SMC Networks AVA2000 Series User manual

Doc. No. AV*-OMZ0091-A

PRODUCT NAME

Soft Start-up Valve

MODEL / Series / Product Number

AV2000-(F,N)02(B,G,S)-1~6(G,D,Y,DO,YO)(Z)(B,C)(-R,Z)-A

AV3000-(F,N)03(B,G,S)-1~6(G,D,Y,DO,YO)(Z)(B,C)(-R,Z)-A

AV4000-(F,N)04(B,G,S)-1~6(G,D,Y,DO,YO)(Z)(B,C)(-R,Z)-A

AV5000-(F,N)06~10(B,G,S)-1~6(G,D,Y,DO,YO)(Z)(B,C)(-R,Z)-A

AVA2000-(F,N)02(B,G,S)(-R,Z)-A

AVA3000-(F,N)03(B,G,S)(-R,Z)-A

AVA4000-(F,N)04(B,G,S)(-R,Z)-A

AVA5000-(F,N)06~10(B,G,S)(-R,Z)-A

AVL2000-(F,N)02(B,G,S)-(1~6)(D,Y,DO,YO,WO)(Z)(-R,Z)-A

AVL3000-(F,N)02(B,G,S)-(1~6)(D,Y,DO,YO,WO)(Z)(-R,Z)-A

AVL4000-(F,N)02(B,G,S)-(1~6)(D,Y,DO,YO,WO)(Z)(-R,Z)-A

AVL5000-(F,N)06~10(B,G,S)-(1~6)(D,Y,DO,YO,WO)(Z)(-R,Z)-A

Contents

Page

1. Safety Instructions 2~14

2. Application 15

3. Specifications 15~16

4. How to Order 17~21

5. Construction / Parts List 22~23

6. Assembly of Optional Parts 24

7. Working Principle 25

8. Trouble Shooting 26

9. Disassembly Drawing 27

10. Dimensions 28~33

-1-

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.

-2-

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 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.

! 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.

-3-

Design

Warning

1. Actuator operation

When using solenoid valve or actuator in the outlet side of tis product, implement

appropriate measures to prevent potential danger caused by actuator operation.

2. Holding pressure

Since the valve might have slight internal leakage, it is not suitable for holding pressure

in a tank or another vessel for a long period of time.

3. 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 for the mentioned applications,

additional safety measures should be adopted.

4. Ventilation

Provide ventilation when using a 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.

5. Lock out

We recommend using a lock with a shackle diameter of 5 or more for this product (with

lock out valve）. If a lock with a shackle of less than 5 is to be used, please test it on the

actual machine.

Selection

Warning

1. Confirm the specifications

The products presented in this catalog are designed only for use in compressed air

systems. Do not operate at pressures, temperatures, etc., beyond the range of the

specifications, as this can cause damage or malfunction. (Refer to the specifications.)

Please contact SMC is using for other fluids than compressed air.

2. Operation of closed center 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.

3. Using a regulator in the outlet side

When mounting a regulator in the outlet side (A port side), use a residual pressure relief

regulator (AR25K to 40K) or a check type regulator. With a standard regulator (AR10

to 60), the outlet side pressure may not be released when this valve is exhausted.

4. Operation of solenoid calves in the outlet side

To operate solenoid valves mounted on this product’s outlet side (A port side), first

confirm that the outlet side’s pressure (PA) has increased to become equal to the inlet

side’s pressure (PP).

5. Operation

The residual pressure release function of this product is for emergency use only;

therefore, avoid the operation in the same manner as ordinary 3 port valves.

6. 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 R port.

-4-

7. 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 (PA) increase to

approximately 1/2 of the inlet side’s pressure (PP).

Caution

1. Leakage voltage

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,

thus increasing leakage voltage.

AC coil is 8% or less of the rated voltage.

DC coil is 3% or less of the rated voltage.

2. Low temperature operation

Although the valve can be operated at temperature as low as 0 oC, measure should be

taken 0 oC to avoid solidifying or freezing drainage and moisture, etc.

Mounting

Warning

1. Opetation manual

Mount and operate the product after reading the manual carefully and understanding

its contents. Also, keep the manual in a place where it can be referred to as necessary.

2. Maintenance space

Allow sufficient space for maintenance and inspection.

3. If air leakage increases or equipment does not operate properly, stop operation.

After mounting or maintenance, etc., connect the compressed air and power supplies,

and perform appropriate function and leakage tests to confirm that the unit is mounted

properly.

4. Painting and coating

Warnings or specifications printed or labeled on a product should not be erased,

removed or covered up.

Furthermore, please contact SMC before painting the resin parts, as this may be cause

adverse effects depending on the solvent.

-5-

Adjustment

Caution

1. Needle operation of low speed air supply

To perform the initial speed adjustment of the outlet side actuator, supply air from this

product’s inlet side and turn ON the pilot valve. Then, rotate the needle

counterclockwise from the fully closed position.

Product bottom surface (exhaust port side)

Piping

Warning

1. Preparation before piping

Before piping is connected, it should be thoroughly blown out by air (flushing) or washed

to remove chips, sutting oil and other debris from inside the pipe.

2. Winding of sealant tape

When screwing together pipies and fittings, etc., be certain that chips from the pipe

threads and sealing material do not get inside the product. Also, when the sealant tape is

used, leave 1.5 to 2 thread ridges exposed at the end of the threads.

3. Tighten threads with the proper tightening torque

When screwing pipes into this product, tighten with the torques giving below. Also, when

using SMC fitting, please tighten with the torque conforming to Catalog or operation

manual.

4. Piping to products

When piping to products, avoid making an error of supply port etc., by referrng to the

operation manuals.

-6-

Recommended tightening torque

Thread size

Torque [N・m]

1/4

12 to 14

3/8

22 to 24

1/2

28 to 30

3/4

28 to 30

36 to 38

5. F.R.L module combination

When connecting to a modular F.R.L. combinations (AC20 to AC60), select one of

the spacers from accessories. (Refer to page 23 for details.) However, modular

combination with AC40-06 is not available.

Forthermore, connect this product to the outlet side of the F.R.L. combination.

Tighten the 2 holding screws on the spacer with bracket or spacer evently. Tighten them

to the recommended tightening torque. Insufficient tightening torque may result in

loosening or sealing failure. Excessive tightening torque may damage the thread, etc.

6. Lockout type handle operating load and moment control

Please do not apply excessive load to the handle when operating the valve switching,

when using this product (lockout type) by connected to the outlet side of the F.R.L.

combination. Application of excessive moment force to the spacer may cause air

leakage. Please consider using one more spacer with bracket on the outlet side of this

product, if necessary.

-7-

Space with bracket

Piping adapter

Assembly Example

Recommended Torque Unit: N・m

Applicable

model

AC20□

AC30□

AC40□

AC50□

AC60□

Spacer with

Bracket part no.

Y200-T-D

Y300-T-D

Y400-T-D

Y600-T-D

Spacer part no.

Y200-D

Y300-D

Y400-D

Y600-D

Torque

0.36

±0.036

1.2

±0.05

1.2

±0.05

2.0

±0.1

7. Inlet side piping conditions

The normal size of the piping material’s or equipment’s bore should be equal to or larger

than the port size of this product. The combine sonic conductance of the inlet side’s (P

port side’s) piping or equipment shoule be equal to or larger than the values below.

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.

Wiring

Caution

1. Applied voltage

When electric power is connected to a solenoid valve, be careful to apply the proper

voltage. Improper voltage may cause malfunction or coil damage.

2. Check the connection

Check if the connections are correct after completing all wiring.

3. External force applied to the lead wire

If an excessive force is applied to the lead wire, this may cause faulty wiring. Take

appropriate measures so that a force of 30N or more is not applied to the lead wire.

Lubrication

Caution

1. This product has been lubricated for life at the factory, and does not require any further

lubrication.

2. If a lubricant is used in the system, use class 1 turbine oil (no additive), ISO VG32. Using

other lubricant may cause damage to the product or malfunction. 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 Safety Data Sheet (SDS).

3. Lubrication amount

If the lubrication amount is excessive, the oil may accumulate inside the pilot valve, causing

a malfunction or response delay. So do not apply a large amount of oil.

Air Supply

Warning

1. Using clear air

Do not use compressed air that contained chemicals, synthetic oils that include organic

solvents, salt, corrosive gases, etc., as they may cause damage or malfunction.

Series

Combined sonic conductance [dm3/(s・bar)]

AV2000-A

AV3000-A

AV4000-A

AV5000-A

-8-

Caution

1. Install an air filter

Install an air filter of 5 m or smaller filtration on upstream side.

2. 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.

3. Install a mist separator

If an excessive amount of carbon powder is present, install a mist separator on the

upstream side. If excessive carbon dust is generated by the compressor, it may adhere

to the inside of this product and cause it to malfunction.

Refer to SMC’s “Air Cleaning Equipment” catalog for further details on compressed air quality.

Operating Environment

Warning

1. Do not use in atmospheres contacting corrosive gases, chemicals, sea water, water,

water steam, or where there is direct contact with any of these.

2. Do not use in explosive atmosphere.

3. Do not use in locations subject to vibration or impact.

4. Do not expose to direct sunlight for an extended period of time. Protective cover should

be used to shield.

5. Do not mound in locations where is nearby heat source. Radiated heat should be also

prevented.

6. Implement suitable protective measures in locations where there is contact with

water droplets, oil, or welding spatter.

7. Install a silencer into exhaust port to prevent the dust ingress if there is a lot of dust in

atmosphere, as dust may cause air leakage.

Maintenance

Warning

1. Perform maintenance inspections according to the procedures indicated in the

operation manual.

If handled improperly, malfunction and damage of machinery or equipment may occur.

2. Removal of equipment and supply/exhaust of compressed air

When components are removed, first confirm that measures are in place to prevent

workpieces from dropping, run-away equipment, etc. Then, cut off the supply pressure

and electric power, and exhaust all compressed air from the system using the residual

pressure release function.

3. Low frequency operation

Valves should be switched at least once every 30 days to prevent a malfunction. (Use

caution regarding the air supply.)

4. Manual override operation

When the manual override is operated, connected equipment will be actuated. Confirm

the safety before operating.

Caution

1. Drain removal

Remove drain from air filters periodically.

-9-

This manual suits for next models

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