KOGANEI CORPORATION FRZ Series User manual

Thank you for purchasing this Koganei product.
Before using it, be sure to read this manual and make sure you use it correctly.
Keep this manual in a safe place for future reference.
M140801
Ver.1.1
Instruction Manual Ver.1.1
FRZ Series
Precautions for the FRZ series
●Selection
Look at the Handling Instructions and Precautions, Specifications, Various
Characteristics, Dimensions, and other technical materials for each product
to make the correct decision.
●Mounting (installation) direction, support, and securing
1. The products cannot be mounted (installed) if a bending moment or twist-
ing moment is applied to the product or piping.
2. Do not attach piping so that just one side is fixed as shown in the follow-
ing diagram. Support external piping separately.
Design and selection
Mounting (installation) and piping
Applying bending moment or twisting moment may damage
the product.
The muffler must be prepared by the user.
(In case of NPT thread specifications)
Operating the knob and the moment caused by the OUT (second-
ary) side pipes may damage the product's piping connections.
Note
Note
Note
●Maintenance space requirements
Assure there is sufficient space for maintenance inspections and mainte-
nance work.
See the dimension diagrams for each of the products regarding the mainte-
nance space.
It there is not enough allowance for maintenance space, it is
impossible to remove the bowl assembly and replace the filter.
Also, it is impossible to do maintenance inspections so the equipment
may stop or the product may be damaged.
If there is not enough allowance for maintenance space, it will be
impossible to do maintenance inspections and maintenance work so the
equipment may stop or the product may be damaged.
3. Use the D□module or a bracket to install all the products.
4. The product can be mounted (installed) in any direction. It is also possi-
ble to install it with the bowl of the filter on top.
Note
Note
Note
Note
Note
Note
Note
aPM
.
.
.
4
.
1
2
3
0
0
0
0
SUP
PUS
0
0
0
0
3
2
1
.
4
.
.
.
MPa
0.80.2
0.4 0.6
0
MPa
1.0
MPa
MPa
1.0
MPa
0
0.60.4
0.2 0.8
aPM
.
.
.
4
.
1
2
3
0
0
0
0
SUP
PUS
0
0
0
0
3
2
1
.
4
.
.
.
MPa
0.80.2
0.4 0.6
0
MPa
1.0
MPa
MPa
1.0
MPa
0
0.60.4
0.2 0.8
Filter bowl section
5. When mounting (installing) the product, always make sure it is secured
and sufficiently supported.
If the product is not securely fixed in place, it may fall over, be dropped,
or operate abnormally and may cause an injury.
●Direction of flow
1. Connect the filter regulators and regulators so that the medium flows in
the IN port (primary) side and out the OUT port (secondary) side.
2. Connect the residual pressure exhaust valves so that the medium flows
from the 1 (P) port (primary) side to the 2 (A) port (secondary) side.
3. Use the flow marks on the products to identify the direction of flow of the
medium in the filter regulators, regulators, and residual pressure exhaust
valves.
See the "Handling Instructions and Precautions" for each product
regarding the relationship of the flow marks and direction of flow of the
medium being used .
Connecting the products so the medium flows in reverse will cause the
product to stop functioning and damage it.
●Attaching steel pipes and fittings
If steel pipes and fittings are attached to the threaded sections of the alumi-
num die-cast parts of the product, tighten them to the torque recommended
in our standards.
Tightening with excessive torque may damage the product or injure
workers or operators.
Connecting thread M5 1/8 1/4 3/8 1/2
Torque 1 to 1.5
[0.74 to 1.11]
4.5 to 6.5
[3.3 to 4.8]
7 to 9
[5.2 to 6.6]
12.5 to 14.5
[9.2 to 10.7]
20 to 22
[14.8 to 16.2]
N・m [ft・lbf]
Recommended tightening torque
Use a tightening torque of 3.0 to 5.0 N・m [2.21 to 3.69 ft・lbf] if the various
pressure gauges are mounted on the Rc1/4 pressure port plate.
If a muffler or something is attached to the 3 (R) port of the residual exhaust
valve, tighten it to 1.8 to 2.2 N
・ m [1.33 to 1.63 ft ・ lbf].

12/’18 KG
* For other details about specifications and precautions, see the catalog.
*For inquiries about the product, contact the Koganei overseas group at the
number below.
OVERSEAS DEPARTMENT
3-11-28, Midori-cho, Koganei City, Tokyo 184-8533, Japan
Tel: [phone] Fax: [phone]
4. Avoid piping that is rigid, such as steel piping, if vibrations are transmitted.
Use flexible tubes so that the product is not subject to the vibrations.
●Usable medium
1. Use clean air (filtered to below 5 μm) for the medium. Contact the nearest
Koganei sales office or overseas department if you are considering using
something other than clean air.
2. Cannot use air that contains moisture and fluid.
3. If air that contains moisture and/or fluids is used, or if it is possible that
they may be mixed in with the air being used, we recommend using the
iB-Cyclone to reliably remove moisture and fluids.
4. Do not use the product if the medium being used is prone to extreme pul-
sating or surging.
●Operating environment
1. Do not use the product in locations that are subject to direct sunlight
(ultraviolet rays); locations with high humidity and temperature, dust, salt,
or iron powder.
2. Cover the unit when using it in locations where it might be subject to
excessive dust, dripping water, dripping oil, etc.
3. Do not use the product in environments subject to external vibration or
impact.
Medium and operating environment
Using air that contains too much moisture and/or fluids will cause the
product's functions to stop after a short period and will reduce the
product performance and service life.
If you use an iB-Cyclone, install an FRZ series filter regulator (without
water and fluids removal functions) on the secondary side.
Medium prone to extreme pulsating or surges will cause the product's
functions to stop after a short period and will reduce the product
performance and service life.
External vibrations or shocks may result in damage to component
parts.
Note
Note
Note
Note
Note
Note
Note
Note
●Medium and operating environment
1. The temperature of the medium and the ambient environment must be
within the range in the specifications.
2. Use a device, such as a freeze-type air dryer or after cooler, to lower the
dew-point temperature of the medium to below the ambient temperature
so condensation or frost does not occur in the secondary pipes.
3. Do not use medium in the product or use the product in an environment
that includes corrosive components such as organic solvents, phosphate
ester type hydraulic oil, sulfur dioxide, chlorine gas, freon gas, ozone,
acids, alkaline, etc.
4. The bowl and the front cover of the pressure gauge of the filter regulator
are polycarbonate. This product cannot be used in environments with the
gases and fluids in item 2, nor threadlocking adhesive, leak detection
fluid, hot water or where it may be exposed to them. This product also
cannot be used in direct ultra-violet light. See the catalog for details.
Using the product in an environment that is outside the specified
temperature or with medium that is outside the specified temperature
will cause the product's functions to stop after a short period and will
reduce the product performance and service life.
If condensation or frost forms in the product, it may get into the
secondary side.
Using the product in an environment or with medium that is specified
in the above item 3 will cause the product's functions to stop after a
short period and will reduce the product performance and service life.
Operation and maintenance inspections
●Method of use
Read the Handling Instructions and Precautions for each product for instruc-
tions on correct usage .
●Maintenance (maintenance inspection)
1. Performance and functions may decrease as the pneumatic equipment
ages. Always conduct daily inspections of the pneumatic equipment, and
confirm that all requisite system functions are satisfied, to prevent acci-
dents from happening.
2. Read the Handling Instructions and Precautions for instructions on main-
tenance and replacing maintenance parts .
3. The product must be disassembled and reassembled to use the seal kit.
The product is no longer under warranty if it is disassembled and
reassembled.
●Preventing contamination by foreign matter
1. Remove all foreign matter, such as metal chips, cutting oil, or dirt, from
inside pipes with compressed air blow (flushing) and thorough washing
before fitting the pipes.
2. Do not allow foreign matter, such as metal chips, or sealing tape from the
piping threads, to get into the pipes when installing the pipes and fittings.
Foreign matter entering the piping may damage the product or reduce
its performance and service life.
Note
Note
Note If liquid sealant gets on the polycarbonate parts, it may damage them.
4. If you are using liquid sealant, do not get it on the polycarbonate parts
(the bowl of the filter regulator and the front cover of the pressure gauge).
3. Wrap the sealing tape in the direction as shown in the diagram below
leaving 1.5 to 2 threads uncovered. When using liquid sealant, apply a
suitable amount and in the same way leave 1.5 to 2 threads uncovered.
If the sealing tape or sealant gets on the lip of pipes or
fittings, bits of it may get into the pipes and cause air leaks.
Leave 2 threads open Leave 2 threads open
Direction of
wrapping
Sealing tape
Liquid
sealant
aPM
.
.
.
4
.
1
2
3
0
0
0
0
SUP
0.80.2
0.4 0.6
0
MPa
1.0
MPa
iB-Cyclone
*See the back of the catalog.