SMC Networks ZKJ Series User manual

No. ZKJ-OM00201
PRODUCT NAME
Vacuum Manifold for fieldbus system
MODEL / Series / Product Number
ZKJ Series

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No. ZKJ-OM00201
Contents
Safety Instructions 2
1. How to Order 9
2. Summary of Product Parts 11
3. Installation 12
3.1. Installation 12
3.2. Air Supply 12
3.3. Piping 13
4. Solenoid Valve 15
5. SI Unit 16
6. Construction/Replacement Parts 18
6.1. Construction 18
6.2. Component Parts 18
6.3. Replacement Parts 19
7. Exploded View of Manifold/Replacement Parts 20
7.1. Exploded View of Manifold 20
7.2. Component Parts for Manifold 20
7.3. Replacement Parts 21
7.4. Manifold Option 22
7.5. How to Increase Manifold Stations 23
8. Maintenance 24
8.1. Maintenance 24
8.2. Replacement Procedure 25
9. Specifications 27
10. Pneumatic Circuit 29
11. Exhaust/Flow Rate Characteristics 30
11.1. Ejector Exhaust Characteristics/Flow Rate Characteristics (Representative value) 30
11.2. Vacuum Release Flow Rate Characteristics (Representative value) 32
12. Limitations of Use 33
13. Troubleshooting 34

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No. ZKJ-OM00201
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: 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.
Safety Instructions

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No. ZKJ-OM00201
Safety Instructions
Caution
1. 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 governed 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 governing that export are
known and followed.
Caution
SMC products are not intended for use as instruments for legal metrology.
Measurement instruments that SMC manufactures or sells have not been qualified by type approval tests
relevant to the metrology (measurement) laws of each country.
Therefore, SMC products cannot be used for business or certification ordained by the metrology
(measurement) laws of each country.

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No. ZKJ-OM00201
■Safety Instructions
Warning
Disassembly
prohibited
Do not disassemble, modify (including the replacement of board) or repair other than
instructed in this manual.
Otherwise, an injury or failure can result.
Do not
Do not operate the product outside of the specifications.
Do not use for flammable or harmful fluids.
Fire, malfunction, or damage to the product can result.
Please check the specifications before use.
Do not
Do not use in an atmosphere containing flammable or explosive gases.
Fire or an explosion can result.
The product is not designed to be explosion proof.
Do not
Do not use the product in a place where static electricity is a problem.
Otherwise failure or malfunction of the system can result.
Do not
Do not cut off the power and compressed air supplied to this product while it is operating.
Otherwise it can cause injury due to dropping of workpieces or damage to the system.
Instruction
If using the product in an interlocking circuit
- Provide a double interlocking system, for example a mechanical system.
- Check the product for proper operation.
Otherwise malfunction can result, causing an accident.
Instruction
The following instructions must be followed during maintenance
- Turn off the power supply
- Stop the air supply, exhaust the residual pressure in piping and verify that the air is
released before performing maintenance work.
It may cause an injury.

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No. ZKJ-OM00201
Caution
Do not touch
Do not touch the terminals and connectors while the power is on.
Otherwise electric shock, malfunction or damage to the switch can result.
Instruction
Perform sufficient trial run.
Otherwise, injury or damage to the system can result due to suction failure depending on
the conditions of the suction of the workpiece or the pressure switch settings.
Perform sufficient verification before using this product.
Instruction
After maintenance is complete, perform appropriate functional inspections and leak test.
Stop operation if the equipment does not function properly or there is leakage of fluid.
If there is leakage from parts other than the piping, the product might be broken.
Cut off the power supply and stop the fluid supply.
Do not supply fluid if there is leakage.
Safety cannot be assured in the case of an unexpected malfunction.
■Handling Precautions
Follow the instructions given below for selecting and handling of the vacuum manifold.
●The instructions on design and selection (installation, wiring, environment, adjustment, operation, piping,
maintenance, etc.) described below must be followed.
Product specifications
- Be sure to check the specifications.
This product is designed only for use in compressed air systems (including vacuum). Do not operate at pressures,
temperatures, etc., beyond the range of specifications, as this can cause damage or malfunction. (Refer to the specifications)
Please contact SMC when using a fluid other than compressed air (including vacuum). We do not guarantee against any
damage if the product is used outside of the specification range.
- It is recommended to use compressed air which purity class is 2:6:3 of ISO8573-1:2010.
If compressed air containing condensate is used, install an air dryer or drain catch before the filter and perform draining
regularly.
If draining is not performed regularly and condensate enters the secondary side, it can cause operating failure of
pneumatic equipment.
When it is difficult to control drainage, the use of a filter with an auto drain is recommended.
- The applicable fluid is air.
Do not use a fluid containing chemicals, synthetic oils including organic solvent, salt and corrosive gases.
Otherwise, damage to the vacuum unit and malfunction can result.
Check the details of the specifications before use.
- Use the specified operating pressure.
Otherwise it can cause damage to the vacuum unit or inability to adsorb correctly.
The parts around the vacuum port of this product are designed to be used with vacuum pressure.
- Reserve a space for maintenance.
Design the system allowing the required space for maintenance.
- Use the specified voltage.
Otherwise failure or malfunction can result.
-Do not exceed the specified maximum allowable load.
Otherwise it can cause damage or shorten the life of the product.
- Design the product to prevent reverse current when the circuit is opened or the product is forced to operate for operational
check.
Reverse current can cause malfunction or damage the product.

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No. ZKJ-OM00201
-Do not use the product to drive an actuator such as a cylinder (when release pressure is constantly applied).
Otherwise this can result in damage or reduced performance.
- Not suitable for use as an emergency shutoff valve, etc.
The valves listed in this catalog are not designed for safety applications such as an emergency shutoff valve. If the valves
are used in such applications, additional safety measures should be adopted.
●Product handling
Installation
- Tighten to the specified tightening torque.
If the tightening torque is exceeded, the product, the mounting screws and brackets can be broken. Insufficient torque can
cause displacement of the product and loosening of the mounting screws.
- Do not drop, hit or apply excessive shock to the product.
Otherwise damage to the internal parts of the product can result, causing malfunction.
- When carrying the vacuum manifold, make sure that the connections are not stressed.
Otherwise, the damage to connections can result. In addition, some combinations of the manifold may be very heavy, so
use more than one person to carry or install the unit.
- Never mount a product in a location that will be used as a foothold.
The product may be damaged if excessive force is applied by stepping or climbing onto it.
- Eliminate any dust left in the piping by using a blast of air before connecting the piping to the product.
It will cause failure or malfunction.
- If the fluid may contain foreign matter, install and connect a filter or mist separator to the inlet.
It will cause failure or malfunction.
Wiring (Including connecting/disconnecting of the connectors)
- Do not pull hard on the lead wire, or lift the product by holding the lead wires of the solenoid valve or the pressure sensor.
Otherwise damage to the solenoid valve or the internal parts of the pressure sensor can result, causing malfunction or
causing the connector to come off.
- Avoid repeatedly bending, stretching or applying a heavy object or force to the lead wire.
- Wire correctly.
Incorrect wiring can cause malfunction or breakage of the SI Unit, control unit, solenoid valve or the pressure sensor.
- Do not perform wiring while the power is on.
Otherwise damage to the SI Unit, control unit, solenoid valve or the pressure sensor can result, causing malfunction.
- Do not route wires and cables together with power or high voltage cables.
Route the wires (piping) of the solenoid valve or the pressure switch/sensor separately from power or high voltage cables
in order to avoid noise or surge entering the signal line from the power or high voltage line.
- Confirm proper insulation of wiring.
Poor insulation (interference with other circuits, poor insulation between terminals etc.) can apply excessive voltage or
current to the SI Unit, control unit, solenoid valve or the pressure sensor, causing damage.
- Take appropriate measures against noise, such as using a noise filter, when the fieldbus system is incorporated into
equipment.
Otherwise, noise can cause malfunction.

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No. ZKJ-OM00201
Operating environment
- IP65 enclosure: The protection structure against solid foreign objects is dust-tight type and the protection structure against
water-jet-proof type.
Dust-tight means that no dust can enter the inside of the equipment.
Water-jet-proof means that the product is not adversely affected by direct water jets from any direction. That is, even when
direct water jets are applied to the product for 3 minutes by means of the pre-determined method, there is no water entry
that hinders the correct operation inside the equipment. Be sure to take appropriate protective measures if the product is to
be used in an environment where it will be constantly exposed to water or fluids other than water splash. In particular, the
product cannot be used in environments where oils, such as cutting oil or cutting fluid, are present.
- When using high-noise reduction silencer, keep the exhaust port of the silencer from coming in direct contact with water or
other liquids.
It will cause failure or malfunction.
- Select the proper type of protection according to the environment of operation.
IP65 protection is achieved when the following conditions are met:
(1) The units are connected properly with fieldbus cable with M12 connector and power cable with M12 connector.
(2) Suitable connecting of connectors for supply valve and release valve assembly, pressure sensor assembly and the
control unit.
(3) Suitable mounting of SI Unit, control unit and vacuum ejectors.
(4) Be sure to fit a seal cap on any unused connectors.
- Do not use in an environment where corrosive gases, chemicals, sea water, water or steam are present.
These may cause failure or malfunction.
- Do not use the product in a place where the product could be splashed by oil or chemicals.
If the product is to be used in an environment containing oils or chemicals such as coolant or cleaning solvent, even for a
short time, the solenoid valve or pressure switch/sensor may be adversely affected (damage, malfunction, or hardening of
the lead wires).
- Do not use in an area where surges are generated.
When there are machines or equipment that generate large surge near the pressure switch/sensor (magnetic type lifter,
high frequency inductive furnace, motor, etc.), this can result in deterioration and damage of the internal elements. Take
measures against the surge sources, and prevent the lines from coming into close contact.
- Do not use a load which generates surge voltage.
When a surge-generating load such as a relay or solenoid is directly driven, use the product with a surge absorbing
element built-in.
- The product is CE marked, but not immune to lightning strikes, so take measures against lightning strikes. Be aware of
excessive surrounding noise.
The product is CE marked and has passed the EMC test, but excessive noises in the surrounding area may affect the
functioning of the product.
- Mount the product in a location that is not affected by vibration or impact.
It will cause failure or malfunction.
- Do not let foreign matter, such as wire debris, get inside the product.
In order to avoid failure and malfunction, do not let foreign matter, such as wire debris, get inside the product.
- Do not use the product in an environment that is exposed to temperature cycle.
Heat cycles other than ordinary changes in temperature can adversely affect the inside of the product.
- Do not expose the product to direct sunlight.
If using in a location directly exposed to sunlight, protect the product from the sunlight.
Failure or malfunction may occur.
- Keep within the specified operating fluid and ambient temperature range.
Operation under low temperature may lead to damage or operation failure due to frozen moisture in the fluid or air.
Protection against freezing is necessary. Mounting of an air dryer is recommended for elimination of drainage and water.
Avoid abrupt temperature changes even within the specified temperature range.
- Do not use in a location where the product is exposed to radiant heat from surrounding heat sources.
Insufficient air quality may cause operation failure.

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No. ZKJ-OM00201
Adjustment and Operation
- If using the product to detect very small pressures, warm up the product for 10 to 15 minutes first.
There will be a drift on the display of approximately 1% for 10 minutes after the power supply is turned on.
- Perform settings suitable for the operating conditions.
Incorrect setting can cause operation failure.
For details of each setting, refer to the Operation Manual of the SI Unit for vacuum manifold.
- Please refer to the PLC manufacturer’s manual tec. For details of programming and addresses.
For the PLC protocol and programming refer to the relevant manufacturer’s documentation.
Piping
- Preparation before piping
Before piping, perform air blow (flushing) or cleaning to remove any cutting chips, cutting oil, dust, etc. from the piping.
- Wrapping of pipe tape
When installing piping or a tube fitting into a port, prevent cutting chips and sealant material from getting inside the product.
If a sealant tape is used, leave 1 thread exposed at the end of threads.
- When connecting tubing, consider factors such as changes in the tubing length due to pressure, and allow a sufficient margin.
Otherwise, it can damage the fitting and cause the tube to come off. Refer to Fittings & Tubing Precautions from 1 to 4 shown
in Best Pneumatics 6 on SMC’s website (URL https://www.smcworld.com) for the recommended piping conditions.
Maintenance
- Turn off the power supply, stop the supplied air, exhaust the residual compressed air in the piping and verify the release of
air before performing maintenance.
There is a risk of unexpected malfunction of component.
- Perform regular maintenance and inspections.
There is a risk of unexpected failure of components due to the malfunction of equipment and machinery.
- After maintenance is complete, perform appropriate functional inspections.
Stop operation if the equipment does not function properly.
Otherwise, safety is not assured due to an unexpected malfunction or incorrect operation.
- Perform draining regularly.
If condensate enters the secondary side, it can cause operating failure of pneumatic equipment.
- Do not use solvents such as benzene, thinner etc. to clean the product.
This may damage the surface of the body or erase the markings on the body.
Use a soft cloth to remove stains. For heavy stains, use a cloth soaked with diluted neutral detergent and fully squeezed,
then wipe up the stains again with a dry cloth.
Wrap this way
Sealant tape
Leave 1 thread exposed

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No. ZKJ-OM00201
1. How to Order
■Manifold
ZZKJ 04 - FAN - L8
(1) (2) (3)
(1) Number of Manifold Stations Note 1) 2) 3)
Symbol
Manifold Stations
Vacuum ejector stations
04
4 stations
Max. 4 stations
08
8 stations
Max. 8 stations
12
12 stations
Max. 12 stations
16
16 stations
Max. 16 stations
Note 1) The product outline is every four stations manifold. Be sure that the total number of the ejectors and the blanking plates is
equal to the manifold stations.
Note 2). The manifold model number cannot be ordered alone.
Note 3) The ejector can be increased by exchanging the blanking plate to an ejector, and also decreased for maintenance. Refer
to How to Increase Manifold Stations on page 23.
(2) SI Unit
(3) End plate U supply (P) port
■Single Unit
ZKJ 07 C8 H - A 5 U - T1 - L
(1) (2) (3) (4) (5) (6) (7) (8)
Remains blank when
no option is selected.
(1) Nominal Nozzle Size
(2) Vacuum (V) port, Supply (P) port
Symbol
Standard
Vacuum (V) port
Supply (P) port
C6
Metric
ø6
Plug
C8
ø8
N7
Inch
ø1/4”
N9
ø5/16”
C6U
Metric
ø6
ø6 Note 4)
C8U
ø8
N7U
Inch
ø1/4”
ø1/4” Note 4)
N9U
ø5/16”
Note 4) When selecting “Plug for individual supply” for options (8) or increasing the flow rate of supply air, select Supply (P)
port.
Symbol
Nominal size
07
ø0.7
10
ø1.0
12
ø1.2
15
ø1.5
Symbol
Protocol
FAN
PROFINET
Symbol
Type
L8
ø8 One-touch fitting elbow
LN9
ø5/16”One-touch fitting elbow

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No. ZKJ-OM00201
(3) Exhaust (EXH) port
(4) Combination of Supply Valve and Release Valve
(5) Rated Voltage
(6) Light/surge voltage suppressor and common specification
(7) Pressure sensor
(8) Option
Symbol
Supply valve
Release valve
A
N.C.
N.C.
E
N.O.
N.C.
Symbol
Exhaust type
H
High-noise reduction silencer exhaust
P
Port exhaust Note 5)
Note 5) Port size of exhaust port; mm: ø8, inch: ø5/16”
Symbol
Voltage
5
24 VDC
Symbol
Light
Surge voltage suppressor
Polarity
U
●
●
Non-polar
Symbol
Specification
T1
-100 to 100 [kPa]
Symbol
Type
Nil
Without option
E
Vacuum release flow adjusting needle
Screwdriver operation type long lock nut
M
Plug for individual supply Note 6)
(Blocking the air supply passage to the D side)
R
Manual override for residual pressure release Note 7)
Y
Vacuum (V) port release to atmosphere type Note 8)
Note 6) The supply (P) port for vacuum manifold is mounted only on the U side. When “M” is selected, select the supply (P)
port for (2) on the D side of the ejector where the plug for individual supply is mounted.
For detail, refer to Manifold Option on page 22.
Note 7) Manual override to release vacuum (V) port to atmosphere.
Note 8) When “Y” is selected, the energy saving function is not available. When the vacuum generation is stopped, the
vacuum (V) port is released to the atmosphere.

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No. ZKJ-OM00201
2. Summary of Product Parts
■Vacuum Ejector
■Manifold
Vacuum (V) port
Vacuum release flow adjusting needle
Air pressure supply (P) port
(Selected by model number)
Manual override for residual
pressure release (Option)
Release valve manual override
Supply valve manual override
Pressure sensor
4 x M6 Mounting hole
Blanking plate
Exhaust (EXH) port
(Selected by model number)
Control Unit
SI Unit
Power supply connector
(PWR)
Fieldbus interface connector
(BUS OUT/Port2)
Fieldbus interface connector
(BUS IN/Port1)
Air pressure supply (P) port

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No. ZKJ-OM00201
3. Installation
3.1. Installation
Mount and tighten the manifold using the holes in the end plate (4 x M6).
■Precaution
1. Do not drop, hit, or apply excessive impact to the product when handling it.
Even if the body looks undamaged, the internal components may be damaged, leading to a malfunction.
2. Load to the vacuum manifold
The vacuum manifold is made of resin; therefore, do not apply load to the port after mounting. Prevent any
kind of operation which generates moment as this may cause reduced performance or damage to the body.
3. Installation
Manifold can be mounted onto the floor using M6 holes on the end plate. The DIN rail installed in the product
is used for connecting the ejectors. Do not use mounting holes of the DIN rail to mount the product.
4. Ensure sufficient space for maintenance activities
When installing the products, allow access for maintenance.
5. Ventilation
Provide ventilation when using a vacuum manifold 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.
3.2. Air Supply
■Use clean air
1. Using compressed air which contains chemicals, synthetic oils containing organic solvents, salts or
corrosive gases, etc. can cause damage or malfunction. Do not use compressed air containing toxic
impurities.
2. If the compressed air contains excessive drainage or carbon powder, it can stick to the vacuum
generating part (the nozzle diffuser) or inside of the solenoid valve or the pressure sensor and cause
deterioration of the performance or operation failure.
4 x M6 Mounting hole

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No. ZKJ-OM00201
3. Quality of supply air
It is recommended to use compressed air which purity class is 2:6:3 of ISO8573-1:2010.
Supply air containing foreign matter, water, oil or condensate, etc. can cause malfunction of supply and
release valve.
It is recommended that an air filter and a mist separator are connected to the upstream side of the ejector
and the pump system to prevent foreign matter (drainage) from entering into the product, and perform
periodic maintenance of the mist separator to keep supply air quality.
The purity class of compressed air quality based on ISO8573-1:2010
Solid particle
Moisture
Oil
Class
Max number of particles per m3
Particle size d(μm)
Class
Pressure dew point
(oC) at air pressure
of 0.7 MPa
Class
Oil
concentration
(mg/m3)
0.1 < d ≤ 0.5
0.5 < d ≤ 1.0
1.0 < d ≤ 5.0
1
≤ 20,000
≤ 400
≤ 10
1
≤ -70
1
≤ 0.01
2
≤400,000
≤6,000
≤100
2
≤ -40
2
≤ 0.1
3
Not specified
≤90,000
≤1,000
3
≤ -20
3
≤ 1
4
Not specified
Not specified
≤10,000
4
≤ +3
4
≤ 5
5
Not specified
Not specified
≤100,000
5
≤ +7
6
≤ +10
3.3. Piping
The sizes of each port and the operating pressure range are as follows:
Use the specified operating pressure. Operation with a pressure exceeding the maximum operating pressure
leads to breakage of the product.
Port
Size
Operating pressure
range [MPa]
Metric
Inch
P(End plate U)
ø8
ø5/16”
0.3 to 0.5
P(Ejector) Note 1) 2)
ø6
ø1/4”
V
ø6, ø8
ø1/4”, ø5/16”
-
EXH
(Port exhaust)
ø8
ø5/16”
-
- : Not applicable
Note 1) P port (Ejector) is available when selecting for ejector model number.
Note 2) P port (End plate U) and P port (Ejector) are connected inside. For an adequate performance, the number of stations
when operated simultaneously depends on the nozzle diameter. Refer to Maximum Number of Manifold Stations that
Can Operate Simultaneously on page 27.
2 : 6 : 3

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No. ZKJ-OM00201
■Precautions
1. When piping to the product, be careful not to confuse a vacuum port with an exhaust port.
Otherwise this can result in damage or reduced performance. Apply compressed air after
confirming that the piping is connected correctly.
2. For maintenance and inspection purposes, ensure to install the residual pressure release system when
piping.
V port is released to atmosphere when performing the manual override for residual pressure release (option).
Please perform after ensuring measured are in place to prevent the workpieces from dropping, etc.
3. Insertion of the tube
(1) Cut the tube perpendicularly, being careful not to damage the external surface. Use SMC’s tube cutter
TK-1, 2 or 3 for cutting. Do not cut the tube with pliers, nippers, scissors, etc. If the tube is cut by any tools
other than a tube cutter, the cut surface of the tube will be slanted or flat, making it difficult to be connected
securely, causing the tube to come off or air leakage after the tube is connected. Also, allow a sufficient
margin of tube length.
(2) Hold the tube and push it in slowly, inserting it securely all the way into the fitting.
(3) After inserting the tubing, pull on it gently to confirm that it will not come out. If it is not installed securely
all the way into the fitting, problems such as leakage or disconnection of the tube can occur.
4. Removal of the tube
(1) Push the release button flange evenly and sufficiently to release the tube. Do not push in the tubing before
pressing the release button.
(2) Hold down the release button while pulling out the tube. If the release button is not held down fully, it will
be more difficult to pull out the tube.
(3) If the removed tubing is to be used again, cut off the section of the tubing which has been gripped. Re-
using the gripped portion of the tube can cause problems such as air leakage or difficulty in removing the
tube.
5. Other manufacturers' tubes
If tubes of brands other than SMC are used, confirm that the materials and tolerance of the tubing outside
diameter will satisfy the following specifications.
(1) Nylon tube: Within ±0.1 mm
(2) Soft nylon tube: Within ±0.1 mm
(3) Soft polyurethane tube: Within +0.15 mm, within -0.2 mm
Do not use tubing which does not meet these outside diameter tolerances. It may not be possible to connect
them, or they may cause other trouble, such as air leakage or the tube pulling out after connection.
6. Piping
(1) Allow a sufficient margin of tube length when piping, in order to prevent twisting, tensile, moment loads,
vibration or impact being applied to the tubes and fittings.
This can cause damage to the tube fittings and crushing, bursting or disconnection of tubing.
(2) Piping to the product is assumed to be static piping.
If the tube moves, it may become worn, elongated or torn due to tensile forces, or disconnected from the
fitting. Ensure the tube is in a static condition at all times before using.
(3) Prevent the connected tube from being rotated.
If the fittings are used in this way, the fitting may be broken.
(4) Do not lift the product by holding the piping after the tube is connected to the vacuum (V) port.
Otherwise, the filter case and/or the One-touch tube fitting will be damaged.
Manual override for residual
pressure release (Option)

-15-
No. ZKJ-OM00201
4. Solenoid Valve
■Manual override operation
Regardless of an electric signal for the valve, the manual override is used for switching the main valve.
Connected actuator is started by manual operation. An alarm may occur when using the manual override
during PROFINET communication. Use the manual override when the power supply is turned off.
Manual override is non-locking push type. Push the manual override with a screwdriver of a diameter smaller
than the hole until it reaches the end.
Confirm that the product operates safely before the manual override is operated.
■LED indication
Red LED turns on when the supply valve is energized. Green LED turns on when the release valve is
energized.
■Electrical wiring
Wiring should be connected as shown below. Light/surge voltage suppressor circuit is equipped.
■Precautions
1. Extended periods of continuous energization
If a valve will be continuously energized for an extended period of time, the temperature of the valve will
increase due to the heat generated by the coil assembly. This will likely adversely affect the performance
of the valve and any nearby peripheral equipment. Therefore, if the valve is to be energized for periods of
longer than 30 minutes at a time, or if during the hours of operation the energized period per day is longer
than the de-energized period, we advise using a N.O. (normally open) valve.
2. Resumption after a long period of holding time
When resuming operation after a long period of holding time, there are cases in which, regardless of whether
the product is in an ON orOFF state,there is a delayin the initial response time due toadhesion. Conducting
several cycles of running-in operation will solve this problem. Please consider implementing this before
resumption.
3. Holding vacuum pressure
When adsorbing the workpieces, ensure to turn on the vacuum instruction signal. The workpiece may drop
due to the foreign matter adhering to the vacuum pad or leakage from the valve.
Do not perform the operation to generate vacuum and release pressure at the same time. It may cause
malfunction.
4. Air leakage
Zero air leakage is not guaranteed for the supply valve or release valve. Be aware that because there is a
chance of air and vacuum leakage, the pressure may change if the V port side is tightly sealed.
LED light position
Supply valve manual override
A (Blue)
Release valve manual override
B (Yellow)
COM
(-) Red
Supply valve
(+) Black
Release valve
(+) White
Coil
Coil
LED (Red)
LED (Green)
Varistor
Varistor

-16-
No. ZKJ-OM00201
5. SI Unit
The SI Unit controls a vacuum manifold. The SI Unit compatible with the vacuum manifold is shown below.
The following vacuum manifold parameters can be set by SI Unit.
■Energy saving function
While the vacuum instruction signal is ON, the supply valve closes automatically when the vacuum pressure
reaches the setting value. The supply valve then opens automatically and generates vacuum when the vacuum
pressure drops.
Part number
Protocol
EX260-VPN1
PROFINET
Parameter
Explanation
Channel
Set whether or not to mount the ejector.
Supply valve type
Set the supply valve type(Normally Open(N.O.) or Normally Close(N.C.)).
Energy saving function
Set Enable/Disable of energy saving function. Note 1)
Pressure range
Set the rated pressure range of pressure sensor.
Pressure value
Set the value for energy saving function and vacuum/release confirmation.
Count value
Set the value for valve protection function.
Note 1) When Option “Y” for vacuum ejector is selected, set Disable for energy saving function.
Atmospheric
pressure
Energy saving
function
Negative pressure
Vacuum
Instruction
Supply
valve
ON
OFF
Open
Close

-17-
No. ZKJ-OM00201
■Pressure value
The pressure value parameter for energy saving function (P2, H2), vacuum confirmation (P1, H1) and release
confirmation (P3, H3) can be set. The release pressure varies depending on the supply pressure, piping
conditions and the number of ejectors operating simultaneously. Set the release confirmation signal value with
care.
■Valve protection
During operation of energy saving function, if the switching of vacuum stop/generate has reached the ‘Count
value’, energy saving operation automatically switches to continuous adsorbing to prevent excessive valve
operation.
Energy saving function resumes by turning the power supply for the logic/sensors or for the valves OFF/ON, or
instruction for releasing valve protection from the SI Unit.
If valve protection operates with high frequency, review the setting value or perform maintenance to the ejectors
and pads.
■Zero clear
This function adjusts the displayed pressure to zero.
When using the SI Unit for the first time, perform zero clear when the residual pressure is exhausted and pressure
is not applied.
■For further details of the parameters and functions, refer to the SI Unit Operation Manual.
Atmospheric
pressure
P3
H3
P1
H1
P2
H2
Pressure of
Vacuum confirmation
Energy saving
function
Negative pressure
Vacuum
confirmation bit
Release
confirmation bit
1
0
1
0
Atmospheric
pressure
Energy saving
function
Negative pressure
Energy saving operation
Continuous adsorbing
1
2
3
In the case of count value parameter is 3.
The number of supply
valve operation:

-18-
No. ZKJ-OM00201
Ejector supply (P) Port
Manual override for
residual pressure release
(Option)
6. Construction/Replacement Parts
6.1. Construction
6.2. Component Parts
No.
Item
Material
Remarks
1
Valve adapter assembly
PBT
FKM, HNBR, SUS and aluminum are also used
2
Valve body assembly
PBT
FKM and SUS are also used
3
Sealing valve body assembly
PBT
FKM, HNBR, SUS and aluminum are also used
4
Ejector body assembly
PBT
HNBR and SUS are also used
5
Supply valve and release
valve assembly
-
Refer to Replacement Parts on Page 19
6
Pressure sensor assembly
-
-
7
Vacuum port adapter
assembly
-
Refer to Replacement Parts on Page 19
One-touch fitting with filter element
8
Filter element
Non-woven
close
Refer to Replacement Parts on Page 19
Nominal filtration rating: 30μm, 10 pcs. per set
9
High-noise reduction silencer
assembly
POM,
PVA
Refer to Replacement Procedure on Page 26
With sound absorbing material(Part number: ZK2-SE4-6-A)
10
Needle assembly
Brass
Electroless nickel plated brass, resin, steel and FKM are
also used
11
Check valve
HNBR
When option “Y” is selected, the check valve on the left
side as shown in the above figure is not mounted
Port exhaust
(6)
(11)
(1)
(8)
(7)
(2)
(3)
(4)
(10)
(9)
(5)

-19-
No. ZKJ-OM00201
Valve type
Symbol
Supply valve
Release valve
A
N.C.
N.C.
E
N.O.
N.C.
6.3. Replacement Parts
(5) Supply valve and release valve assembly
[With two mounting screws] (Tightening torque for mounting screw: 0.2 Nm)
ZKJ - JSY3 A 00 - 5U
(7) Vacuum port adapter assembly
(Purchasing order is available in units of 10 pieces.)
ZKJ - VA1S 8 F - A
(10) Filter element
(10 pcs. per set)
ZK2 - FE1 - 3 - A
(16) High-noise reduction silencer assembly
(10 pcs. per set)
ZK2 - SC3F - 4 - A
Nozzle size
4
For nozzle size 07, 10
6
For nozzle size 12, 15
Nominal filtration rating
3
30μm
One-touch fitting size
6
ø6
Metric
8
ø8
7
ø1/4”
Inch
9
ø5/16”