SY3000(SY100)-TFM53


Installation and Maintenance Manual Tube Connecting (Fig 3) (Push in Fitting) Change of electrical entry (orientation)
After separating terminal block and housing, mount housing at any
assembly(1), check orientation
b) Re-fit valve and tighten securing screws(5)
Series SY3000/5000/7000/300/500   1. Ensure that the end of the tube is cut square position (total 4 directions, per 90 degrees), therefore changing elec- c) Re-connect electrical connections (see section on electrical con-
Body ported/base mounted 2. Push the tube firmly into the fitting until it stops. Pull back on the trical entry. nection)
 tube to ensure that it is gripped * In the case of indicator light, avoid damaging the light with lead d) Re-connect compressed air and power
For future reference, please keep this manual in a safe place 3. To dis-connect the tube, push down on the collect flange, hold down wire. (In the case of a manifold type, change in the direction of e) Test function
and withdraw the tube electrical entry is limited depending on the mounting position). Removal/Refitting Valve from a plug-in Manifold (Fig 13)
This manual should be read in conjunction with the current catalogue
  Precautions Ensure compressed air and power supplies are first isolated
Porting Block (Body Ported Valve) (Fig 3) Plug connector in or out vertically, never at an angle. 1. Remove securing screws(6) and retain
Safety Instructions 2. Only trained personnel should operate pneumatically 2. Lift (pre-wired) valve off of manifold block(1), retain gasket(7)
operated machinery and equipment.  1. To remove the porting block, remove the two block retaining screws Increasing manifold blocks Refitting:-
These safety instructions are intended to prevent a hazardous situa- Compressed air can be dangerous if an operator is unfamiliar and lift off the block 1. Re-place gasket(7) into recess in manifold block(1)
tion and/or equipment damage.These instructions indicate the level with it. Assembly, handling or repair of pneumatic systems should  2. Note position of the gasket and retain (Figs 13, 14, 15, 16 & 17) 2. Re-fit valve ensuring plug in connector engages in terminal
of potential hazard by label of “Caution”, “Warning” or “Danger”. be performed by trained and experienced operators. 3. Replace the block, ensuring the gasket is in place and fit and tight- Ensure air and power supplies are isolated from manifold block and tighten screws(6)
To ensure safety, be sure to observe ISO4414 (Note1), JIS B 8370 (Note2) en retaining screws 1. Slacken the bolt holding the manifold base(a) Fig 13 3. Reconnect air and power supplies
and other safety practices. 3. Do not service machinery/equipment or attempt to 2. Press the din rail(8) release button(c) and separate the manifold
Note 1: ISO 4414: Pneumatic fluid power – Recommendations for the remove component until safety is confirmed. CAUTION base from the din rail(8) Throttle
application of equipment to transmission and control systems. 1) Inspection and maintenance of machinery/equipment should Note: Additional bases must be added to the “U” side Fig 13
Note 2: JIS B 8370: Pneumatic system axiom. only be performed after confirmation of safe locked-out  3. Press the dis-connecting button(b) Fig 13 until button locks, then Due to the fact that the pilot valve and main valve share, exhaust care
Port block for SY300 (SY500) is not the same one for SY3000
control positions. (SY5000). separate block assemblies must be taken to ensure that the piping of the common exhaust air
CAUTION : Operator error could result in injury or 2) When equipment is to be removed, confirm the safety process Do not assemble port block for SY300 (SY500) to SY3000 (SY5000). 4. Separate the connector block assembly as in (3) and remove con- does not become restricted.
equipment damage. as mentioned above. Switch off air and electrical supplies and Port block assembly nector mounting screw Fig 14
exhaust all residual compressed air in the system. SY300 - 2A - ** (for SY300) 5. Slacken the valve mounting screw Fig 15, remove the valve, and ‘Q’ Suffix Modifications
3) Before machinery/equipment is re-started, ensure all safety SY500 - 2A - ** (for SY500) remove receptacle housing Fig 15
WARNING: Operator error could result in serious measures to prevent sudden movement of cylinders etc. 6. Insert the (red) common wire of the manifold block to be added, Base Mounted
SY3000 - 6A - ** (for SY3000)
injury or loss of life. (Bleed air into the system gradually to create back-pressure, into the pin insertion terminal (N) Fig15 of receptacle housing. Mount The base mounted valve is fitted with a location pin  adjacent
SY5000 - 6A - ** (for SY5000)
i.e. incorporate a soft-start valve). on to manifold block and replace valve to the solenoid end. A matching hole 5 is machined into the man-
DANGER : In extreme conditions, there is a 7. Mount the additional manifold block(1) onto the din rail(8) (on the ifold and the gasket  has a matching hole to accept the above
possible result of serious injury or loss of life. 4. Contact SMC if the product is to be used in any of the Converting from 5 Port to 3 Port Valve (Fig 4) “U” side) refer to circuit diagram and insert black wire Fig 16 & 10 pin, ensuring that these are located correctly on assembly
following conditions: 8. Press blocks together until they click
1) Conditions and environments beyond the given specifica- 1. By plugging either port A or B it is possible to convert a 5 port valve 9. Replace the lead wire into the manfold block, close lid Fig 15 & 16
WARNING tions, or if product is used outdoors. to a 3 port N.O. or N.C. valve. Ensure exhaust ports are not restricted. ensuring wire is not “pinched”
2) Installations in conjunction with atomic energy, railway, air See Fig 4. 10. Hold blocks together and re-tighten bolt(a) Fig 13 to fix to din
1. The compatibility of pneumatic equipment is the respon- navigation, vehicles, medical equipment, food and beverage, 2. SY300 and SY500 can be mounted on the manifold base for rail(8) (tightening torque 1Nm)  
sibility of the person who designs the pneumatic system recreation equipment, emergency stop circuits, press
Fig. 1 7 Valve housing screw
SY3000 and SY5000 respectively. 11. Insert wires from additional blocks into the appropriate connector
Body ported type 8 Valve body 
or decides its specifications. applications, or safety equipment. 9 Mounting gasket Fig 17 
1 Gland nut
Since the products specified here are used in various operating 3) An application which has the possibility of having negative 10 Port block Manual Override Operation (Fig 5) 12. Re-apply air and power connections and test
2 Washer
conditions, their compatibility for the specific pneumatic system effects on people, property, or animals, requiring special 11 Mounting screw
3 Grommet 
must be based on specifications or after analysis and/or tests to safety analysis.
4 Housing 12 Gasket WARNING Manifold Push-in Fitting Removal & Assembly
meet your specific requirements. 13 Solenoid pilot Refer to Fig 5 for correct operation of a manual override exercise
5 Set screw
CAUTION 6 Gasket 14 Bar manifold extreme caution when operating any manual override as connected Fig 11 Type 45 Fig. 25
equipment will commence operation. Ensure all safety precautions are Isolate air and power supplies
Ensure that the air supply system is filtered to 5 micron. Plug connector in place prior to operation 1. Remove valve from manifold (as explained earlier)
2. Remove fitting assembly, retaining clip Fig 11 using a small screwdriver Energising in a long run
Valve Specifications Electrical Connector – Fig’s 6, 7 & 8 3. Remove fitting assemblies from manifold block
Ensure compressed air and power supplies are isolated before con- Note: It is possible to replace existing fitting for either Ø4, Ø6 or Ø8 For use of long run energising, specifications should be consulted.
Series SY3000/300 SY5000/500 SY7000 necting/disconnecting electrical connectors. 4. Replace fittings into manifold block
Fluid Air 5. Re-fit cup, ensuring it locks into position Leakage voltage-Fig 26
Internal pilot operating pressure range MPa {kgf/cm2} Connection – Fig 6 6. Re-fit valve When connecting a C-R element in parallel with a switching element,
2 position single 0.15~0.7 {1.5~7.1} Push the connector in a straight line onto the solenoid pins, 7. Re-connect air and power supplies leakage current will flow through the C-R element increasing the
2 position double 0.1~0.7 {1~7.1} ensure that the lever, of the connector, is securely positioned in 8. Function test leakge voltage. Ensure that the voltage leakage across the coil is as
3 position 0.2~0.7 {2~7.1} the groove of the solenoid cover Note: P & R ports cannot be changed (Fig.10) follows:-
Ambient & fluid temperature °C -10~50°C Dis-connection:- Fig 6 Protect O-rings from scratches and dust to prevent air leakage. DC Coil - Max. 3% of the rated voltage
Max operating frequency Hz Press the lever down against the connector body, and pull the con- AC Coil - Max. 8% of the rated voltage
2 position single, double 10 5 5 nector out from the solenoid in a straight line movement Individual Supply and Exhaust Spacers (Body Ported)
3 position 3 3 3 Bar manifold Connection/Disconnection of Socket complete with Lead Switching element
Manual override Non-locking push type, push turn-locking slotted type, push locking lever type Wire:- Fig 8 Fig 18 & 19 OFF
Pilot exhaust Common exhaust for main & pilot valve 1. Connection: These spacers fit between the manifold base and the valve as shown
Lubrication Not required Fig. 2 a) Insert the socket into the solenoid, ensuring a straight line entry in Fig”s 18 and 19
Base mounted valve: bar manifold type Resistor Valve

Voltage leakage
Mounting position Free b) Ensure that the level fully locks into position, by lightly pulling Before removal or fitting isolate air and power supplies from the man-
Impact/vibration resistance m/s Note 1)
150/30  back on the wire ifold Power source
Protection structure Grommet and Plug connector: IP40, DIN connector: IP65 2. Disconnection: 1. Fittings: Current leakage
Use dry air for operation at low temperature to prevent moisture a) Press the lever down, and remove the socket from the solenoid a) Remove valve(1)
Specification are subject to change without notice  in a straight line movement b) Retain mounting gasket(2)
Note 1)
Shock resistance . . . . . .No malfunction from test using drop impact tester, to exist and right angle direction of main valve and armature, Din-Connector:- Fig 1 c) Fit supply or exhaust spacer(3) ensuring gasket(4) fits between
each one time when energised and de-energised. 1. Dis-connection: manifold and spacer(3) Fig. 26

Vibration resistance . . . . . . .No malfunction from test with 8.3 to 2000Hz 1 sweep, to axis and right angle direction of main valve and a) Unscrew the housing screw(5) 2. Replacement:
armature, each one time when energised and de-energised. b) Lift off the housing(4) a) Replace valve(1) and ensure gasket(2) fits between spacer(3)
 c) Retain gasket(6) and valve(1) Lubrication
Solenoid Specifications 2. Re-connection: b) Re-instate air and power supplies
a) Replace gasket(6) over pins c) Function test The valve has been lubricated for life at manufacture and requires no
Electrical entry Grommet (G) (H), L type plug connector (L),  b) Replace housing(4) onto pins, ensuring correct orientation additional lubrication.
M type plug connector (M), *DIN connector (D) c) Tighten securing screws(5) Blanking Plate Assemblies
Coil rated voltage V Connecting Wires to Din Type:- Fig 12 CAUTION
DC 24, 12, 6, 5, 3 Remove housing from the solenoid valve as shown above 1. Non plug in manifolds Fig 20 However, if a lubricant is to be used, a turbine oil type #1 (ISO VG32)
AC 50/60 Hz *100, 110, 200, 220 Note 2) 1. Unscrew the gland nut(1) from the housing(4) and retain This blanking plates is fitted on stations as per valve fitting should be used. If a lubricant is used, continuous lubrication must be
Allowable voltage ±10% rated voltage 2. Remove and retain washer(2) and grommet(3) 2. Plug in manifold Fig 21 carried out, as the original lubricant will be washed away.
Power consumption (W) 3. Remove the terminal block(6) from inside of the housing as fol- As above with the addition of the fitting of a short cap over the
DC 0.5 {with light: 0.55 (DIN connector with lamp:0.6)} lows:- using a small screw driver, lever the terminal block(6) out electrical connection
Apparent power VA (at rated voltage) of the housing(4) (Fig 12) Piping
AC Fig. 3 Use the cabtire cable (ø3.5 to ø7) for wiring to meet IP65 stan- Supply and Exhaust Block Disc (Plug in Manifold)
Body ported valve 3 Port block
100V 0.9 (with light: 1.0) 4 Gasket dard (protective construction). Thread Correct clamping torque N-m (kgf-cm)
110V {115V} 1.0 (with light: 1.1) {1.1 (with light: 1.2] 1 Collet flange Tighten the ground nut and set screw with the specified range of Fig 9 and 13 M5 1.5~2 (15~20)
2 Retaining screw 5 Valve body
200V 1.8 (with light: 1.9} torque. Inserted into manifold block when differing supply pressures are Rc(PT)1/8 7~9 (70~90)
220V [230V] 1.9 (with light: 2.0) [2.2 (with light: 2.3)] 4. Before connecting the wires to the terminal block(6) (no-polar- required or when valve exhausts effect other stations (Fig 22 and 23) Rc(PT)1/4 12~14 (120~140)
Surge voltage suppressor Diode (DIN connector is ZNR) Installation ity) thread the wire through the gland nut(1), washer(2) and or externally piloted dual pressure valve is used. Rc(PT)3/8 22~24 (220~240)
Indicator light LED (AC of DIN connector is neon lamp) grommet(3) (Fig 12) Remove/Refitting a Valve from a non-plug in Manifold/Base
When you enquire about the product, please contact the following
Note 2)
AC type is applicable to only DY and DZ, YZ. CAUTION 5. Connect the wires to terminals 1 and 2 (Fig 9)
SMC Corporation:
Ensure all air and power supplies are isolated before commencing 6. Re-fit terminal blocks(6) into housing(4) and check correct ori- Ensure compressed air and power supplies are first isolated
ENGLAND Phone 01908-563888 TURKEY Phone 212-2211512
Torque Figures for Valve Holding Screws installation. entation of electrical entry before dismantling
ITALY Phone 02-92711 GERMANY Phone 6103-402-0
7. Push grommet(3) into the housing(4) 1. Removal:-
HOLLAND Phone 020-5318888 FRANCE Phone 01-64-76-10-00
SY3000 Series 0.15 N.m {1.5 kgf} WARNING 8. Push washer(2) into the housing(4) a) Disconnect electrical connections
SWITZERLAND Phone 052-396 31 31 SWEDEN Phone 08-603 07 00
SY5000 Series 0.6 N.m {6 kgf} DO NOT INSTALL THESE VALVES IN EXPLOSIVE ATMOSPHERES. 9. Screw in gland nut(1) and fully tighten
SPAIN Phone 945-184100 AUSTRIA Phone 02262-62-280
SY7000 Series 1.4 N.m {14 kgf} If these valves are exposed to water or oil droplets, ensure that the 10. Re-fit housing(4) to the solenoid valve ensuring the hous- b) Remove securing screws(5) 2 off and retain
Phone 902-255255 IRELAND Phone 01-4501822
valves are protected. ing(4) is kept vertical when pushing onto the pins c) Lift off valve from manifold block(1) ensure gasket(6) is retained
GREECE Phone 01-3426076 DENMARK Phone 70 25 29 00
If it is intended to energise a valve for an extended period please con- 11. Tighten retaining screws(5) securely 2. Refitting:-
FINLAND Phone 09-68 10 21 NORWAY Phone 67-12 90 20
sult SMC. a) Replace gasket(6) into the recess in the manifold block
BELGIUM Phone 03-3551464 POLAND Phone 48-22-6131847
PORTUGAL Phone 02-610 8922
Using a 5 port valve as a 3 port valve
Series SY3/5/7000 may be use a N.C. or N.O. 3 way valve by
plugging one end of the A, B ports. Be sure not to plug the
exhaust ports. Can be used when a double solenoid, 3 way
valve is required. Tightening
Plug position torque
B port A port Tightening
0.3~0.4 N.m
torque
Configuration N.C N.O 1.65~2.5 N.m
(Plug) (Plug)
A4 B2 A4
Number of solenoids

B2
Single

EA5 P1 EB3 EA5 P1 EB3

(Plug) (Plug)
B2 A4 B2
Double

A4

EA5 P1 EB3 EA5 P1 EB3

Fig. 4 Fig. 12 Tightening torque

0.2~0.25 N.m

Fig. 6
Fig. 5
Hook this section onto the
DIN rail and press in the
direction of the arrow
until it clicks into position

Fig. 13

Fig. 8
 
CAUTION
Installing DIN rail manifold
When DIN rail manifold for 45 and 45 ■
type is installed on the place by bolt, please
fix it with 2 locations for 2-5 stations, with 3
locations for 6-10 stations, with 4 locations  
for 11-15 stations and with 5 locations for
16-20 stations.
Unless DIN rail is fixed with less locations than
our instructions, DIN rail and manifold might
twisted and it causes trouble like air leakage.   Note: After inserting pins, lightly
pull lead wires to check that the
Note: Insert pins after removing the
connector from the main unit. After
Note: Insert tab terminals fully.

CAUTION pins are locked. inserting pins, lightly pull lead wires
to check that the pins are locked.
Screw tightening torque:
M2: 0.15 N-m

  M3: 0.6 N-m

M4: 1.4 N-m CAUTION
When supplying a manifold with more than one
Fig. 18 Fig. 19 pressure, insert a block disk in between the stations
1. Depending on the type of connector, there is a limit to the number of
solenoids that can be used. Manifold bases that can be added cannot
subjected to different pressures. exceed the number of usable solenoids.
CAUTION 2. The manifold block assembly mounting position for addition of mani-
The supply and exhaust ports may be fitted either at the lead wire fold bases is always on the U side, because wires are connected to
end of the valve or the end plate side. If supplied factory-assem- respective connectors sequentially from the D side.
bled they are fitted at the end plate side. 3. When bolt (a) for the end block is not sufficiently tightened during
reassembly, air leakage may result. Before supplying air, check that
Note: For protection of the wiring unit section from drain, pip- there is no gap between blocks and that the manifold block is firmly
Note 1: When adding manifold bases to use more than 10 ing at the EA port shall be so arranged that it will not fixed to the DIN rail in order to ensure air supply without leakage.
stations, add SUP/EXH block assemblies, as well. be directly exposed to exhaust from the valve.
Fig. 9 Note 2: When bolt (a) for the end block is not sufficiently
tightened during reassembly, air leakage may result. One-touch fittings
Before supplying air, check that there is no gap The size of the ports on the SY manifolds (P, A, B etc.), subplates,
between blocks and that the manifold block is firm- valves determines the pitch between the ports, permitting the use
ly fixed to the DIN rail in order to ensure air supply of one-touch fittings of the KJ series.
without leakage. However, some fittings of this series will cause clearance prob- Fig. 22
lems depending on the type size. Please check catalogue for fit-
ting dimensions before ordering.
Block disc indication seal
When a valve exhaust affects the other station in the These seals are attached to the block when SUP and EXH block discs are fit-
R circuit or when an externally piloted, dual pressure ted, for confirmation from outside. (3 sheets respectively)
valve is used on a standard manifold, insert EXH block
P disc(s) in between stations to isolate the exhaust.

Hook this part on the

DIN rail and then press in Fig. 21
the direction of the arrow
until a click sound is
produced. Note: When ordering block discs for installation at the factory, labels will be attached
to the manifold showing the locations.
Fig. 10 Supply and Exhaust Block Fig. 11 Fig. 20 Fig. 23 Fig. 24