Components for air preparation and pressure adjustment. OUT port position ( ) connected Rear side. of IN port. Air tank. directly.

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1 Components preparation and pressure adjustment ABP Overview ABP is a component that enables boosting by s only up to twice primary pressure (.0MPa max.) in combination with using air tank but not using electricity. Energy and cost saving will be achieved in total manufacturing lines, since pressure can be increased at the required point in plant. tank and optional pressure gauge directly combined to air are also available. Features Boosting up to double ratio Boosting ratio is adjusted within range of twice primary pressure (.0MPa max.) by pressure adjustment knob, since boosted with compression by piston. Flexible installation This can be installed vertically due to flexible installation attitude. Pipe can be connected from 3 directions. Tool not required pressure adjustment Enabling pressure adjustment by single hand and lock by one push. Futhermore knob can be easily manually adjusted even for high pressure setting. Longitudinal direction shortened compact shape. C O N T E N T S Series variation 8 Product introduction 8 Safety precautions 8 (ABP) 86 tank (AT) 8 : Standard, : Option nic sensor Pressure OUT port position Option Model Model no. JIS symbol Same side of IN port ( ) Bottom tank directly connected Rear side of IN port Pressure gauge Foot bracket Page Blank D L G S B ABP IN OUT 86 EXH 8

2 Double high compressed air is obtained. less air ABP Produce high compressed air (.0MPa max.) up to twice primary pressure (equivalent). (Option) longitudinal direction Pressure adjustment knob Tool not required and a lock by one push Pressure gauge (option) For primary pressure and secondary pressure Primary pressure (supply pressure) nic Boosting to twice pressure sensor Pressure Set screw Flexible installation attitude design and flexible installation Always read precautions on page 8 before starting use. 8

3 Plant wide total cost reduction is achieved. Pressure source Example of increasing thrust of cylinder for welding Pneumatic cylinder Low pressure line air unit Regulator Pneumatic 5 port solenoid valve Regulator Medium pressure line tank AT tank Regulator High pressure line ABP nic sensor Pressure Other applications. Downsized air cylinder. Improving unsatisfied actuator (air cylinder, air motor etc.) output 3. High pressure and quick filling to air tank. Boosting in explosive environment 5. For pressure change (such as pressure decrease of line) of plant line 83

4 ABP Series WARNING Pneumatic components Safety precautions Always read this section before starting use. Refer to Intro 67 for general precautions. Do not use the air for continuous operation such as in a compressor. The air is designed for partial boosting in a factory, etc. Life is shortened if used for high frequency continuous operation, such as in a compressor. (The air 's nominal life is approximately 5 million times when used under normal conditions) Refer to page 87 for the estimate life calculation. Design & Selection CAUTION Do not use this product if vibration exceeds 50 m/s or impact exceeds 300 m/s. Pressure is raised by air pressure, so half of the air is discharged during boosting. If the secondary side flow rate must be, the primary side requires a flow rate of + =. The inside is cylindrical, so noise of 60 to 80 db (primary side 0.9 MPa and secondary side 0.95 MPa for measurement of m) is generated during boosting. * This is noise when a silencer is used. nic sensor Pressure WARNING Do not supply pressure exceeding 0.99 MPa onto the primary side. Check that set pressure does not exceed 0.99 MPa. CAUTION Install a on the primary side to remove rust, foreign matter, and drainage. The air compresses compressed air so drainage is discharged easily from the secondary side. Installation of a is recommended to remove any moisture from piping. Install primary side piping at /B and over to attain sufficient flow. Install a silencer (SLW-5A, SL-5) or exhaust cleaner (FA30-5A) on the exhaust port of the air. When using exhaust cleaner, common porting of the exhaust port is recommended. Use piping with a stop valve to the air tank's drain port. Regularly discharge from the tank. Installation & Adjustment There are no set regulations regarding the air 's installation angle, it should optimally be horizontally installed on a flat surface. Install the air using -M8 depth 0 screw holes on the bottom or -M0 depth 5 screw holes on both sides. Use these screw holes only for installing the air. -M8 depth 0 OUT port position D rear side (air tank fixing side) The bolt used to install the air must not exceed the screw hole depth. Forcibly tightening a long bolt could damage the screw hole and cause air leakage. CKD edge -M0 depth 5 8

5 ABP Series A foot bracket installed on both ends is available as an option. (Model no. ABP--B) Fix the air tank with the - ø3 anchor bolt hole on the bottom. When directly connecting the air to the air tank (AT-), use OUT port position D, and mount the enclosed with the air tank on the air. Then, fix to the top of the air tank with a hexagon head bolt. Hexagon head bolt Hole -ø3 Installation of an air tank and after the air is recommended for attaining stable secondary pressure. WARNING Stop primary pressure and release secondary pressure before maintenance, inspecting, or repairing the air. During Use & Maintenance CAUTION When setting pressure, lift the pressure adjustment knob to release the lock, and then the pressure adjustment knob. Secondary pressure increases when the pressure adjustment knob is turned clockwise. Pressure adjustment knob must be locked after using. If primary pressure exceeds set pressure due to fluctuation in pressure, etc., air is released from the pressure adjustment knob. Set a on the primary side, and adjust the pressure at least 0.MPa lower from the set pressure. nic sensor Pressure The silencer and pressure gauge are consumables and must be regularly replaced. *Refer to the separate Maintenance Manual (ST-30606) for the maintenance procedures. 85

6 nic sensor Pressure Functional explanation Primary pressure flowed from IN passes through check valve on IN side, and flows in chamber A and B. Primary pressure also passes through pressure adjustment section and switching valve, and flows in drive room A. Piston moves to left hand due to pressure of drive room A. in chamber A is compressed, and passes through check valve on OUT side, and goes to OUT side. If piston reaches stroke end, changeover switch is pushed, and compressed air is supplied to pilot room of switching valve, and switching valve is switched. Then the air in drive room A is exhausted, and the air is delivered to drive room B. Therefore, piston moves to right hand and air in chamber B is compressed, and passes through check valve on OUT side, and goes to OUT side. Boosting on OUT side is compressed, if operations above are repeated. Feedback pressure is transmitted to pressure adjustment section due to OUT side pressure passes through shuttle valve, and boosting is continued until pressure adjustment spring and pressure is balanced. ABP Series JIS symbol Specifications Descriptions Working fluid Max. working pressure MPa Min. working pressure MPa Set pressure range MPa Withstanding pressure MPa Flow m 3 /min. (ANR) Boosting ratio Ambient temperature range C Lubrication Port size Weight kg Product sevice life How to order ABP D G Internal air circuit diagram Drive room B Fixed orifice ABP Compressed air From primary pressure+0.mpa to twice primary pressure (0.99MPa max.).5 Refer to the right graph rate flow characteristics Max. double pressure (or equivalent) 0 to 50 (no freezing) Not required (use the turbine oil Class ISO VG3 if lubricated) Rc/.6 5 million (nominal) Switching valve Booster chamber B A OUT port position Blank Same side of IN port D Bottom (air tank directly connected) L Rear side of IN port B Option G Pressure gauge S B Foot bracket IN side check valve Pressure adjustment section Booster chamber A Note) Option G (pressure gauge) is installed onto air at shipment. B (foot bracket) and S (silencer) are attached. IN (primary pressure) Drive room A Select switch Piston OUT side check valve Piston OUT side (secondary pressure) 86

7 ABP Series Specifications Flow characteristics (With air tank AT- installed, double pressure increase) Secondary pressure (MPa) MPa 0.MPa Primary pressure 0.5MPa Pressure characteristics (Setting: Primary pressure 0.69MPa, secondary pressure 0.97MPa, flow rate 0.0m 3 /min.anr) Secondary pressure (MPa) Flow (m 3 /min. (ANR)) Flow rate characteristics show max. flow rate of air. If primary pressure is constant and secondary side flow rate is increased, max. secondary pressure decreases. Note) needs approx. twice secondary side flow rate (max.) for primary side due to structure. Confirm that the instantaneous flow rate is within the curve. Filling characteristics Filling time (second/ ) Boosting ratio (time) Filling characteristics show relations between boosting ratio and filling time, if tank etc. filled with compressed air. To find filling time, when filling tank with air, where secondary side air pressure P0, air pressure in tank before filling P, air pressure after filling P, boosting ratio before filling k and boosting ratio after filling k, therefore k = P and k = P are led. P0 P0 Find k and k at first, then read filling time t and t according to graph where boosting ratio k, k, finally filling time for tank capacity A ( ) is obtained with t = (t-t) A Primary pressure (MPa) Pressure characteristics show variation of set secondary pressure according to primary pressure variation. If primary pressure is decreases, secondary pressure decreases slightly. Pulsation Pulsation width (MPa) Tank capacity ( ) Pulsation shows width of pulsation if air tank is installed onto secondary side of air. Formula of air operational cycle N= Formulation of air service life Since nomin.al service life of operational cycle is 5 million T= Q P ,000,000 N60 AT- N : Operational cycle Q : Required flow (m 3 /min.(anr)) P : Primary pressure (MPa) T : Service life (hour) nic sensor Pressure Each characteristics are just reference, but not assured conditions. 87

8 ABP Series Internal structure E PUSH T E E A-A cross section nic 55 sensor Pressure A 65 CKD A

9 ABP Series Parts list Part list No. Parts name Material Quantity No. Parts name Material Valve stem (A) C type snap ring for hole Body block assembly Spring Spacer ball Packing seal Detection valve body Valve stem (B) Pipe Tie rod Plug with hexagon head hole Plain washer Spring washer Hexagon nut MY packing seal Rod bushing Cylinder tube Piston rod Piston Piston packing seal Head cover Cap Gasket Lip packing seal Piston Cylinder Hexagon socket head cap bolt Cylinder Lip packing seal Piston Spool Stopper Copper alloy Oil impregnated bearing alloy Soft packing seal Spacer Spacer Soft packing seal C type snap ring for hole Spring sheet Spring Valve seat Slip ring Adjusting assembly Guard Mounting nut Adjusting spring Diaphragm assembly Valve seat Bottom spring Stud Knob Valve assembly Regulator assembly Cross-recessed tapping screw Fixed orifice Master valve gasket Hexagon socket head cap bolt Cross headed pan Gasket Valve Plug Spring washer Urethane rubber Urethane rubber PBT resin Copper alloy Copper alloy Copper alloy Discrete consumable parts and options Parts name Model no. Part number Remarks Select switch packing set ABP-K, 3 5, 6,,, 3 Quantity 8 nic sensor Pressure Cylinder section packing seal set ABP-K 8 5, 6,, 3, 7 Switching valve piston assembly Switching valve sealant assembly shuttle valve assembly ABP-K3 ABP-K ABP-K5 3, 3, 37, 38 0,,, 3, 8, 50, 5, 53, 5 Using parts prior to minor changes Diaphragm assembly ABP-K6 60 Pressure adjustment section valve assembly ABP-K7 6, 6, 67, 69 assembly ABP-K8 8, 53, 5 Bracket ABP-B For unit Pressure gauge ABP-GAUGE Pressure gauge pc. SLW-5A pc. 89

10 nic sensor Pressure ABP Series Dimensions ABP- Optional dimensions ABracket (ABP-B) installation 95 -ø Rc/ IN Rc/ IN Rc/8 IN gauge port Rc/ OUT E L PUSH L to IN OUT LO CK H 5 65 IN OUT H 50 E CKD Rc/ OUT APressure gauge (ABP-GAUGE) A (SLW-5A) R/ R/ ø7 ø Rc/ EXH Rc/8 OUT gauge port () (0) (7) 7 5 -M0 depth Rc/ (OUT port position: L) OUT -M8 depth0 60 Rc/ OUT (OUT port position: D) (98) Rc/(OUT port position: L) OUT 80

11 6 Features tank directly connected to air ABP- with compact body. tank (related AT Series JIS symbol Specifications Descriptions AT Working fluid Max. working pressure Hydraulic test pressure MPa MPa Compressed air Ambient temperature range C 0 to 50 (no freezing) Capacity Port size Material Weight m 3 kg 0.0 Rc/ 7.5 Note:, hexagon head bolt and spring washer are attached to install air. How to order AT tank Capacity Dimensions Rc/ A ø36 Part model no. AT-K (, hexagon head bolt, spring washer) ±0.3 30±0.3 Rc/ nic sensor ø ± Pressure 00± -ø Fixing 00± 60±0.3 30±0.3 ø ø A view Rc/

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