SMC Engineering Aids

Energy Conservation Products

ALDS

Features:

• Detects air leakages when they occur, even on a daily basis.
• Confirms the exact value of the leak.
• Provides maintenance personnel with a detailed report on where leaks are located without needing to detect leaks in individual components.
• Operates an automatic test cycle outside production to detect leakages.
• Integrates with machine software without external supervision systems (SCADA, etc.).

[Image: SMC ALDS unit]

MLDS

Features:

• Portable air leakage measurement tool.
• Measures from 50 - 500 liters per minute.
• IP67 rated case.
• Rechargeable battery pack.
• Contact SMC's Energy Saving Team for more details.

[Image: SMC MLDS in portable case]

Features:

• Monitors pressure and flow characteristics from compressed air systems.
• Software allows a detailed report of pressure/flow fluctuations throughout the system.
• Can record 8 channels at once.
• DataQ acquisition equipment packaged for rough service.
• Contact SMC's Energy Saving Team for more details.

[Image: SMC Data Logger units]

ZK2

Features:

• Monitors the vacuum level and turns itself off when it doesn't need to operate.
• Ejector air consumption reduced by 90% (compared to conventional products).

Air Preparation - "Smart" FRL

Series: FRL

Features:

• Know when filters need to be replaced and avoid unwanted pressure adjustments.
• Smarter FRL: Metal bowls protect against damage; Regulator with digital pressure switch prevents over-pressurization by operators; Differential pressure gauges ensure consistent air quality and warn when filter changes are needed; Combination quick-dump, soft start, lock-out/tag-out valve to remove pressure when machines are idle.
• Smartest FRL: Metal bowls protect against damage; Optional epoxy coated bowls for wash-down; Digital differential pressure gauges indicate when filter changes are required; Regulator with digital pressure switch prevents over-pressurization by operators; Combination quick-dump, soft start, lock-out/tag-out valve to remove pressure when machines are idle.

[Image: SMC FRL unit with corrosion-resistant epoxy coating]

Corrosion resistant epoxy coated option available!

Air Blow Gun

Series: VMG

Features:

• Made of shock-resistant resin.
• Uses 20% less energy than conventional air guns.
• Not affected by fluctuations in supply pressure.
• Maintains effective impact pressure at low inlet pressure.

[Image: SMC VMG Air Blow Gun with extension nozzle]

Extension nozzle available in 100, 150, 300 and 600mm lengths.

Air Saving Valve

Series: ASR / ASQ

Features:

• ASR: Pressure valve with regulator, check valve, and speed controller.
• ASQ: Flow control valve with quick supply, exhaust valve, and speed controller.
• Cuts air consumption by operating the return stroke at a reduced pressure.
• Offers easy piping.
• Set pressure can be fixed or variable.

[Images: SMC ASR and ASQ series components]

General Recommendations

Near the air inlet, an identification plate should show the minimum air pressure required, average air consumption per machine cycle, and required flow rate (peak air flow). Air quality standards (e.g., pressure dew point) should also be noted.

Machines should be designed to operate with the lowest reasonable air pressure. Verify end-user compressed air capacity. For applications requiring higher pressure, consider a booster. The operating program should include measures to automatically shut off inlet air during prolonged downtime.

[Image: SMC VXD Series component with "SET POINT 85 psi" indicator]

[Diagram: Pneumatic system overview]

Air Preparation

• A 3-port shut-off valve with lock-out/tag-out should be included to remove inlet pressure during maintenance or extended downtime.
• An AMG Series water removal filter should be included to remove any water present in air lines.
• Inlet Air Filter:
  • Sized to minimize pressure drop (less than 3 psi).
  • Micron filtration rating should meet component supplier recommendations.
  • Should have an automatic drain to reduce routine maintenance.
  • Use a differential pressure indicator to show when the element needs replacement.
  • For higher filtration needs, a coalescing mist separator and/or odor removal filter can be included.
• A pressure regulator should have a fixed or tamper-resistant setting.
• For frequent pressure adjustments, an ITV series electro-pneumatic regulator tied to the machine controller can be utilized.
• A final Safety valve should include E-stop, quick exhaust, soft start, and a second lock-out/tag-out. For shut-down redundancy per ISO 13849-1, consider a Category 3 and 4 Safety Shut-off Valve.
• If compressed air is lubricated, an exhaust reclassifier can capture entrained oil.

[Images: SMC AMG Series water removal filter, AFF-X6, ITV Series electro-pneumatic regulator, AR Series pressure regulator, AMC, AVL Series components, VG342 Cat 3/4 valve, PF2A flow meters]

Sustainability

• Install an ALDS (Automatic Leak Detection System) to cycle through the pneumatic system during downtime, measuring and recording air leaks at the component level.
• Alternatively, install flow meters and pressure switches at the air inlet to measure and record air usage.
• At minimum, install flow meters and pressure switches on start-up to document initial air usage, allowing comparison with later measurements to detect degradation in machine efficiencies.

[Image: SMC ALDS unit]

[Image: SMC VHS Series component]

Air Power Components

• Minimize distance between directional control valves and actuators to reduce wasted air volume.
• Use AS Series tamper-resistant flow control valves on actuators.
• Include KE Series residual pressure release valves at select locations for manual relief of trapped air pressures.
• For frequent adjustment of flow control valves, consider electronically controlled proportional valves tied to the machine controller.
• If parts of the machine operate at lower pressures, install regulators to reduce pressure.
• For wash-down environments, specify epoxy coated or stainless steel components.
• Air blow systems should include an engineered nozzle, a pressure regulator set for optimum impact force, and a solenoid valve to shut off air supply during idle time.
• Blow guns should be of efficient design and meet OSHA requirements.
• Use low wattage coils (0.5 watts or less) on solenoid valves.
• For actuators requiring thrust in one direction, investigate lowering pressure on the return stroke. Alternative speed/pressure control valves may be needed.
• For potential machine failures causing tooling/product damage or operator injury, examine fine-lock or end-lock options.
• Always include a high-quality muffler on air exhausts to minimize noise.

[Images: SMC CVQ series actuator + valve, PVQ Series proportional valves, AS Series, KE Series, KNH Series, ASR/ASQ Series, ARM series manifold regulator, VMG Blow Gun, SV Valve, CLA series fine lock cylinder, AN Series, ZM-X298 Vacuum Ejector, ZL Series Multiple-stage ejectors, ZP2V]

Vacuum Components

Venturi style vacuum ejectors can be used in non-continuous applications and should include:

• Tamper-resistant inlet air regulator to maintain optimum air pressure (typically no more than 65 PSI).
• Multiple-stage vacuum ejectors for best efficiency.
• Vacuum switches as part of a control system to shut off air supply when a part is adsorbed and restore airflow if vacuum pressure degrades.
• ZP2V series vacuum saving valves to isolate a failed pad in a multi-pad application using a single ejector.
• Minimal distance between the ejector and the end effector to reduce line volumes.

[Images: SMC AR Series, ZM-X298 Vacuum Ejector with Energy-Saving Function, ZL Series Multiple-stage ejectors, ZP2V]

SMC Energy Saving Program Ver.2

The SMC Energy Saving Program is a tool to optimize energy consumption during the design phase of pneumatic systems. It is available for download from www.smcusa.com.

Key Features:

• Pneumatic Basic Calculation: For fundamental pneumatic system calculations.
• Calculation for energy savings at a plant: Optimize energy consumption across an entire plant.
• Model Selection: Assist in choosing appropriate components.
• Other calculations: Various other calculation tools.

[Screenshot: SMC Energy Saving Program Ver.2 interface showing various calculation options]

[Indicates added features and improvements in Ver. 2.]

Selection and characteristic calculation for an air blow system

Allows selection and calculation of characteristics for different air blow nozzles and upstream piping. Pressure distribution can also be calculated, offering easy visual understanding with graphs.

[Screenshots: SMC Energy Saving Program showing air blow system selection and characteristic calculation with graphs]

Air consumption of devices

Air consumption calculations are possible for actuators and air blowers. Cost can be calculated.

Accumulation function: Calculates air consumption for each device and the total volume of air consumption by device and line, including total cost. A total of 88 different actuators are registered. Demonstrates savings possible with dual-pressure circuits.

Complicated calculations are no longer needed; the program offers quick results.

[Screenshot: SMC Energy Saving Program showing air consumption calculation for actuators and air blowers]

Complicated calculations such as volume of air consumption and pressure drop are no longer required. Calculation results are acquired by simply inputting user conditions.

Pneumatic line net

Calculation of pressure loss in pipeline networks

Enables work with more complicated pipeline networks. Features simplified input, works with loop piping, and supports a variety of pipelines.

[Screenshot: SMC Energy Saving Program for calculating pressure loss in pipeline networks]

Charge and discharge to/from a tank

Calculation on the charge and discharge between two tanks has been added.

[Screenshot: SMC Energy Saving Program for calculating charge and discharge to/from a tank]

Calculation of gases, liquids and saturated steam

Supports calculation with various gases and fluids by entering their specific gravity.

[Screenshot: SMC Energy Saving Program for calculating gases, liquids, and saturated steam]

Selection of devices

Added selection for: After cooler, air filter, regulator, booster regulator, and air tank.

Search for the conductance of components

Added selection for: After cooler, air filter, regulator, and air tank.

Global Manufacturing, Distribution and Service Network

[Image: Map showing SMC's global manufacturing, distribution, and service network]

Worldwide Subsidiaries

North & South America

• U.S.A. SMC Corporation of America
• CANADA SMC Pneumatics (Canada) Ltd.
• MEXICO SMC Corporation (México), S.A. de C.V.
• BRAZIL SMC Pneumáticos do Brasil Ltda.
• CHILE SMC Pneumatics (Chile) S.A.
• COLOMBIA SMC Colombia Sucursal de SMC Chile S.A.
• ARGENTINA SMC Argentina S.A.
• BOLIVIA SMC Pneumatics Bolivia S.r.l.
• VENEZUELA SMC Neumatica Venezuela S.A.
• PERU (Distributor) IMPECO Automatización Industrial S.A.C.
• ECUADOR (Distributor) ASSISTECH CIA. LTDA.

Asia/Oceania

• CHINA SMC(China)Co.,Ltd.
• CHINA SMC Pneumatics (Guangzhou) Ltd.
• HONG KONG SMC Pneumatics (Hong Kong) Ltd.
• TAIWAN SMC Pneumatics (Taiwan) Co.,Ltd.
• KOREA SMC Pneumatics Korea Co., Ltd.
• SINGAPORE SMC Pneumatics (S.E.A.) Pte.Ltd.
• MALAYSIA SMC Pneumatics (S.E.A.) Sdn.Bhd.
• THAILAND SMC (Thailand) Ltd.
• PHILIPPINES Shoketsu SMC Corporation
• INDIA SMC Pneumatics (India) Pvt.Ltd.
• ISRAEL (Distributor) Baccara Geva A.C.S. Ltd.
• INDONESIA (Distributor) PT. Sinar Mutiara Cemerlang
• VIETNAM (Distributor) Dy Dan Trading Co.,Ltd.
• PAKISTAN (Distributor) Jubilee Corporation
• SRI LANKA (Distributor) Electro-Serv (Pvt.) Ltd.
• IRAN (Distributor) Abzarchian Co. Ltd.
• U.A.E. (Distributor) Machinery People Trading Co. L.L.C.
• KUWAIT (Distributor) Esco Kuwait Equip & Petroleum App. Est.
• SAUDI ARABIA (Distributor) Assaggaff Trading Est.
• BAHRAIN (Distributor) Mohammed Jalal & Sons W.L.L. Technical & Automative Services
• SYRIA (Distributor) Miak Corporation
• JORDAN (Distributor) Atafawok Trading Est.
• BANGLADESH (Distributor) Chemie International
• AUSTRALIA SMC Pneumatics (Australia) Pty.Ltd.
• NEW ZEALAND SMC Pneumatics (N.Z.) Ltd.
• JAPAN SMC Corporation

Europe/Africa

• GERMANY SMC Pneumatik GmbH
• SWITZERLAND SMC Pneumatik AG
• U.K. SMC Pneumatics (U.K.) Ltd.
• FRANCE SMC Pneumatique SA
• SPAIN/PORTUGAL SMC España S.A.
• ITALY SMC Italia S.p.A.
• GREECE SMC HELLAS E.P.E
• IRELAND SMC Pneumatics (Ireland) Ltd.
• NETHERLANDS (Associated company) SMC Pneumatics BV
• BELGIUM (Associated company) SMC Pneumatics N.V./S.A.
• DENMARK SMC Pneumatik A/S
• AUSTRIA SMC Pneumatik GmbH (Austria)
• CZECH REPUBLIC SMC Industrial Automation CZ s.r.o.
• HUNGARY SMC Hungary Ipari Automatizálási Kft.
• POLAND SMC Industrial Automation Polska Sp. z o.o.
• SLOVAKIA SMC Priemyselná Automatizácia Spol s.r.o.
• SLOVENIA SMC Industrijska Avtomatika d.o.o.
• BULGARIA SMC Industrial Automation Bulgaria EOOD
• CROATIA SMC Industrijska Automatika d.o.o.
• BOSNIA AND HERZEGOVINA (Distributor) A.M. Pneumatik d.o.o.
• SERBIA (Distributor) Best Pneumatics d.o.o.
• UKRAINE (Distributor) PNEUMOTEC Corp.
• FINLAND SMC Pneumatics Finland Oy
• NORWAY SMC Pneumatics Norway AS
• SWEDEN SMC Pneumatics Sweden AB
• ESTONIA SMC Pneumatics Estonia OÜ
• LATVIA SMC Pneumatics Latvia SIA
• LITHUANIA (LIETUVA) UAB "SMC Pneumatics"
• ROMANIA SMC Romania S.r.l.
• RUSSIA SMC Pneumatik LLC.
• KAZAKHSTAN SMC Kazakhstan, LLC.
• TURKEY (Distributor) Entek Pnömatik Sanayi ve. Ticaret Şirketi
• MOROCCO (Distributor) Soraflex
• TUNISIA (Distributor) Byms
• EGYPT (Distributor) Saadani Trading & Industrial Services
• NIGERIA (Distributor) Faraday Engineering Company Ltd.
• SOUTH AFRICA (Distributor) Hyflo Southern Africa (Pty.) Ltd.

U.S. & Canadian Sales Offices

WEST

• Austin
• Dallas
• Los Angeles
• Phoenix
• Portland
• San Francisco
• Vancouver

CENTRAL

• Chicago
• Cincinnati
• Cleveland
• Detroit
• Indianapolis
• Milwaukee
• Minneapolis
• St. Louis
• Toronto
• Windsor

EAST

• Atlanta
• Birmingham
• Boston
• Charlotte
• Nashville
• New Jersey
• Rochester
• Tampa
• Montreal

[Map legend: Sales Branches, Regional Distribution Centers, Central warehouse]

SMC Corporation of America: 10100 SMC Blvd., Noblesville, IN 46060. www.smcusa.com

SMC Pneumatics (Canada) Ltd.: www.smcpneumatics.ca

Contact: (800) SMC.SMC1 (762-7621), e-mail: sales@smcusa.com

For International inquiries: www.smcworld.com

©2013 SMC Corporation of America. All Rights Reserved. RX-RRD-5M. Specifications subject to change without notice.