................................................................... 5
1.2.2 Manifold ..........................................................................................................8
1.2.3 Related products ..........................................................................................13
1.2.4 Kit parts ........................................................................................................14
1.3 Specifications.................................................................................................... 20
1.3.1 Common specifications ................................................................................20
1.3.2 Electrical specifications ................................................................................20
1.3.3 Response times............................................................................................ 21
1.3.4 Flow characteristics......................................................................................21
1.3.5 Weight...........................................................................................................23
1.4 Internal Structure ..............................................................................................25
1.4.1 Description of operation ...............................................................................25
2. INSTALLATION ....................................................................................................... 28
2.1 Environment......................................................................................................28
2.2 Unpacking .........................................................................................................29
2.3 Mounting ...........................................................................................................29
2.3.1 How to mount a body piping type single valve............................................. 30
2.3.2 How to mount a base piping type single valve............................................. 33
2.3.3 How to mount a manifold..............................................................................34
2.4 Piping ................................................................................................................36
2.4.1 Recommended tightening torque.................................................................36
2.4.2 Seal material.................................................................................................37
2.4.3 Flushing ........................................................................................................37
2.4.4 M5 fitting .......................................................................................................37
2.4.5 Blow circuit ...................................................................................................37
2.4.6 Exhaust port .................................................................................................37
2.4.7 Piping connection .........................................................................................37
2.4.8 Piping ports for external pilot (option symbol: K) ......................................... 39
2.5 Wiring................................................................................................................40
2.5.1 E-type connector ..........................................................................................41
2.5.2 A-type connector ..........................................................................................41
2.5.3 EJ-type ("socket with cover" type) connector...............................................42
2.5.4 DIN terminal box...........................................................................................42
2.5.5 Common terminal block (T10/T11)............................................................... 44
2.5.6 D-sub connector (T30) .................................................................................47
2.5.7 Flat cable connector (T50) ........................................................................... 51
2.5.8 Flat cable connector (T51/T52/T53)............................................................. 54
3. USAGE..................................................................................................................... 60
3.1 Safety Instructions ............................................................................................ 60
3.1.1 Air quality...................................................................................................... 60
3.1.2 Electric circuit ...............................................................................................62
3.1.3 Surgeless (option symbol: S) ....................................................................... 63
3.1.4 Low heat generating/energy saving circuit (option symbol: E) .................... 63
3.1.5 AC voltage models ....................................................................................... 63

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3.1.6 Pressure sensor (option symbol: G1, G2).................................................... 64
3.2 Manual Operation .............................................................................................67
3.2.1 Non-locking/locking combination manual override ......................................67
3.2.2 Residual pressure exahust mechanism (option symbol: X, X1) .................. 68
4. MAINTENANCE AND INSPECTION....................................................................... 69
4.1 Periodic Inspection............................................................................................69
4.2 Disassembling and Assembling........................................................................ 70
4.2.1 Replacement of solenoid valve ....................................................................70
4.2.2 How to replace a coil assembly.................................................................... 70
4.2.3 How to replace a cartridge type fitting (4GA/B R, 4GD/E R) .......................71
4.2.4 How to change piping connection specifications (4GA/B R) .......................73
4.3 Adding a Valve to the Reduced Wiring Manifold .............................................. 74
4.3.1 How to add to the position where spare wiring is equipped ........................74
4.3.2 How to add to the position where no spare wiring is equipped ...................74
4.3.3 How to open and close the reduced wiring cover ........................................75
4.3.4 Instructions for wiring the electric circuit board connectors......................... 76
5. TROUBLESHOOTING............................................................................................. 79
5.1 Problems, Causes, and Solutions ....................................................................79
6. REFERENCE INFORMATION................................................................................. 80
6.1 Port Identification ..............................................................................................80
7. WARRANTY PROVISIONS..................................................................................... 81
7.1 Warranty Conditions .........................................................................................81
7.2 Warranty Period ................................................................................................81

SM-P00077-A/3 1. PRODUCT OVERVIEW
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1. PRODUCT OVERVIEW
1.1 Part Name
Mounting plate
Individual wiring manifold
Reduced wiring manifold
(figure shown is DIN rail mount)
Common terminal block (T10)
M3 thread fastening type
Common terminal block (T11)
Clamping type
D-sub connector (T30)
Body piping type single valve
Base piping type single valve

SM-P00077-A/3 1. PRODUCT OVERVIEW
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Serial transmission (T6)
Serial transmission (T8)
DIN terminal box (B)
Socket with cover (EJ)
Flat cable connector (T50)
Flat cable connector (T51)
Pressure sensor (G1)
Pressure sensor (G2)
Residual pressure exhaust
mechanism (X, X1)

SM-P00077-A/3 1. PRODUCT OVERVIEW
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No.
Part name
Description
1
Lead wire
Wire which has no polarity.
2
Electrical component cover
Cover provided with a power indicator on the top surface which lights green while the
coil is energized (only for E-type and A-type connectors).
3
Coil assembly
Coil assembly which varies depending on the type of electrical connection and voltage
selected for the valve. Not interchangeable with No. 36.
4
Manual protection cover
Cover which prevents accidental operation of the manual override and is opened to
operate the manual override.
5
Manual override
Manual operation device which has both locking and non-locking overrides.
6
Single valve
Valve equipped with a mechanism which opens/closes an air passage.
7
Single valve mounting screw
Screw used for securing a single valve to various bases (2 screws provided for each
valve).
8
Subplate
Subplate which comes assembled to a base piping type single valve.
9
Piping port
Port provided for supply, indicated by 1(P); for exhaust, indicated by 3(R2) or 5(R1); for
output, indicated by 2(B) or 4(A).
10
Fitting
Cartridge type push-in fitting which can be replaced.
11-1
Fitting stopper pin
Pin used for securing a cartridge type fitting.
(4GA R Series)
11-2
Fitting stopper plate
Plate used for securing a cartridge type fitting. Not interchangeable with No. 17.
(4GD R Series)
12
Pipe adaptor
Adaptor which comes assembled to a body piping type single valve.
13
Mounting hole
Hole used for direct mounting.
14
Mounting plate
Plate used for vertical mounting of a body piping type single valve.
15
Manifold base
Metal base manifold provided with multiple piping ports.
16
Masking plate
Plate replaced by a single valve when adding a valve.
17
Fitting stopper plate
Plate used for securing a cartridge type fitting.
Not interchangeable with No. 11-2.
18
Electrical component block
Component block which stores and secures a printed circuit board mounted with PCB
connectors.
19
Wiring duct
Duct provided for protecting cables contained.
20
DIN rail
Rail which complies with DIN standard (German Industry Standard) and is used for
mounting a solenoid valve.
21
DIN rail mounting screw
Screw used for securing the entire manifold in place on the DIN rail and located at both
ends of the base.
22
Holder
Holder used together with the DIN rail mounting screw (only for 4G2/4G3).
23
Spare cable
Cable used when adding a valve.
24
Terminal block
Connector block provided with a set of terminals for controlling the manifold valves.
25
Cover
Cover which is opened to work on wiring and must be closed before energization in
order to avoid an electric shock.
26
Terminal block layout
Diagram which indicates the layout of the terminal block and on which notes can be
written.
27
D-sub 25-pin connector
Connector provided with a set of terminals for controlling the manifold valves.
28
Mounting screw
Screw used for securing the connectors (screw size is M2.6).
29
Connector rotation button
Button used for changing the direction of the connector wiring upward or sideways.
Pressing in the button releases the lock and allows the connector to rotate.
Rotating the connector to a predetermined position pushes out the button and locks the
connector.
30
Power supply terminal block
Terminal block used when an external power supply is required.
31
Power polarity marking
Marking which indicates the power polarity (▽ mark indicates the ground side).
32
Power indicator
Indicator which lights up when power is supplied with right polarity.

SM-P00077-A/3 1. PRODUCT OVERVIEW
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No.
Part name
Description
33
Flat cable connector
Connector provided with a set of terminals for controlling the manifold valves.
34
Serial transmission slave unit
Slave unit specifically designed for manifold manufactured by CKD.
35
DIN terminal box
Terminal box provided with a power indicator which lights green while the coil is
energized.
36
Coil assembly
Coil assembly provided for DIN terminal box type valve. Not interchangeable with No. 3.
37
Socket with cover
Socket provided with a covered cabtyre cable (only for E-type connectors).
38
Pressure sensor
Sensor used for detecting pressure of port 4(A).
39
Pressure sensor
Sensor used for detecting pressure of port 2(B)/4(A).
40
Residual pressure exhaust
mechanism
Mechanism in 3-position all ports closed and 3-position ABR connection models and
used for releasing pressure of outlet port to the atmosphere.