SMC Networks AKP Series User manual

PRODUCT NAME

Pilot Check Valve Compact Type

MODEL/ Series/ Product Number

AKP-

＊＊＊＊

＊

Doc. no. DOC1013639

-1-

Contents

1. Safety Instructions 2～3

2. Specific Product Precautions 4～9

3. Application

4. Specifications 10

5. Malfunctions and Countermeasures

6. Construction 11～12

-2-

Pilot Check Valve Compact Type

AKP Series

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: Manipulating industrial robots -Safety.

etc.

Caution

indicates a hazard with a low level of risk which, if not avoided, could result

in minor or moderate injury.

Warning

indicates a hazard with a medium level of risk which, if not avoided, could

result in death or serious injury.

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.

-3-

Pilot Check Valve Compact Type

AKP Series

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.

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.

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.

The exports of SMC products or technology from one country to another are governed by the

relevant security laws and regu

lation 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.

-4-

2. Specific Product Precautions

Warning

(1) Confirm the specifications.

The products are designed to be used in

compressed air systems (including vacuum) only.

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 SM 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 specifications

range.

(2) Do not disassemble the product or make any

modifications including additional machining.

Doing so may cause human injury and/or an

accident.

(3) Sonic conductance (C) and critical pressure

ratio (b) values for products are

representative values.

(4) Check if PTFE can be used in application.

PTFE powder (Polytetrafluoroethylene resin) is

included in the seal material of the male thread

type piping taper thread. onfirm that the use of

it will not cause any adverse effect on the system.

Please contact SM if the Safety Data Sheet

(SDS) is required.

(5) The pilot check valve is a product aimed at

the control of the actuator via a temporary

intermediate stop.

The pilot check valve is used for temporarily

stopping the actuator. Until a pilot signal is input,

the valve shuts off the flow path from 2 to 1 and

the actuator stops. When a pilot signal is input,

the flow path from 2 to 1 is opened. When the

residual pressure exhaust button is operated, all

flow paths (2 to 1, 21, and exhaust port) are

opened.

Warning

(6) The product cannot be used for accurate

and precise intermediate stop of the actuator.

Due to the compressibility of air as a fluid, the

actuator will continue to move until it reaches a

position of pressure balance, even though the

pilot check valve closes with an intermediate

stop signal.

(7) The product cannot be used for retention of

the stop position for long hours.

Pilot check valve and actuators are not

guaranteed for zero air leakage. Therefore, it is

sometimes not possible to hold a stop position

for extended period of time. In the event that

holding for an extended time is necessary, a

mechanical means for holding should be devised.

(8) Pay attention to the residual pressure within

the actuator at the time of intermediate stop.

When the actuator is stopped at the

intermediate position by this product, there may

be pressure contained inside the actuator,

therefore the actuator may suddenly move when

the residual pressure is released. Before

operating the residual pressure exhaust button,

confirm that the surrounding area is secure from

any potential hazards or accidents occurring.

(9) Use this product after checking the

surrounding areas in advance before the

release of residual pressure.

The actuator may move at a speed quicker

than the intended speed from the original circuit

set up when exhausting from the residual

pressure release. onfirm this speed will not

create additional hazards and pay attention to

the air discharged from the exhaust port.

Design/ Selection

Residual pressure

exhaust button (ø2.9)

Exhaust Port

Design/ Selection

Exhaust

Port

-5-

Warning

(10) Pay attention to the motion of the actuator

at the time of release of the residual pressure.

When operating the residual pressure exhaust

button or conducting maintenance or inspection,

the actuator may start moving due to the residual

pressure. Take appropriate measures in

advance to prevent an actuator movement from

posing a hazard.

Also pay attention to the operation speed and

the movement of the cylinder during exhaust.

When an exhaust center valve is used on the

actuator supply side (Figure A below), the

residual pressure is released from port 1, 21, and

the exhaust port. However, when using a closed

center valve like the example shown in Figure B

below, air is discharged only from port 21 and the

exhaust port..

For the moving direction of the actuator against

the corresponding exhaust side, refer to the

figure below.

Warning

(11) Push the residual pressure exhaust button

all the way to the end position by using a

tool.

Push the residual pressure exhaust button all

the way to the end position by using a tool having

a tip diameter of φ2.8 or below. For the insertion

depth and insertion force, refer to the table below.

AKP-*-*01 AKP-*-*02

0.1 5.1 6.6

0.3 7.5 11.3

0.5 10.0 16.0

0.7 12.4 20.8

2.4

Working pressure

[MPa]

Insertion depth

[mm]

Insertion force [N]

(reference value)

(12) After operating the residual pressure

exhaust button confirm that the button has

returned to the normal position.

Make sure that the residual pressure exhaust

button has returned to the end face of the

product before operating again. If the button

cannot return to the normal position, the

intermediate stop function of the actuator will not

work. Therefore, replace the product with a new

one.

(13) Pay attention to the motion of the actuator

at the time of restart after the release of

residual pressure.

When restarting the product after releasing the

residual pressure, check the initial driving

direction, confirm that the work area is secured,

and then restart the product. Failure to follow this

instruction may cause the actuator to suddenly

move.

(14) When the product is used in a balance

control circuit the check valve may not be

released even when the pilot pressure is

50% of the operating pressure. In this case

obtain the pilot pressure from a position so

that the pilot pressure is equivalent to the

operating pressure.

When using the product at the minimum

operating pressure set the pilot pressure to

0.1 MPa or higher.

(15) As a reference we have confirmed

through our durability tests that the check

valve has a durability against 10 million

cycles of ON and OFF operations and the

residual pressure exhaust button has a

durability against 10 000 cycles of

operation at the maximum operating

pressure.

However note that the tests were

conducted under limited conditions.

Moves to the

extended end side.

Moves to the

retracted end side.

Exhaust side

Figure A: Example of piping using exhaust center valve

Figure B: Example of piping using closed center valve

(Recommended example)

Design/ Selection Design/ Selection

Moves to the

extended end side.

Moves to the

retracted end side.

Exhaust side

-6-

Warning

(16) In the following cases malfunctioning or

noise due to oscillation may occur.

- When the differential pressure between the port

1 side and port 2 side is smaller than the

minimum operating pressure

- When the IN side piping of the product or the

effective area of the directional control valve is

smaller than that of the product

- When the pressure drop on the port 1 side is

slower than that of the port 2 side during

operation of the product

- When the supply pressure at the port 21 is

reduced (Refer to the piping diagram below.)

- When the port 1 side piping (tube) is bent or

crushed

Warning

(1) Operation Manual

Install the products and operate it only after

reading the operation Manual carefully and

understanding its contents. Also, keep the Manual

where it can be referred to as necessary.

(2) Ensure sufficient space for maintenance

activities.

When installing the products, allow access for

maintenance.

(3) Tighten threads with the proper tightening

torque.

When installing the products, follow the listed

proper torque.

(4) Use R external threads with Rc internal

threads and NPT external threads with NPT

internal threads and G external threads with

G internal threads.

Warning

(5) Check piping directions before mounting.

onnect the inlet to the directional control valve

and the outlet to the actuator.

(6) Do not apply excessive force or shock to the

body or fittings with an impact tool.

It can cause damage or air leakage.

(7) For handling One-touch fittings refer to the

Fittings and Tubing Precautions.

(8) Pay attention to the method of mounting on

the cylinder.

For the horizontal type, a hexagon wrench needs

to be used. The product cannot be mounted with

an open-end wrench. For the mounting of the

vertical type, an open-end wrench needs to be

used.

(9) Conduct mounting and removal of the

vertical type by holding the width across flats

of the body B and turning it by using an

appropriate wrench.

Do not apply torque at other points as the

product may be damaged. Rotate Body A

manually for positioning after installation.

(10) To install and remove the product with

hexagonal hole use an appropriate hex key

and push it into the hexagon hole of the stud.

Do not apply torque at other points as the

product may be damaged. Rotate Body A or B

manually for positioning after installation. Refer to

the applicable dimension of the hexagon wrench.

Metric (mm) Imperial (Inch)

R1/8, G1/8 6 ―

NPT1/8 ―7/32"

R1/4, G1/4 8 ―

NPT1/4 ―5/16"

Hex Key (Nominal)

Connection

Thread

Mounting

Design/ Selection Mounting

Body B

Body A

Stud

End Body

*Illustrations of vertical type (left)

and horizontal type (right) products

Recommended

-7-

Warning

(11) Do not use the product in application that

involves continuous rotation. Do not use the

product in a manner that applies a moment

load.

Failure to follow these instructions may cause

the fitting or product to be damaged.

Caution

(1) For R, NPT, G thread

①Tightening method

To tighten a screw on the vertical type, first

tighten it by hand and then hold the width across

flats of the body B and turn it by using an

appropriate wrench. To tighten a screw on the

horizontal type, tighten it by hand and then insert

an appropriate hexagon wrench to the hexagonal

socket of the stud and turn it.

Refer to the reference values in the table below

for the tightening torque.

1/8 3 to 5

1/4 8 to 12

Connection

Thread size

Tightening Torque

(N・m)

②Chamfered area for female thread

By chamfering as shown in the following table,

machining of threads is easier and effective for

burr prevention.

Rc NPT G Face seal

1/8 10.2 to 10.4 10.5 to 10.7 9.8 to 10.2

1/4 13.6 to 13.8 14.1 to 14.3 13.3 to 13.7

Chamfer dimension φD（Recommended value）

Connection

Thread size

*G thread (face seal) complies with ISO16030-

2001.

Caution

(1) If the fitting is tightened with excessive

torque, a large amount of sealant will seep

out. Remove the excess sealant.

(2) Insufficient tightening may loosen the

threads, or cause air leakage.

(3) Reuse

①Normally, fittings with a sealant can be reused

2 to 3 times.

②To prevent air leakage through the sealant,

remove any loose sealant stuck to the fitting

by blowing air over the threaded portion.

③If the sealant no longer provides effective

sealing, wrap sealing tape over the sealant

before reusing. Do not use the sealant in any

form other than a tape type.

(4) Once the fitting has been tightened, backing

it out to its original position often causes the

sealant to become defective. Air leakage will

occur

(5) Use R external threads with Rc internal

threads and NPT external threads with NPT

internal threads.

Caution

(1) Refer to the Fittings & Tubing Precautions for

handing One-touch fittings.

(2) Preparation before piping

Before piping is connected, it should be

thoroughly blown out with air (flushing) or washed

to remove chips, cutting oil and other debris from

inside the pipe.

(3) Winding of sealant tape

When screwing together pipes and fittings, etc.,

be certain that chips from the pipe threads and

sealing material do not get inside the pipe. Also,

when the sealant tape is used, leave approx. 1

thread ridges exposed at the end of the threads.

Piping Threads with Sealant

Piping

Mounting

-8-

Caution

(1) Connection and disconnection of tube from

one-touch fitting

① Installation of tube

1) ut the tube perpendicularly, being careful not

to damage the external surface. Use an SM

tube cutter TK-1, 2, 3 or 6. Do not cut the tubing

with pliers, nippers, scissors, etc., otherwise

the tubing will be deformed and problems may

result.

2) The outside diameter of the polyurethane

tubing swells when internal pressure is applied

to it. Therefore, it may be impossible to re-

insert the tubing into One-touch fittings. heck

the tubing outside diameter, and when the

accuracy of the outside diameter is +0.07mm

or larger for φ2, and +0.15mm or larger for

other sizes, re-insert it into the One-touch fitting

without cutting the tube. When the tubing is

re-inserted into the One-touch fitting, confirm

that the tubing goes through the release button

smoothly.

3) Grasp the tubing, and slowly push it straight (0

to 5°) into the One-touch fitting until it comes to

a stop.

4) Pull the tubing back gently to make sure it has

a positive seal. Insufficient installation may

cause air to leak or the tubing to release.

As a guide for checking if the tubing is pulled

out or not, refer to the following table.

②Removal 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) Pull out the tubing while keeping the release

button depressed. If the release button is not

held down sufficiently, the tubing cannot be

withdrawn.

3) To reuse the tubing, remove the previously

lodged portion of the tubing. If the lodged

portion is left on without being removed, it may

result in air leakage and make the removal of

the tubing difficult.

Caution

(2) Connection of the metal rod accessories

Do not use tube, resin plug, reducer, etc. after

connecting a fitting with a metal rod (K series,

etc.) to a One-touch fitting. This can cause the

disconnection of tube.

(3) When mounting the tube resin plug or metal

rod do not press the release button.

Do not press the release button unnecessarily

before mounting tubing, resin plugs and metal

rods. This can cause the disconnection of tube.

(4) When using a tubing other than from SMC

confirm that the tube material and the O.D.

accuracy satisfy the following specifications.

1) Nylon tube ±0.1 mm max.

2) Soft nylon tube ±0.1 mm max.

3) Polyurethane tube +0.15 mm at max.

Within -0.2 mm

Do not use the tubing which does not satisfy the

specified tubing O.D. accuracy, or if the tubing

has a different I.D., material, hardness, or

surface roughness from those of SM 's tubing.

If you have any questions, please consult SM .

Failure to satisfy the specifications may lead to

difficulty in connecting the tubing, leakage,

disconnection of the tubing, or fitting damage.

(1) When connecting piping to the One-touch

fitting use a pipe length with sufficient

margin in accordance with the piping

conditions shown in Figure 1.

Also, when using a tying band, etc., to bind the

piping together, make sure that external force

does not come to bear on the fitting.

(see Figure 2)

Unit:mm

φ4,φ5/32" 56 or more 44 or more 26 or more 20 or more

φ6 84 or more 66 or more 39 or more 30 or more

φ1/4" 89 or more 70 or more 57 or more 32 or more

φ8, φ5/16" 112 or more 88 or more 52 or more 40 or more

Tubing size Straight-line

Pipe length

Mounting pitch A

Nylon

tube Soft nylon tube Polyurethane

tube

Precautions for One-Touch Tube Fittings

Piping

Recommended Piping Conditions

Piping

-9-

Warning

(1) Type of fluids

Please consult with SMC when using the product

in applications other than compressed air.

(2) When there is a large amount of drainage

Compressed air containing a large amount of

drainage can cause the malfunction of pneumatic

equipment. An air dryer or water separator should

be installed upstream from filters.

(3) Drain flushing

If condensation in the drain bowl is not emptied

on a regular basis, the bowl will overflow and allow

the condensation to enter the compressed air lines.

This causes the malfunction of pneumatic

equipment.

If the drain bowl is difficult to check and remove,

the installation of a drain bowl with an auto drain

option is recommended.

For compressed air quality, refer to SMC catalog

"Compressed Air Purification System".

(4) Use clean air

Do not use compressed air that contains

chemicals, synthetic oils that include organic

solvents, salt, corrosive gases, etc., as it can

cause damage or malfunction.

Caution

(1) Install an air filter.

Install an air filter upstream near the valve.

For the filtration rating, select 5 μm or below, or

select a rating equivalent to or lower than ISO

8573-1:2010 [6:4:4]*.

*This is equivalent to the filtration performance

achieved when an air filter is attached for inlet

side compressed air with purity class of [7:4:4].

(2) Ensure that the fluid and ambient

temperatures are within the specified range.

If the fluid temperature is 5

℃

or less, the

moisture in the circuit could freeze, causing

damage to the seals or leading to equipment

malfunction. Therefore, take appropriate

measures to prevent freezing.

For compressed air quality, refer to SMC

catalog "Compressed Air Purification System".

Warning

(1) Do not use in an atmosphere containing

corrosive gases, chemicals, sea water, water,

water steam, or where there is direct contact

with any of these.

(2) Do not expose the product to direct sunlight

for an extended period of time.

(3) Do not mount the product in locations where

it is exposed to radiant heat.

Warning

(1) Perform maintenance and inspection

according to the procedures indicated in the

operation manual.

If handled improperly, malfunction or damage of

machinery and equipment may occur.

(2) Maintenance work

If handled improperly, compressed air can be

dangerous.

Assembly, handling, repair and element

replacement of pneumatic systems should be

performed by a knowledgeable and experienced

person.

(3) Drain flushing

Remove drainage from air filters regularly.

(4) Removal of equipment, and supply/exhaust

of compressed air

Before components are removed, first confirm

that measures are in place to prevent workpieces

from dropping, run-away equipment, etc.

Then, Cut the supply pressure and electric power,

and exhaust all compressed air from the system

using the residual pressure release function.

When machinery is restarted, proceed with

caution after confirming that appropriate

measures are in place to prevent sudden

movement.

Air Supply Operating environment

Maintenance

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