CKD GPS3 Series User manual

SM-P00143-A
DIGITALGAPSWITCH
GPS3Series
●Please read this instruction manual carefully before using
this product, particularly the section describing safety．
●Retain this instruction manual with the product for
further consultation whenever necessary．
ＩＮＳＴＲＵＣＴＩＯＮＭＡＮＵＡＬ

Safety precautions
When designing and manufacturing a device using CKD products, the manufacturer is obligated
to manufacture a safe product by confirming safety of the system comprising the following 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.
Consult with CKD for details when using the product beyond the unique specification range,
outdoors, or in the following conditions or environment: Additionally, the product must not be
modified or machined.
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, amusement equipment, emergency shutoff circuits, press machine,
brake circuits, or for safeguard.
②
Use 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, body standards and regulations, etc.
４．Donothandle,pipe,orremovedevicesbeforeconfirmingsafety.
①
Inspect and service the machine and devices after confirming safety of the entire system
related to this product.
②
Note that there may be hot or charged sections even after operation is stopped.
③
When inspecting or servicing the device, turn off the energy source (air supply or water
supply), and turn off power to the facility. Discharge any compressed air from the system,
and pay enough attention to possible water leakage and leakage of electricity.
④
When starting or restarting a machine or device that incorporates pneumatic components,
make sure that the system safety, such as pop-out prevention measures, is secured.
５．Observewarningsandcautionsonthepagesbelowtopreventaccidents.
WARNING
−1− [SM-P00143-A]

■Thesafetycautionsarerankedas"DANGER","WARNING"and"CAUTION"inthis
section.
：When a dangerous situation may occur if handling is mistaken
leading to fatal or serious injuries, or when there is a high degree
of emergency to a warning.
：
When a dangerous situation may occur if handling is mistaken
leading to fatal or serious injuries.
：
When a dangerous situation may occur if handling is mistaken
leading to minor injuries or physical damage.
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:
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.
Failure resulting from causes that could not be foreseen by the technology available at the
time of delivery.
⑥
Failure 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 delivered 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.
DANGER
WARNING
CAUTION
[SM-P00143-A] −2−

【INDEX】
１．UNPACKING
…………………………………………………
4
２．INSTALLATION
２．１ Installationenvironment
…………………………………………………
5
２．２ Installation
…………………………………………………
5
２．３ Piping
…………………………………………………
6
２．４ Wiring
…………………………………………………
7
３．PROPEROPERATION
３．１ Importantsafetyinstructions
…………………………………………
10
４．ＯPERATION
４．１ Namesandfunctionsofdisplay/operationsection 13
４．２ Setting
…………………………………………………
13
４．３ RUNmode
…………………………………………………
14
４．４ Easysetting
…………………………………………
15
４．５ ESmode
…………………………………………………
17
４．６ OSmode
…………………………………………………
18
４．７ IO-Linkparameterspecification
…………………………………………………
21
５．MAINTENANCE
５．１ Periodicinspection
…………………………………………
27
５．２ Disassemblyandreassembly
…………………………………………
27
６．TROUBLESHOOTING
…………………………………………
29
７．PRODUCTSPECIFICATIONS
７．１ Productspecifications
…………………………………………………
30
７．２ Howtoorder
…………………………………………………
30
７．３ Dimensions
…………………………………………………
32
７．４ Peripheraldevices
…………………………………………………
34
７．５ Technicaldata
…………………………………………………
37
−3− [SM-P00143-A]

１
．
UNPACKING
Topreventforeignmatterfromenteringtheproduct,unpacktheproduct
justbeforepipingstarts.
(1)Checkthemodelnumberimprintedontheproducttomakesurethattheproductyoureceivedisexactlythe
productyouordered.
(2)Checktheexterioroftheproductforanydamage.
(3)Beforeusingtheproduct,readthesupplieddocumentation.
CAUTION
UNPACKING
１
[SM-P00143-A] −4−

２
．
INSTALLATION
２．１ Installationenvironment
a）Avoidinstallingthisproductwhereitissubjecttoultravioletrays.
b）Preventinstallationwheretheproductisexposedtoadirectsunlight.
c）Avoidinstallationatplaceswherethereisexcessivevibrationorimpact.
d）Largedrainage
Installtheairdryeranddrainseparatorbeforetheairfilter.
Ifthereisalargedrainagefromthecompressor.Hotandhighlyhumidaircould
shortenthedevicelifeorresultincorrosion.
e）Forcompressorcircuitofwaterlubricationmethod
Takemeasurestopreventchlorine-basedsubstancesfromenteringthe
compressedair.
(1)Avoidusingthisproductunderthefollowingconditions.
・Whereambienttemperatureandproducttemperaturemayfalloutsidetherangeof0to50℃.
・Theairmaybefrozen.
・Thehumidityishighandthetemperaturechangeslargely,causingdewcondensation.
・Seabreezeorseawaterissplashedontotheproduct.
・Avoidusingtheproductinanatmospherecontainingcorrosivegas.
・Avoidusingtheproductinanatmospherewhereozoneisproduced.
２．２ Installation
a)Securingmaintenancespace
Pleasesecureenoughspaceformaintenanceandinspection.
b）Observethefollowingitemswheninstalling:
・Installthisproductsothedetectionportfacesdownward.
・Installthisproductatapositionhigherthantheseatingsurfacetopreventcoolant
fromentering.
・Provideenoughspaceforadjustment,monitoring,andmaintenance.
・Donotstrikeorbumpthisproduct.
・Whenhousingthisproductinabox,provideanexhaustportsoatmospheric
pressureismaintainedinthebox.
・Whenweldingnearthisproduct,coverittopreventspatterfromcomingincontact.
・Wheninstallingthisproductonadevice,checkthatnoloadisappliedtothedevice.
CAUTION
CAUTION
INSTALLATION
２
−5− [SM-P00143-A]

(1)Toinstallthebracket(modelnumber:GPS3-B),pleaseusetheincludedmountingscrewsandinstallfrom
thebackoftheproduct.
Mountingscrewtighteningtorqueshouldbe1.2±0.12N·m.
(2)Aftermountingbracket(modelnumber:GPS3-B),pleaseattachittothewall.
InstallwithM5equivalentscrews(2).
２．３ Piping
a）Flushtheairpipingtobeusedsufficientlybeforeconnectingtheregulator.
Ifdustorsealantenterstheproductduringpipingwork,thismay
causetheproducttomalfunctionoroperateincorrectly.
b）Ifdustorsealantenterstheproductduringpipingwork,thismay
causetheproducttodeclineinperformance.
c）Whenconnectingthepiping,tightenwithpropertighteningtorque.
d）Userust-resistantmaterialsuchasnylontubesorstainlesssteelpipesforpiping
material.
e)Whenusingsteelpipes,securelyfixthepipetopreventexcessivebendingforce
frombeingappliedtotheconnection.
Mountingscrew
CAUTION
INSTALLATION
２
[SM-P00143-A] −6−

(1)Flushairintothepipetoblowoutforeign
substancesandchipsbeforepiping.
(2)Whenusingsealmaterial,takecaretoavoidgettingitinthepipesoroverflowingontheexteriorsurface
ofthepipes.
Whenapplyingfluororesinsealingtapetothescrewthreads,windthetapetwoorthreetimesaround
thethreadsbutleavetheoneortwothreadsatthepipeenduncovered.
Firmlypressthetapeagainstthethreadsusingthetipofyourfingernail.
Whenapplyingliquidtypesealmaterial,applythematerialtoallthethreadsexceptoneortwothreads
atthepipeendandtakecarenottoapplytoomuchofit.
Neverapplythesealmaterialtothefemalethreadsinthedevicesidepipingport.
(3)Useappropriatetorquetotightenthepipeswhenconnectingthem.
Thepurposeistopreventairleakageanddamagetobolts.
Firsttightentheboltsbyhandtoensurethatthethreadsarenotdamaged,thenuseatool.
２．４ Wiring
a)Usewithpowersupplyvoltageandoutputinthespecifiedrange.
Applyingavoltagethatisoutsideofthespecifiedrangemaycausemalfunction,
damagetothesensor,electricalshock,and/orfire.
Donotuseanyloadthatexceedstheratedoutput.
Usingsuchaloadmayresultindamagetotheoutputpartorfire.
b）Whencarryingoutelectricaconnections,pleaseperformdisassemblingand
assemblingworkafterreadingtheInstructionManualcarefullyandwithfull
understandingofitscontents.
Portthread
Rc1/8 3to5
TighteningtorqueN·m
DANGER
INSTALLATION
２
−7− [SM-P00143-A]

a）Checkthelinecolorandterminalnumberwhenconnectingwires.
Whileanovercurrentprotectioncircuitfortheoutputtransistorandaprotection
circuitforerroneouswiring,usingdiodesforpreventingreverseconnection,are
implemented,thesedonotprotectagainstallincorrectwiring.Incorrectwiringcan
resultinmalfunction,failure,ordamagetothesensor.Checktheinstructionmanual
forlinecolorsandterminalnumbersinordertoensurecorrectwiring.
b）Ensurethatwiresareproperlyinsulated.
Checkthatwiresdonotcomeintocontactwithothercircuits,thatnoground
faultsoccur,andthattheinsulatorbetweenterminalsisnotdefective.
Otherwise,overcurrentmayflowintothesensor,causingdamage.
a）Observethefollowingitemswhenwiring:
・Whenusingaswitchingregulatorforthepowersupply,
groundtheF.G.(frameground).
・Avoidusinginthetransientstate,1safterpoweristurnedON.
・Takespecialcaretopreventloadshort-circuitsorincorrectwiring.
Theprotectivecircuitisactivated.
・M12connectorpinsarearrangedasshowninlowerfigure.
Takespecialcaretopreventincorrectwiring.
・Whenusingaloadwithalargerushcurrent,suchasamotor,theprotectioncircuit
willactivate.Inthiscase,usearelay.
・Ifthereisadevice(motor,welder)thatgeneratesalargesurgenearthisproduct,
insertasurgesuppressor,suchasavaristor,atthesourceofthesurge.
・Ifthisproduct'sleadwireiswiredwiththedrivecableorpowercable,
itisaffectedbysurgeandnoisedeterioratingordamagingthesensorelement
intheswitch.Useseparatewiring.
b）Keepunusedwiresfromcomingintocontactwithotherwires.
c）Donotapplyloadtothecable.Itmaycausebreakageorbreakage.
Also,Usecabletiestofixthecableinplace.
d）DonotbindthesensorcabletogetherwithACpowerwiring.
Connector pin array
(body side)
CAUTION
WARNING
INSTALLATION
２
[SM-P00143-A] −8−

(1)ConnectthecablesideconnectortotheM12connectorpartoftheproduct.
Turntheknurledportionofthecablesideconnectorclockwise.
Connectioniscompletedwhentheknurledpartgotout.Pleasecheckwhetherthereislooseness.
(2)NPNoutputtypeandPNPoutputtypeareavailable.
Wiretheswitchbasedontheoutputasshowninlowerfigure.
Usetheloadcurrentof100mAorless.
CablesideM12connector
M12connectorpart
INSTALLATION
２
−9− [SM-P00143-A]

３
．
PROPEROPERATION
３．１ Importantsafetyinstructions
a）Usetheproductintherangeofconditionsspecifiedfortheproduct.
ContactCKDwhenusingtheproductoutsidespecificationsorforspecial
applications.Useoftheproductoutsidethespecificationsrangemayresult
ininsufficientperformance,anditssafetycannotbeguaranteed.
b）Thisproductisforindustrialuse.Mustnotbeusedincomponentsorcircuits
formedicalequipmentorcomponentsthatinvolvehumanlives.
c）Confirmbeforeusethattheproductwillwithstandtheworkingenvironment.
・Themainmaterialofthisproductisresin.
Donotuseinatmosphereswherecorrosivegasesaregenerated.
Suchenvironmentsincludehightemperatures,chemicalatmospheres,where
chemicalliquids,vibration,moisture,waterdripping,coolant,orgasispresent;
whereozoneisgenerated;chemicalplants,semiconductorpre-processing,
outdoors,etc.
・CompressedairqualitymustsatisfyJIS1.4.1,"oillesscleandryair."
d）Thisproductcannotbeusedtodisplaytheabsolutedistancefromthereference
surfacetotheworkpiece.Itisapressuresensorforcalculatingthedetection
output anddisplayingareferencevalue(dimensionlessnumber).
Refertothecharacteristicsdatainthetechnicaldataforinformationaboutthe
relationshipbetweenreferencevalueanddistance.
e）Checkthatthepipingloadortorqueabove10N·misnotappliedtothebodyor
pipingsections.
f）Workingfluidmustbecleanairfromwhichsolids,waterandoilhavebeen
sufficientlyremovedusingadryer,filterandoilmistfilter.Neversupplyoiledair.
・Thisproducthasasmallorifice,sotopreventtheentryofforeignmatter,
useanairfilterforcleanair(5μmorless)withtherecommendedcircuitshown
below.
・Thisproductcannotbeusedinenvironmentswherefunctionalobstaclescouldoccur.
WARNING
PROPER
OPERATION
３
[SM-P00143-A] −10−

g）Donotusethefollowingaircircuitswhenblowingairfromthedetectionnozzle.
・Circuitwithcheckvalve
Thecheckvalveactsasexhaustresistance,andlimitstheadjustablerange.
・Circuitwithshuttlevalveand2-wayvalve
ResidualpressureintheOUTsideofthe2-wayvalvepreventscorrectdetection.
Evenifa3-wayvalveisused,theshuttlevalvemayvibrateexcessively.
a）Theentryofcompressoroilandtarrysubstancesmayobstructtheflowofairand
resultinproblems.Regularlyinspectthecompressoranddischargedrainage.
b）Keeptheairflowconstantsocoolantandoildonotflowbackfromthedetection
nozzle,oruseasolenoidvalvewithneedleandletinasmallamountofairfromthe
bypassasshownintherecommendedcircuit.
CAUTION
WARNING
PROPER
OPERATION
３
−11− [SM-P00143-A]

c）Swarfandgrinderchips,etc.,couldclogthenozzle.Switchthesupplypressure
(max.600kPa)whentransportingtheworkpieceduringmachiningprocessesto
preventthedetectionnozzlefrombecomingclogged.
d）Selectanoutputformat(NPN,PNP)matchingtheinputunitoftheprogrammable
controllerbeingused.
e）OperationmaybedisabledifacapacitanceloadsuchasanAC/DCbuzzeris
connectedtotheload.Aprotectioncircuitisprovidedtopreventdamagefrom
incorrectwiringorovercurrent.Arelaymustbeusedwhenconnectinga
capacitanceload.
f)Usingthemastergaugeandgapgauge
・Becarefulnottobedangerousasitwillbeadjustedwhileoperatingthemachine.
 Adjustmentis1)gaugeset,2)machineoperation,3)adjustmentofthisproduct,
 atotalof3peoplearerequired.
・Clearancecannotbesetunlessthemastergaugeorgapgaugeisaccurately
 pressedagainstthedetectionnozzle.
g)Onedetectionnozzlecanbeusedforoneoftheseproductunits.
h）Immediatelyafterworkisstarted,thecoolantfromthenozzlemayaccumulatein
thepipeandcausethesensortoturnONforashorttime.Waitforcoolanttobe
dischargedbythedetectionairbeforestartingthemachine.
i）Ifthenozzlebecomesblocked,removethepipeonthisproduct'ssideandblowout
stuckforeignmatterwithanairgun.Ifforeignmattercannotberemoved,
pokeaneedle,etc.,throughthedetectionnozzleontheend.
j）Iftheoutputsettingvalueischanged,controlsystemdevicescouldoperate
unintentionally.
Stopdevicesbeforechangingsettings.
k）Ensureproperoperationthroughperiodicinspections.
CAUTION
PROPER
OPERATION
３
[SM-P00143-A] −12−

４
．
OPERATION
４．１ Namesandfunctionsofdisplay/operationsection
４．２ Setting
OPERATION
４
−13− [SM-P00143-A]

４．３ RUNmode（normaloperation）
●RUNmodeistheregulardisplayandoutputoperationmodewhichsucceedsthestartupdisplay
whenthepoweristurnedon.
４．３．１ Startupdisplay
Thefollowingstartupdisplayappearswhenthepoweristurnedon.
４．３．２ Normalscreen
４．３．３ Detectingabnormalities
Aterrordetection,themainscreendisplaysanerrorcodeindicatingthecontentoftheabnormality.
(Errorcodedisplayremainsuntiltheerroriscanceled.)
OPERATION
４
[SM-P00143-A] −14−

４．３．４ Initializing
WiththepowersupplyOFF,pressSET+△+▽buttonssimultaneouslyandturnthepowerON.
Note1)Wheninitializing,makeanoteinadvanceofanyofthecurrentsettingsyouwishtopreserve.
Note2)DisplayOFFatshipping(optioncode:T)productswillswitchtodisplayONwheninitialized.
４．４ Easysetting（inRUNmode）
●Frequentlyusedsettingscanbeconfiguredduringregularoperation.
４．４．１ Subscreenselection
●△or▽canbeusedtoswitchtothesubscreen.
Whenoption"KA"isselected,detectionsidepressureunitcanbeswitchedtobar,psidisplay
andwhen"L"isselected,seatingON/OFFdisplaycanbeswitched.
４．４．２ CH1autothresholdsetting
●DisplayvaluecanbesettothethresholdofCH1.
PressandholdSET+△(2secondsormore)tosetthecurrentdisplayedvaluetotheCH1threshold.
Note)Er3willbedisplayedonthesubscreenifthisisoutsidetheconfigurablerange.
４．４．３ CH2autothresholdsetting
●DisplayvaluecanbesettothethresholdofCH2.
PressandholdSET+▽(2secondsormore)tosetthecurrentdisplayedvaluetotheCH1threshold.
Note)Er3willbedisplayedonthesubscreenifthisisoutsidetheconfigurablerange.
Displayvalue
SettoCH1threshold
Displayvalue
SettoCH2threshold
OPERATION
４
−15− [SM-P00143-A]

４．４．４ 0-pointcalibration
△+▽(2secondsormore)tosetthedetectionsidepressure0-pointcalibration.
0-pointdriftcanbecalibrated.
SetthesupplypressuretoOFFbeforemakingthissetting.
Note)Er2willbedisplayedonthemainscreenifthisisoutsidetheconfigurablerange.
４．４．５ Keylock
PressandholdSET+△+▽(2secondsormore)toconfigurekeylockandreleasesettings.
Takecareduringbuttonoperationtoensurethateachsettingisnotmodifiedincorrectly.
OPERATION
４
[SM-P00143-A] −16−

４．５ ESmode
●Setsthethresholdandhysteresis.
RegularoperationishaltedwhenenteringESmode.
Note)Outputsretaintheirstatusasofwhenthemodewasentered.
(1)ESmodelist
(2)MovingtoESmode
PressandholdSET(2secondsormore)tomovefromthenormalscreentoESmode.
AftermovingtoESmode,use△or▽toswitchamongsettingitems.
(3)Returningtothenormalscreen
PressandholdSET(2secondsormore)tomovetoRUNmode.
４．５．１ CH1thresholdsetting （Factorydefault:50）
CH1thresholdshouldbesettonodisplayortoavalueinthetablebelow.
４．５．２ SettingCH1hysteresis （Factorydefault:10）
CH1hysteresiscanbesetfrom1to20.
OPERATION
４
−17− [SM-P00143-A]

４．５．３ CH2thresholdsetting （Factorydefault:50）
CH2thresholdshouldbesettonodisplayortoavalueinthetablebelow.
４．５．４ SettingCH2hysteresis （Factorydefault:10）
CH2hysteresiscanbesetfrom1to20.
４．６ OSmode
●Setsothersettings.
RegularoperationishaltedwhenenteringOSmode.
Note)Outputsretaintheirstatusasofwhenthemodewasentered.
(1)OSmodelist
(2)MovingtoOSmode
PressandholdSET(4secondsormore)tomovefromthenormalscreentoOSmode.
AftermovingtoOSmode,use△or▽toswitchamongsettingitems.
(3)Returningtothenormalscreen
PressandholdSET(2secondsormore)tomovetoRUNmode.
OPERATION
４
[SM-P00143-A] −18−

４．６．１ Actualmeasurementcalibration
Displaysthenewlyconvertedreferencevaluebasedonthemastersettingandopensettingpressure.
Settingorder[1]→[2]
Note)Thethresholdmustbereconfiguredafterconductingactualmeasurementcalibration.
[1]Mastersetting:
Afterinstallingthereferencemastergauge,enterthereferencevaluenumerically
andrecordthepressurewiththemastergaugeinstalled.
[2]Opensetting:
Recordthepressurewiththenozzleopen.
Note)Fullyopenthenozzlewhenusingthissetting.
４．６．２ Settingofdisplaycolor （Factorydefault:Goo）
SetstheCH1/2ON/OFFdisplaycolors.
４．６．３ Settingofscreennon-display （Factorydefault:OFF）
Setsthemain/subscreennon-displaysettings.
Non-displayforallexceptoutputdisplayandnotificationdisplay.
(WiththissettingONand3minuteswithoutkeyoperation)
green
Setting
contents
Displaycolor
Nooutput CH1：ON CH2：ON
Goo green orange orange
oGG orange green
OPERATION
４
−19− [SM-P00143-A]