SMC Networks AV2000~5000-A Series User manual

AV-SMU70EN-A
Page 1 of 3
Instruction Manual
Soft Start-up Valve
Series AV2000~5000-A
The intended use of this product is to protect machine mechanism
against sudden movement during start up.
1 Safety Instructions
These safety instructions are intended to prevent hazardous situations
and/or equipment damage. These instructions indicate the level of
potential hazard with the labels of “Caution,” “Warning” or “Danger.”
They are all important notes for safety and must be followed in addition
to International Standards (ISO/IEC)*1), and other safety regulations.
*1) ISO 4414: Pneumatic fluid power - General rules relating to systems.
ISO 4413: Hydraulic fluid power - General rules relating to systems.
IEC 60204-1: Safety of machinery - Electrical equipment of machines.
(Part 1: General requirements)
ISO 10218-1: Manipulating industrial robots - Safety. etc.
Refer to product catalogues, Operation Manual and Handling
Precautions for SMC Products for additional information.
Keep this manual in a safe place for future reference.
Caution
Caution indicates a hazard with a low level of risk which, if
not avoided, could result in minor or moderate injury.
Warning
Warning indicates a hazard with a medium level of risk
which, if not avoided, could result in death or serious injury.
Danger
Danger indicates a hazard with a high level of risk which, if
not avoided, will result in death or serious injury.
Warning
Always ensure compliance with relevant safety laws and
standards.
All work must be carried out in a safe manner by a qualified person in
compliance with applicable national regulations.
Warning
When using a solenoid valve or actuator on the outlet side of this
product, implement appropriate measures to prevent potential danger
caused by actuator operation.
This product may experience air leakage (within tolerance), therefore
this valve is not suitable for holding pressure in a pressure vessel for a
long period of time.
This valve is not to be used as emergency shutoff valve. Using the
valve in such applications, take a separate measure to ensure safe
use.
Provide ventilation when using the valve in a confined area, such as in
a closed control panel. For example, install a ventilation opening, etc.
in order to prevent pressure from increasing inside of the confined
area and to release the heat generated by the valve.
The circuit designer shall ensure external cables have strain relief and
correct protective bonding in accordance with the requirements of EN
60204-1
The circuit designer shall ensure correct insulation monitoring in
accordance with the requirements of EN60204-1.
2 Specifications
2.1 Mechanical Specification
Model
AV2000-A
AV3000-A
AV4000-A
AV5000-A
Port Size
1(P), 2(A)
1/4
3/8
1/2
3/4
1
3(R)
1/4
3/8
1/2
3/4
Pressure Gauge Port Size
1/8
Fluid
Air
Ambient/Fluid Temperature
0-50Note 1)
Proof Pressure [MPa]
1.5
Operating Pressure Range [MPa]
0.2-1.0
Max. operating frequency
5 cycles/min not exceeding 100 cycles/day
Min. operating frequency
Once every 30 days
Min. air quality
5 µm filtration
IP rating
IP65 (DIN terminal only)
Weight [kg]
0.43
0.45
0.80
1.30
1.25
Flow characteristics
1(P)–›2(A)
C(dm3/s･bar)
9.2
13.1
19.2
34.8
41.3
b
0.36
0.27
0.32
0.66
0.34
Cv
2.4
3.1
5.1
12.6
13.7
2(A)–›3(R)
C(dm3/s･bar)
8.8
9.2
10.1
23.7
b
0.46
0.48
0.55
0.67
Cv
2.5
2.6
3.2
9.2
Impact resistance Note 2)
1000 m/s2(11ms)
Vibration resistance Note 3)
50 m/s2(0.35mm)
Note 1) Please use dry air when operating at a low temperature to avoid freezing
Note 2) Two axes (horizontal and vertical) and two directions were tested and no
malfunction of the valve occurred (pulse shape: sine shape), 3 times for each
condition (pilot valve ON and OFF, test sample mounted with bracket)
Note 3) No malfunction occurred in a sweep cycle test between 10 to 150 Hz at
vibration sweep 0.35mm. The test was performed in the two axes and two
directions, 7 min per cycle (20 cycles) 20 times for each condition (pilot valve ON
and OFF)
2.2 Electrical Specification
Electrical Entry
Grommet
DIN Terminal
Coil Rated
Voltage [V]
DC
24 , 12
AC 50/60Hz
100 , 200 , 110[115] , 220[230] Note1)
Power
Consumption [W]
DC
0.35 (with light: 0.4)
0.35(with light: 0.45)
Allowable
Voltage
Fluctuation
DC
24V
±10% of rated voltage
12V
±10% of rated voltage
AC
100V
±10% of rated voltage
110VNote1)
[115V]
±10% of rated voltage
[-15% to +5% of rated voltage]
200V
±10% of rated voltage
220VNote1)
[230V]
±10% of rated voltage
[-15% to +5% of rated voltage]
Apparent Power
[VA]
AC
100V
0.78 (with light: 0.81)
0.78(with light: 0.87)
110V
[115V]
0.86 (with light: 0.89)
[0.94 (with light: 0.97)]
0.86(with light: 0.97)
[0.94(with light: 1.07)]
200V
1.18 (with light: 1.22)
1.15(with light: 1.30)
220V
[230V]
1.30 (with light: 1.34)
[1.42 (with light: 1.46)]
1.27(with light: 1.46)
[1.39(with light: 1.60)]
Surge Voltage Suppressor
Refer to Specific Product Precautions 3.7
Indicator light
LED
LED (neon bulb for AC)
Note 1) The 110VAC and 115VAC are interchangeable. The 220V AC and 230V
AC are interchangeable as well.
Note 2) Valve state is not defined if electrical input is outside of specification
2.3 Working Principle
Initial Operation Return Stroke
Figure 1
PA–outlet pressure
PP–inlet pressure
PR–atmospheric pressure
2 Specifications - continued
2.3.1 Low speed supply –Pilot valve ON
Operation
When the pilot valve is energised, the spool is pushed down by pilot air
and closes the main valve, closing the flow passage to port 3 (R). In
this case, force pushing the valve up is larger or equal to force pushing
the spool down. Therefore, the flow path from the valve to Port A is
also kept closed.
When the pilot valve turns on, the piston is pushed down by pilot air,
and the flow passage from the needle to Port A opens. The air pressure
whose flow rate is adjusted by the needle flows to Port A.
Cylinder actuation
The meter-in control of the needle slowly moves cylinder From A to B
(Figure 1).
Pressure
Ps＞PA
Ps –pressure for switching to rapid air supply
2.3.2 High speed supply –Solenoid valve ON
Operation -When the outlet side is filled with the air supply from the
needle, PAincreases. When PAreaches a certain pressure level, force
pushing the valve up is smaller than force pushing the spool down. The
valve is pushed down, opening the flow passage and is supplied to Port
A rapidly.
Cylinder actuation -When Ps<PAafter the cylinder reaches B (Figure 1),
the main valve fully opens and PAincreases rapidly as shown from C to
D (Figure 1) and becomes the same pressure as PP.
Ps –pressure for switching to rapid air supply
PA–outlet pressure
Pressure
Ps < PA
2.3.3 Normal operation –Pilot valve ON
Operation - The valve holds the fully open condition.
2 Specifications - continued
Cylinder actuation - The cylinder operation is controlled by a meter-out
circuit on the cylinder side.
PP=PA
2.3.4 Quick exhaust –Pilot valve OFF
Operation
When the pilot valve is turned off, the pilot air of the spool is exhausted
from the pilot valve. The spool and the valve are returned upward due
to spring. This opens the flow pressure to port R exhausting the air
pressure on Port A.
The pilot air of the piston is also exhausted from the pilot valve and the
piston is returned upward due to the spring, closing the flow passage
from the needle.
Caution
Special products might have specifications different from those shown
in this section. Contact SMC for specific drawings.
3 Installation
3.1 Installation
Warning
Do not install the product unless the safety instructions have
been read and understood.
Stop operation if air leakage increases or the equipment does not
operate properly.
After mounting or maintenance, etc., connect the compressed air and
power supply, then perform appropriate function and leakage tests to
ensure that the unit is mounted properly.
Operation manual/Instruction manual
Mount and operate the product after reading the manual carefully and
understanding its contents. Keep the manual in a place where it can be
referred to as necessary.
Painting and coating
Warnings or specifications printed or labelled on a product should not
be erased, removed or covered up. Please contact SMC before painting
the resin parts, as this may cause adverse effects depending on the
solvent.
Maintenance space
Allow the sufficient space for maintenance and inspection.
Warning
Confirm the specifications.
The product presented in this document is 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 the specifications).
Please contact SMC if using for any fluid other than compressed air.
Operation of closed centre solenoid valves
Even if this product is used for closed center solenoid valves or actuator
with a load factor of 50% or more, lurching (quick extension) cannot be
prevented.
Using a regulator on the outlet side
When mounting a regulator on the outlet side (A port side), use a
residual pressure relief regulator (AR25K to 40K) or check type
ORIGINAL INSTRUCTIONS
Refer to Declaration of
Conformity for relevant
Directives
Varistor
NO.1
(-) (+)
NO.2
(+) (-)
Coil
LED

AV-SMU70EN-A
Page 2 of 3
Ground nut
Tightening torque
1.65 to 2.5 N∙m
Washer
Grommet
(Rubber)
(Rating symbol)
Refer to the catalogue for DIN
connector part no.
Terminal screw
(3 locations)
Tightening torque
0.2 to 0.25 N∙m
0.2 to 0.25 N∙m
Holding screw
Tightening torque
0.4 N∙m
Housing
(Light mounting
location)
3 Installation - continued
regulator. With a standard regulator (AR10 to 60), the outlet side
pressure may not be released when this valve is exhausted.
Operation of solenoid valves on the outlet side
To operate solenoid valves mounted on this product’s outlet side (A port
side), make sure that the outlet side’s pressure (PA) has increased to
the pressure equal to the inlet side (PP).
Operation
The residual pressure release function of this product is for emergency
use only. Avoid using this valve in the same manner as ordinary 3 port
valves.
Using a lubricator
If mounting a lubricator, mount it on the inlet side (P port side) of this
product. If mounted on the outlet side (A port side), back flow of oil will
occur and may spurt out of the valve’s R port.
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 outlet side’s
pressure increases to approximately 1/2 of the inlet side.
Warning
Solenoid valve for 200, 220VAC
The AC solenoid valves with grommet have a built-in rectifier circuit in
the pilot section to operate the DC coil.
With 200V and 220 VAC pilot valves, this built-in rectifier generates
heat when energised. The surface may become hot depending on the
energised condition. To prevent burns, do not touch the solenoid valve.
3.2 Environment Warning
Do not use in an environment where corrosive gases, chemicals, sea
water or steam are present.
Do not use in an explosive atmosphere.
Do not expose to direct sunlight. Use a suitable protective cover.
Do not install in a location subject to vibration or impact in excess of
the product’s specifications.
Do not mount in a location exposed to radiant heat that would result
in temperatures in excess of the product’s specifications
Take suitable protective measures if water, oil or welding spatter is
likely to adhere to the valve.
Take measures to ensure air quality, such as by installing an
aftercooler, air dryer, or water separator. Compressed air that contains
a large amount of drainage can cause a malfunction of pneumatic
equipment such as valves. Therefore, take appropriate measures to
ensure air quality, such as by providing an aftercooler, air dryer, or
water separator.
Take suitable measures to prevent dust or noise if operating in an
environment generating dust or intrusive valve switching noise, by
providing a silencer in the R port.
Caution
Low temperature operation
Although the valve can be operated at temperature as low as 0°C,
measures should be taken to avoid solidifying or freezing drainage and
moisture.
3.3 Piping Caution
Before connecting piping make sure to clean up chips, cutting oil, dust
etc.
When installing piping or fittings, ensure sealant material does not
enter inside the port. When using seal tape, leave 1.5-2 thread ridges
exposed on the end of the pipe/fitting.
Refer to the instruction manual/operation manual during installation
and make sure to connect to the correct supply port, etc.
F.R.L module combination
When connecting to a modular F.R.L. unit (AC20 to 60), select one of
the spacers, included amongst the accessories. However, modular
combinations with AC40-06 are not possible.
3 Installation - continued
Furthermore, connect soft start-up valves to the outlet side of the F.R.L.
combination.
Inlet 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
combined sonic conductance of the inlet side’s (P port side’s) piping or
equipment should be equal to or larger than the values below.
Model
Combined sonic conductance
[dm3/(s·bar)]
AV2000-A
5
AV3000-A
22
AV4000-A
35
AV5000-A
50
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.
Tighten fittings to the specified tightening torque.
Connecting threads
Proper tightening torque (N▪m)
Rc 1/4
12 to 14
Rc 3/8
22 to 24
Rc 1/2
28 to 30
Rc 3/4
28 to 30
Rc 1
36 to 38
3.4 Lubrication Caution
The valve has been lubricated for life at the factory, and does not
require any further lubrication.
If a lubricant is used in the system, refer to catalogue for details.
Once lubricant is utilized within the system, since the original lubricant
applied within the product during manufacturing will be washed away,
please continue to supply lubrication to the system. Without continued
lubrication, malfunctions could occur. If turbine oil is used, refer to the
corresponding Material Safety Data Sheet (MSDS).
Lubrication amount
If a lubricant is applied excessively, it may accumulate inside the pilot
valve, causing malfunction or delayed response. Avoid using large
amount of lubricant. If it is not avoidable, use an external pilot type,
whereby supply air to the external pilot port contains no oil. This
prevents accumulation of oil inside the pilot valve.
3.5 Wiring Caution
When electric power is connected to a solenoid valve, make sure to
apply correct voltage. Incorrect voltage may cause malfunction or coil
damage.
Check the connections.
Check if the connections are correct after completing all wiring.
External force applied to lead wire
An excessive force to the lead wire may cause wire breakage. Take
appropriate measures to avoid applying a force of 30 N or more to the
lead wire.
Voltage leakage
Particularly when using a C-R element (surge voltage suppressor) to
protect the switching element, take note that leakage current will flow
through the C-R element, increasing leakage voltage.
AC coil is 8% or less of rated voltage.
DC coil is 3% or less of rated voltage.
3.6 Air supply Caution
Install air filters close to the valve on the upstream side.
Implement countermeasures by installing after-cooler or air dryer, or
water separator, etc.
3 Installation - continued
The compressed air containing a large amount of moisture may result in
a malfunction of the valve and other pneumatic equipment. Install an
after-cooler, air dryer or water separator or otherwise take an
appropriate measure.
3.7 Surge voltage suppressor Caution
3.7.1 DC power supply
3.7.1.1 Grommet –standard type (with polarity)
With light/surge voltage suppressor (Z)
NOTE1: Connect correctly the lead wires to + (positive) and - (negative)
indications on the connector.
NOTE2: Solenoids, whose lead wires have been pre-wired: positive
side (+) is red and negative side (-) is black.
3.7.1.2 DIN Terminal
With light/surge voltage suppressor (DZ)
DIN terminal has no polarity.
3.7.2 AC power supply
3.7.2.1 Grommet
With light (GZ)
3.7.2.2 DIN Terminal
With light (DZ) and (YZ)
NOTE1: Surge voltage suppressor of varistor has residual voltage
corresponding to the protective element and rated voltage; therefore,
protect the controller side from the surge voltage. The residual voltage
of the diode is approximately 1V.
3.8 How to use DIN terminal
3.8.1 Construction
Type “Y”
Y type DIN connector is a DIN connector that confirms to the DIN pitch
8-mm standard.
Type “D”
D type DIN connector with 9.4 mm pitch between terminals is not
interchangeable with Y type connector.
To distinguish between “Y”and “D”type DIN connector, “Y”has “N”
listed at the end of voltage symbol. For connector parts without lights,
“N” is not indicated. Refer to the name plate to distinguish.
“Y” Dimensions are the same as “D”type DIN connector.
When exchanging the pilot valve assembly only, “V115K-□D-X400”
is interchangeable with “V115K-□Y-X400”. Do not replace “V111K-
□G-X400”with “V115-□D/□Y-X400”(DIN terminal), and vice versa.
3.8.2 Connection
1. Loosen the holding screw and pull the connector out of the solenoid
valve terminal block.
3 Installation - continued
2. After removing the holding screw, insert a flat head screwdriver, etc.
into the notch on the bottom of the terminal block and pry it open,
separating the terminal block and the housing.
3. Loosen the screw (slotted screws) on the terminal block. Insert the
lead cores wires into the terminals according to the connection
method, and secure the wires by re-tightening the terminal screw.
4. Secure the cord by tightening the gland nut.
Caution
When making connections, take note that using other than the
supported size (ø3.5 to ø7) heavy duty cord will not meet IP65
(enclosure) standards. Ensure to tighten the gland nut and holding
screw within their specified torque ranges.
3.8.3 Changing the entry direction
After separating the terminal block and housing, the cord entry can be
changed by attaching the housing in the desired direction (4 directions
at 90° intervals).
*When equipped with light, handle carefully to avoid damage to the light
with the lead wires in the cable.
NOTE: Plug in and pull out the connector vertically without tilting to one
side.
3.8.4 Compatible cable
Cable O.D.: ø3.5 to ø7
(Reference) 0.5mm2, 2-core or 3-core, equivalent to JIS C 3306
3.8.5 DIN Connector part numbers
Type
Option
Rated Voltage
Rated Symbol
Part number
“D” Type
Without light
-
-
SY100-61-1
With light
24 VDC
24 V
SY100-61-3-05
12 VDC
12 V
SY100-61-3-06
100 VAC
100 V
SY100-61-2-01
200 VAC
200 V
SY100-61-2-02
110 VAC
110 V
SY100-61-2-03
220 VAC
220 V
SY100-61-2-04
“Y” Type
Without light
-
-
SY100-82-1
With light
24VDC
24 VN
SY100-82-3-05
12VCD
12 VN
SY100-82-3-06
100VAC
100 VN
SY100-82-2-01
200VAC
200 VN
SY100-82-2-02
110VAC(115VAC)
110 VN
SY100-82-2-03
220VAC(230VAC)
220 VN
SY100-82-2-04
3.8.6 Circuit Diagram with light
Coil
Coil
NL: neon bulb
Notch
Figure of
notch.
Terminal block

AV-SMU70EN-A
Page 3 of 3
4 Settings
4.1 Initial speed adjustment
To perform the initial speed adjustment of the outlet side actuator,
supply air from this valve’s inlet side and turn ON the pilot valve. Then,
rotate the needle counterclockwise from the fully closed position.
4.2 How to Find the Flow Rate (At air temperature of 20°C)
Choke flow: (P2+0.1)/(P1+0.1)  0.5
󰇛󰇜

Subsonic flow, when: 󰇛󰇜󰇛󰇜
󰇛󰇜󰇛󰇜

Q: Air flow rate [L/min (ANR)]
S: Effective area [mm2]
P1: Inlet pressure [MPa]
P2: Outlet pressure [MPa]
t: Air temperature [OC]
NOTE: The above formulas above are applied to pneumatics only
4.3 Manual override Warning
Since connected equipment will operate when the manual override is
activated, confirm that conditions are safe prior to activation.
4.3.1 Push-turn locking slotted type [Type B]
While pressing, turn in the direction of the arrow.
If it is not turned, it can be operated in the same way as the non-locking
type.
Caution
When operating the locking type D with a screw driver, turn it gently
using a watchmakers screw driver [Torque: Less than 0.1Nm]
4.3.2 Push-turn locking lever type [Type C]
While pressing, turn in the direction of the arrow.
If it is not turned, it can be operated in the same way as the non-locking
type.
Caution
When locking the manual override on the push-turn locking type (B, C),
make sure to push it down before turning. Turning without first pushing
4 Settings - continued
it down can cause damage to the manual override and failures such as
air leakage, etc.
4.3.3 Non-Locking push type (AV-A-X2004)
Press the blue button to override solenoid valve.
5 How to Order
Refer to catalogue and drawings for “How to Order”
6 Outline Dimensions (mm)
Refer to catalogue for outline dimensions.
7 Maintenance
Not following proper maintenance procedures could cause the
product to malfunction and lead to equipment damage.
If handled improperly, compressed air can be dangerous.
Maintenance of pneumatic systems should be performed only by
qualified personnel.
Before performing maintenance, turn off the power supply and be
sure to cut off the supply pressure. Confirm that the air is released to
atmosphere.
After installation and maintenance, apply operating pressure and
power to the equipment and perform appropriate functional and
leakage tests to make sure the equipment is installed correctly.
If any electrical connections are disturbed during maintenance,
ensure they are reconnected correctly and safety checks are carried
out as required to ensure continued compliance with applicable
national regulations.
Do not make any modification to the product.
Do not disassemble the product, unless required by installation or
maintenance instructions.
Removal of equipment, and supply/exhaust of compressed air
Before equipment removal, ensure that measures are in place to
prevent falling or run-away of the driven objects. Then, cut off the air
supply, electric power and exhaust air pressure from the system
using the residual pressure release function.
If handled improperly, damage or malfunction of machinery or
equipment may occur.
Low frequency operation:
Valves should be operated at least once every 30 days to prevent
malfunction (use caution regarding the air supply)
Caution
Drain flushing
Remove drained fluid from air filters periodically.
8 Limitations of Use
8.1 Limited warranty and Disclaimer/Compliance Requirements
Refer to Handling Precautions for SMC Products.
8.2 Safety relays Warning
If a safe output from a safety relay or PLC is used to operate this valve,
ensure that any output test pulse duration is shorter than 1 ms to avoid
the valve solenoid responding.
8 Limitations of Use - continued
Warning
Soft start function is not to be used as a safety function.
8.3 failure modes
The system designer should determine the effect of the possible failure
states on the system
Energy source status
Single
Air supply present, electricity
cut
Spool returns to the off position by
spring force
Air supply cut before electricity
cut
Spool returns to the off position by
spring force
Air supply cut after electricity
cut
Spool returns to the off position by
spring force
9 Contacts
Refer to Declaration of Conformity or www.smcworld.com for contacts.
URL :
http// www.smcworld.com (Global) http// www.smceu.com (Europe)
'SMC Corporation, Akihabara UDX15F, 4-14-1, Sotokanda, Chiyoda-ku, Tokyo
101 0021
Specifications are subject to change without prior notice from the manufacturer.
© 2018 SMC Corporation All Rights Reserved.
Template DKP50047-F-085H
Output signal
Test pulse