SMC Networks AWM20-01 Series Bedienungsanleitung

Doc. No. AW-OMZ0061-A

PRODUCT NAME

Mist Separator Regulator

MODEL / Series / Product Number

AWM20-(F,N)01～(F,N)02(B,C,E,E1,E2,E3,E4,G,H,M)(-1,2,6,C,J,N,R,Z,ZA)-D

AWM30-(F,N)02～(F,N)03(B,C,D,E,E1,E2,E3,E4,G,H,M)(-1,2,6,8,J,N,R,W,Z,ZA)-D

AWM40-(F,N)02～(F,N)04(B,C,D,E,E1,E2,E3,E4,G,H,M)(-1,2,6,8,J,N,R,W,Z,ZA)-D

Contents

Page

1. Safety Instructions

2-8

2. Application

3. Standard Specifications

4. How to Order

5. Options

6. Structural Drawing and Replacement Parts

12-13

7. Bowl Assembly Specifications

14-21

8. Assembly of Optional Parts

9. Operation and Adjustment

23-25

10. Trouble Shooting

26-27

11. How to Replace the Components

28-37

11-1. Diaphragm Assembly Replacement

11-2. Bowl Assembly Replacement

29-30

11-3. Element Replacement

31-32

11-4. Valve Assembly Replacement

33-34

11-5. Square Embedded Type Pressure Gauge Replacement

11-6. Blanking Plate Assembly Replacement

11-7. Plug (with O-ring) Replacement

12. Disassembly Drawing

38-39

13. Dimensions

40-41

-1-

-2-

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 and safety requirements for systems and their components

ISO 4413: Hydraulic fluid power - General rules and safety requirements for systems and their components

IEC 60204-1: Safety of machinery - Electrical equipment of machines - Part 1: General requirements

ISO 10218-1: Robots and robotic devices - Safety requirements for industrial robots - Part 1:Robots

etc.

Danger

Danger indicates a hazard with a high level of risk which, if not avoided, will result

in death or serious injury.

Warning

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

result in death or serious injury.

Caution

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

in minor or moderate 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. Our products cannot be used beyond their specifications. Our products are not developed,

designed, and manufactured to be used under the following conditions or environments. Use

under such conditions or environments is not covered.

1. Conditions and environments outside of the given specifications, or use outdoors or in a place exposed to

direct sunlight.

2. Use for nuclear power, railways, aviation, space equipment, ships, vehicles, military application, equipment

affecting human life, body, and property, fuel equipment, entertainment equipment, emergency shut-off

circuits, press clutches, brake circuits, safety equipment, etc., and use for applications that do not conform

to standard specifications such as catalogs and operation manuals.

3. Use for interlock circuits, except for use with double interlock such as installing a mechanical protection

function in case of failure. Please periodically inspect the product to confirm that the product is operating

properly.

-3-

Safety Instructions

Caution

We develop, design, and manufacture our products to be used for automatic control equipment, and

provide them for peaceful use in manufacturing business.

Use in non-manufacturing business is not covered.

Products we manufacture and sell cannot be used for the purpose of transactions or certification specified in the

Measurement Act.

The new Measurement Act prohibits use of any unit other than SI units in Japan.

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 regulations 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.

Precautions for Design

Warning

(1) Do not use the product if no leakage is allowed due to the environment, or if the fluid is not air.

(2) Polycarbonate resin is used for the external parts including the bowl. Organic solvents including

thinner, acetone, alcohol and ethylene chloride; chemicals including sulphuric acid, nitric acid and

hydrochloric acid; cutting oil, synthetic oils, ester-based compressor oil, alkali, kerosene, gasoline,

lock material of screw are harmful. Do not use the product where these are present.

Chemical resistance of polycarbonate and nylon bowl

When the above factors are present or there is some doubt, use a metal bowl for safety.

-4-

Polycarbonate Nylon

Hydrochloric acid

Sulfuric acid

Phosphoric acid

Chromic acid

Sodium hydroxide (Caustic soda)

Potash

Calcium hydroxide (Slack lime) ×

○

Ammonia water

Carbotane of soda

Sodium sulfide

Potassium nitrate ×

△

Sulfate of soda

Carbon tetrachloride

Chloroform

Ethylene chloride

Methylene chloride

Benzene

Toluene

Paint thinner

Acetone

Methyl ethyl ketone × ×

Cyclohexane

Ethyl alcohol

IPA

△×

Methyl alcohol

Gasoline

Kerosene

Phthalic acid dimethyl

Phthalic acid diethyl ×

○

Acetic acid

Methyl ether

Ethyl ether

× ×

Thread-lock fluid

Sea water ×

△

Leak tester

○: Essentially safe.　　　△: Some effects may occur.　　　×: Effects will occur.

Amino

Methyl amino

Cutting oil

Brake oil additives

Rubber accelerator

Others

○

Ester

Synthetic oil

Anti-rust additives

Ether

Brake oil additives

○

Ketone

Photographic film

Dry cleaning

Textile industries

Alcohol

Antifreeze

Adhesives

Oil

△

Aromatic series

Coatings

Dry cleaning

△

Alkaline

Degreasing of metals

Industrial salts

Water-soluble cutting oil

Inorganic salts

Chlorine solvents

Cleaning liquid for metals

Printing ink

Dilution

Type

Chemical name

Application examples

Material

Acid

Acid washing liquid for metals

△

(3) Avoid the application where charge and discharge of pressure to/from a standard bowl is switched

frequently. This may damage the bowl.Ametal bowl is recommended in these cases.

(4) Shield from ultra violet light and radiation with protective cover.

(5) A safety device needs to be installed if output pressure is exceeding the set pressure, otherwise

this can cause breakage of outlet device and equipment or lead to malfunction.

Caution

(1) AD27-D with auto drain may have leakage of accumulated drain during pressure exhaust (this

leakage is allowed in their constructions and not considered failure). Be sure to connect piping for

drain.

(2) Allowed air consumption from the exhaust port is 0.1 L/min(ANR) or less.

(3) Please install the product in a location where pulsation is unlikely to occur. When the difference

between the inside and outside exceeds 0.1MPa, the element might be broken

Selection

Warning

(1) Grease used on the internal sliding parts and seals may flow to the outlet side.

(2) N.O. type auto drain should be operated under the following conditions to avoid malfunction.

Operating compressor: 0.75 kW or more, Discharged flow rate: 100 L/min (ANR) or more

When using 2 or more auto drains, multiply the value above by the number of auto drains to find

the capacity of the compressors you will need. For example, when using 2 auto drains, 1.5 kW

(200 L/min (ANR)) of the compressor capacity is required. The operating pressure should be 0.1

MPa or more.

(3) N.C. type auto drain should be operated under the following conditions to avoid malfunction.

Operating pressure forAD27: 0.1 MPa or more, for AD37 and AD47: 0.15 MPa or more.

(4) Removing of residual pressure (removing of outlet pressure) will not be achieved by releasing inlet

pressure. To remove residual pressure, please use the combination of a filter regulator with

backflow function and mist separator.

(5) Long absence of operation or operation with sealed circuit or balancing circuit on the outlet side

may cause set pressure fluctuation.

(6) Set range of outlet pressure shall be 85% or less of the inlet pressure. Operating at a setting

exceeding 85% causes the outlet pressure to be easily affected by fluctuations in flow rate and inlet

pressure, leading to instability.

(7) Since the safety margin is calculated to the maximum value of the set pressure range shown in the

specification table, the pressure setting may be over the maximum value. However, use the

product within the specified range.

(8) Do not use the product with circuit which requires high exhaust sensitivity or set precision.

(9) Do not flow air exceeding the maximum air flow rate. If the maximum air flow rate is momentarily

exceeded, it may cause splashing of drainage and oil on the outlet side, and damage to the

equipment.

-5-

Installation

Warning

(1) Do not drop or apply impact during transportation or installation. It will cause damage to the

product and result in operation failure.

(2) Do not install in areas of high humidity or high temperature. Operation outside of the product

specification range may cause damage to the product or operation failure, or shorten the product

life.

(3) Connect the product ensuring the direction of "1"(IN) and "2"(OUT) for air direction and indicated

arrow. Incorrect connections may cause malfunction.

(4) Install with adequate space for maintenance beneath the product. Refer to section [13.

Dimensions] (p. 40 and p. 41) for necessary space.

(5) Install vertically so that outlet of drain is downward. It cannot be used in horizontal or upward

direction as it may cause operation failure.

Adjustment

Warning

(1) Adjust the set pressure ensuring correct inlet and outlet pressures. Turning the knob excessively

can cause damage to the internal parts.

(2) Do not use tools on the pressure regulator knob as this may cause damage. It must be operated

manually.

Caution

(1) For the product with a pressure gauge, do not apply pressure exceeding the maximum scale of the

pressure gauge in order to protect the gauge.

(2) Adjust the pressure whilst the pressure is increasing. Pressure may become lower than the set

pressure if adjusted by decreasing the value. Rotate the knob clockwise to increase the set

pressure. Counterclockwise to decrease the pressure. Moreover, please lock the knob after setting

pressure.

(3) Outlet pressure may rise when the inlet pressure is discharged and resupplied after pressure

setting. In this case, consume air at the outlet which will bring the pressure closer to the set

pressure.

(4) Outlet pressure may change if the product is used for a long period of time. Please confirm the set

pressure regularly.

(5) When pressure difference between the inlet side and the outlet side is large, chattering may occur.

In that case, please reduce the pressure difference between the inlet and the outlet.

-6-

Piping

Warning

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

remove chips, cutting oil and solid foreign material from inside the pipe. Contamination of piping

may cause damage or malfunction.

(2) When screwing together pipes and fittings, etc., be certain that chips from the pipe threads and

sealant do not get inside the pipe. When a sealant tape is used, leave 1 thread ridges exposed at

the end of the threads.

(3) Connect piping/fittings using the recommended torque while holding the female thread side tightly.

Insufficient tightening torque leads to cause of loosening or sealing failure, and excessive

tightening torque leads to cause of breakage of screws. Tightening without holding female thread

applies an excessive force to the piping bracket directly, leading to breakage.

Recommended tightening torque

of tube connection port

Unit: N m

Thread size

1/8

1/4

3/8

1/2

Torque

3 to 5

8 to 12

15 to 20

20 to 25

Recommended tightening torque of

pressure gauge connection port

Unit: N m

Thread size

1/8

Torque

3 to 5

(4) Before using an SMC fitting and S coupler, please refer to "Tightening the threaded portion of the

connection thread" of the Fittings & Tubing Precautions.

(5) Do not apply torsion or bending moment other than the weight of the product itself. External piping

needs to be supported separately as it may cause breakage. Non-flexible piping like steel tube is

susceptible to excessive moment load or vibration. Insert flexible tubes to prevent this.

(6) Drain guide is not equipped with valve function. Be sure to connect piping for drain. No piping for

drain allows the drain and compressed air to exhaust freely. Also, the piping installation should be

performed with drain guide held by spanner to prevent breakage of bowl.

(7) The piping for drain from auto drain should be connected under the following requirements to avoid

operating failure.

Tubing for AD27-D: I.D. ø2.5 (ø3/32") or larger, Length 5 m (200 inch) or shorter

Tubing forAD37, 47(N)-D: I.D. ø4 (ø3/16") or larger, Length 5 m (200 inch) or shorter

Tubing forAD38, 48(N)-D: I.D. ø6.5 (ø1/4") or larger, Length 5 m (200 inch) or shorter

Air Source

Warning

(1) Use clean air. Do not use compressed air containing chemicals, organic solvent, synthetic oil or

corrosive gas as it may be cause of breakage of components or operation failure.

(2) Air containing too much moisture may cause malfunction. Install an air drier or aftercooler before

the product.

Caution

(1) When the element becomes clogged at an early stage, please check the air quality. In addition,

early clogging can be prevented by attaching a pre-filter on the inlet side of the product.

-7-

Maintenance

Warning

(1) Release the pressure in the product to the atmosphere when replacing parts or removing piping.

(2) Maintenance and checks should be done by following the procedure in this operation manual.

Incorrect handling of the product may cause breakage or operation failure of the equipment or

device.

(3) Perform periodical check to find cracks, flaws or other deterioration on resin bowl. If any of these

appear, replace with a new or metal bowl. Otherwise, breakage may occur. Investigate and/or

review the operating conditions if necessary.

(4) Check for dirt in resin bowl periodically. If any dirt is seen, replace with new bowl. If removing dirt by

washing the resin bowl, never use washing material other than neutral detergent. Otherwise, the

bowl is damaged.

(5) Open and close the drain cock manually. The use of tools can result in damage to the product.

(6) Replace the element every 2 years or when the pressure drop at the output pressure from initial

operation becomes 0.1 MPa, whichever comes first, to prevent damage to the element.

(7) Discharge the drain inside the case before it reaches the element assembly. Refer to 9. Operation

and Adjustment (p. 24 and p. 25) for the drain discharging method.

Caution

(1) If an emergency countermeasure is to be taken during setting failure or exhaust leakage, the

internal valve seating part should be checked. If failure such as foreign matter is found, remove it

before performing the emergency countermeasure.

(2) Check the element periodically and replace it with a new one if necessary. If it is found that outlet

pressure drops lower than the normal condition or the flow is restricted during operation, check the

condition of the element.

(3) For the N.C. type auto drain, when there is no pressure, drain which does not operate the auto

drain mechanism will remain in the bowl. It is recommended to release the residual drain manually

at the end of the working day.

-8-

2. Application

3. Standard Specifications

-9-

This product is used for removing oil content and solid foreign matter in the air line as well as

for pressure control.

AWM20-D AWM30-D AWM40-D

Port size 1/8, 1/4 1/4, 3/8 1/4, 3/8, 1/4

Pressure gauge port size Note 1)

Fluid

Ambient and fluid temperature Note 2)

Proof pressure

Max. operating pressure

0.1 to 0.85MPa

Auto drain (N.O)

ー

150L/min(ANR) 330L/min(ANR) 820L/min(ANR)

8cm325cm345cm3

Semi-standard (Steel)

0.23kg 0.35kg 0.66kg

Polycarbonate

Standard (Polycarbonate)

Relieving type

Max. air flow capacity Note 3)

Filtration rating

0.3 μm (99.9% filtered particle size)

Outlet side oil mist concentration

MAX.1.0mg/m3(≒0.8ppm)

Compressed air quality class Note 4)

Auto drain (N.C)

0.15 to 0.85MPa

Set pressure range

0.05 to 0.85MPa

0.1 to 0.85MPa

ISO8573-1:2010[3:4:3]

Model

1/8

Air

-5 to 60 oC (with no freezing)

1.5MPa

1.0MPa

Without auto drain

Drain capacity

Bowl material

Bowl guard

Construction

Weight

Note 1) Pressure gauge connection threads are not available for product with a square enbedded type pressure gauge or

with a digital pressure switch.

Note 2) -5 to 50oC for the products with the digital pressure switch.

Note 3) Inlet pressure is 0.7 MPa and outlet pressure is 0.5 MPa. Flow at 20oC, atmospheric pressure,

and 65% of relative humidity.

The maximum air flow capacity varies depending on the inlet pressure.

Keep the air flow below the maximum air flow capacity to prevent an outflow of lubricant to the outlet side.

Note 4) Based on ISO8573-1:2010 Compressed air - Part 1: Contaminants and purity classes.

The compressed air quality class on the inlet side is [7:4:4].

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