SMC Networks IL100 User manual

No.IL01-OM00006-B
PRODUCT NAME
BOOSTER RELAY
MODEL/ Series
IL100

Table of Contents
Instructions for your Safety 1～2
1. Outline 3
2. Specification 3
3. Structure and the Operation Principle 3～4
4. Transportation and Storage 5
5. Precautions in Using 6
6. Maintenance 7～8
7. Countermeasures for Failure 9
8. Spare Parts List 10
9. Drawing 11

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 10218-1992: Manipulating industrial robots -Safety.
etc.
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
1. The compatibility of the product is the responsibility of the person who designs the
equipment or decides its specifications.
Since the product specified here is used under various operating conditions, its compatibility with specific
equipment must be decided by the person who designs the equipment or decides its specifications based on
necessary analysis and test results.
The expected performance and safety assurance of the equipment will be the responsibility of the person who
has determined its compatibility with the product.
This person should also continuously review all specifications of the product referring to its latest catalog
information, with a view to giving due consideration to any possibility of equipment failure when configuring the
equipment.
2. Only personnel with appropriate training should operate machinery and equipment.
The product specified here may become unsafe if handled incorrectly.
The assembly, operation and maintenance of machines or equipment including our products must be
performed by an operator who is appropriately trained and experienced.
3. Do not service or attempt to remove product and machinery/equipment until safety is
confirmed.
1.The inspection and maintenance of machinery/equipment should only be performed after measures to
prevent falling or runaway of the driven objects have been confirmed.
2.When the product is to be removed, confirm that the safety measures as mentioned above are implemented
and the power from any appropriate source is cut, and read and understand the specific product precautions
of all relevant products carefully.
3. Before machinery/equipment is restarted, take measures to prevent unexpected operation and malfunction.
4. Contact SMC beforehand and take special consideration of safety measures if the product
is to be used in any of the following conditions.
1. Conditions and environments outside of the given specifications, or use outdoors or in a place exposed to
direct sunlight.
2. Installation on equipment in conjunction with atomic energy, railways, air navigation, space, shipping,
vehicles, military, medical treatment, combustion and recreation, or equipment in contact with food and
beverages, emergency stop circuits, clutch and brake circuits in press applications, safety equipment or
other applications unsuitable for the standard specifications described in the product catalog.
3. An application which could have negative effects on people, property, or animals requiring special safety
analysis.
4.Use in an interlock circuit, which requires the provision of double interlock for possible failure by using a
mechanical protective function, and periodical checks to confirm proper operation.
-1-
Safety Instructions

Caution
The product is provided for use in manufacturing industries.
The product herein described is basically provided for peaceful use in manufacturing industries.
If considering using the product in other industries, consult SMC beforehand and exchange
specifications or a contract if necessary.
If anything is unclear, contact your nearest sales branch.
Limited warranty and Disclaimer/Compliance Requirements
The product used is subject to the following “Limited warranty and Disclaimer” and “Compliance
Requirements”.
Read and accept them before using the product.
Limited warranty and Disclaimer
1.The warranty period of the product is 1 year in service or 1.5 years after the product is
delivered,whichever is first.2)
Also, the product may have specified durability, running distance or replacement parts.
Please consult your nearest sales branch.
2. For any failure or damage reported within the warranty period which is clearly our
responsibility, a replacement product or necessary parts will be provided.
This limited warranty applies only to our product independently, and not to any other damage
incurred due to the failure of the product.
3. Prior to using SMC products, please read and understand the warranty terms and
disclaimers noted in the specified catalog for the particular products.
2) Vacuum pads are excluded from this 1 year warranty.
A vacuum pad is a consumable part, so it is warranted for a year after it is delivered.
Also, even within the warranty period, the wear of a product due to the use of the vacuum
pad or failure due to the deterioration of rubber material are not covered by the limited
warranty.
Compliance Requirements
1. The use of SMC products with production equipment for the manufacture of weapons of
mass destruction(WMD) or any other weapon is strictly prohibited.
2. The exports of SMC products or technology from one country to another are govemed by
the relevant security laws and regulation of the countries involved in the transaction. Prior
to the shipment of a SMC product to another country, assure that all local rules goveming
that export are known and followed.
-2-
Safety Instructions

1. Outline
Increase the operating speed of controlling part when the piping between the instruments and the
controlling part is very long, or the controlling part capacity is large.
2. Specification
Supply pressure
MAX.1.0MPa
Input・Output pressure
MAX.0.7MPa
Output flow
More than 600l/min(ANR)(SUP.0.5MPa)
Air consumption
Less than 3l/min(ANR) (OUT.0.5MPa)
Linearity
Within ±1%
Hysteresis
Within 1%
Effective orifice (Cv factor)
1.1
Ambient temperature and operating
fluid temperature
－5℃～60℃
Port size
Rc1/4・Rc3/8
Mass
560g
3. Structure and the operation principle
Input force from the instrument enters to the input chamber and act to diaphragm A. This works
against the force generated by diaphragm B. When the force generated by the input is strong, the
internal valve is pressed down and the supply air flows to the output side. When not strong, the
internal valve is closed and the exhaust port opens for exhaust. This is how the force generated by
diaphragmAand B is balanced. Opening of the needle valve connect the air path of the input and the
output. The adjustment of the throttle valve, the stability of the closed loop including the booster relay
is improved.
-3-

-3-
MODEL IL100 BLOCK DIAGRAM
-4-
MODEL IL100 BOOSTER RELAY
DIAPHRAGM(A)
㎡
PRESSURE
IN
FORCE
+
―
N
1
EQUIVALENT SPRING
m/N
MAIN VALVE
Pa/M
PRESSURE
Pa
DIAPHRAGM(B)
㎡
FORCE
N
m
DISPLACEMENT
Pa
(S)
SUP
ADJUSTABLE NEEDLE VALVE
NEEDLE VALVE
IN
DIAPHRAGM(A)
INPUT CHAMBER
DIAPHRAGM(B)
EXHAST HOLE
OUT
SUP
INTERNAL VALVE
EXH
OUT

4. Transportation and Storage
Warning
(1) Handle the product with care.
(2) Do not expose to rain.
(3) The product is packed in a vinyl bag for shipment to prevent from dust. Avoid taking out of
the bag just before piping even after unpacking.
(4) If the product is kept unpacking for a certain period, select a place where there is no
moisture nor corrosive gas.
While the product shipped has been applied specified paint and surface treatment, take
care that inappropriate storing environment may cause generating rust.
-5-
!

5. Precautions in using
Warning Operation
(1) Do not operate the booster relay out of the specifications, because it causes malfunction.
(2) If booster relay failure affecting the system is expected, provide a safety circuit for the
system to avoid danger.
Warning Handling
(1) Excess vibration and impact on the booster relay cause failure, may cause failure, so that
take care in handling during transportation and operation.
(2) Mount the filter to the pressure supply line. Use the mist separator when the oil mist and
carbon are contained.
(3) Flush the air piping before connecting the booster relay.
(4) Mind the arrow direction of the air flow when piping.
(5) The needle valve is opened for 3/4 turn and locked. No adjustment is necessary except
when the control system is unstable.
(6) Opening the needle valve delays the response, closing quickens the response.
Warning Air supply
(1) Please use the filter to the supply line. Where contained oil mist and carbon, please use the
mist separator.
(2) Avoid using compressed air compressed air containing chemicals, synthetic fluid including
organic solvent, salinity, and corrosive gas as it may cause malfunction.
Warning Environment
(1) Do not use in environment where the product is exposed to corrosive gas, chemicals, salt
water, water or steam.
(2) Do not operate the product in a location where it is subject to strong vibration and/or shock.
For vibration, it should be within IG 60Hz.
-6-
!
!
!
!

6. Maintenance
Warning
(1) To handle compressed air, person that has experienced and has knowledge about
instrumentation machine is suitable. That kind of person should operate unit replacement and
maintenance with keeping product specification.
(2) To remove booster relay or to replace unit with product set, please exhaust residual pressure
within piping with supply air stopped.
(3) After mounting, maintenance and disassemble, please test leakage and function with
compressed air supplied. When louder breed sound than initial, or when machine do not
operate properly, please confirm correct mounting.
Caution
(1) Periodical check (recommended : once / year)
Please check once per year on this product. To check, disassemble product following
disassemble drawing, and check following item. When disassemble, pay attention in order
not to damage diaphragm, in the case of diaphragm stick to body.
To re-assemble, ensure no foreign matter inside product and pay attention for air path
position of each part.
(2) Product replacement (recommended : once / 3 years)
This product rubber part is recommended to replace once per 3 years. Part replacement
adjustment (valve seat centering, main valve length adjustment etc.) make effects on property.
Product replacement is recommended by whole product per 3 years if it is used on extremely
important point.
-7-
!
!
Part description
Check items
Confirmation
Countermeasure
Diaphragm (2,10)
No crack or flaw on
the surface
Visual inspection
Part replacement if
abnormality is found.
“O”ring (11,12)
No crack or flaw on
the surface
Visual inspection
Valve stem spring (6)
No crack due to hold
Visual inspection
Main valve (3)
Without lock nut
loosen
Hand or tool
If loosen, retighten.
*( ) shows booster relay disassemble drawing part no.

Warning
(Adjustment on Part replacement)
Diaphragm replacement and product disassemble & re-assemble may change in/output
characteristics. For that circumstances, adjust main valve length. Main valve, as shown below, is
adjusted the length by screw and fixed with lock nut. To adjust length, loose lock nut. For the main
valve length adjustment, make longer when output is low to input signal. Make shorter when output
is high to input signal. Main valve total length is basically 25±1mm.
-8-
!
INNER VALVE Ass’y (26100-6)
INNER VALVE(B)
(261020)
INNER VALVE (A)
LOCK NUT
(M3)
(26102)
25±1

7.Countermeasures for failure
Warning
Avoid use when failure is not solved.
-9-
!
Phenomenon
Cause
Countermeasures
Too much flow from exaust
port
Dust attach supply port or
exaust port
Disassemble and clean.
(If flawed, replace the part.)
Broken diaphragm
Replace diaphragm
No signal even if input
signal is applied
Pressure leak due to loosen
screw
Tighten screw
Restrictor open too much
Decrease open degrees of
restrictor, and lock.
Broken diaphragm
Replace diaphragm
Bad characteristic
Valve stem length is
changed due to loosen lock
nut
Readjust into optimum
valve, and lock.
Plugged restrictor
Disassemble and clean
Deformed diaphragm
Replace diaphragm

Spare parts list
Doc.No.
IL01-SL00008
Page 1/1
Model Name IL１００・Spare parts list
Model No. ＫＴ－ＩＬ１００
No
.
Description
Sketch
Material
Pcs.
Drawing
Using
Spare
Drawing No.
Symbol
1
A2017
A2017
A2017
NBR
A2017
A2017
RESINIUM
1
26100-1
261017
261015
261014
261012
261010
26108
26109
2
Spring
SUS304W
1
26105
3
NBR
1
KA00085
(JIS B2401
P6)
4
NBR
1
KA00069
(JIS B2401
P12)
5
Diaphragm
NBR
1
261018
＊1～5 are in a set as a repairing parts kit.
Diaphragm
Ass’y
“O”Ring
φ86
20
φ86
φ9.6
φ16.6
“O”Ring
-10-

No.IL01-OM00006-B
-
-11-

No.IL01-OM00006-B
ＡSafety instructions update
ＢDrawing update
4-14-1, Sotokanda, Chiyoda-ku, Tokyo 101-0021 JAPAN
Tel: + 81 3 5207 8249 Fax: [phone]
URL http://www.smcworld.com
Note: Specifications are subject to change without prior notice and any obligation on the part of the manufacturer.
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