KCC user manual, KAW series

Safety instructions symbols

The symbols "Caution", "Warning" and "Danger" indicate hazard levels.

DANGER - Imminent danger, will result in death or serious injury

WARNING - Danger, can result in death or serious injury

CAUTION - Risk of minor injury if not observed

Safety precautions

Safety instructions

Before using the product, please read the user manual thoroughly and follow the safety rules.
Keep this manual in a safe place for future reference.
Do not modify, disassemble, or assemble the product arbitrarily.
Observe the conditions of use specified on product's label or instruction.
Operate, install, and disassemble product after confirming the safety of the surrounding conditions.
For use in unspecified conditions or environments, we recommend that you thoroughly review safety measures and consult with us.

Qualifications of professional personnel

We recommend handling by a person with sufficient knowledge and experience about the product.
The person who determines the design or specifications of the system should determine whether the product is suitable for use.

Warranty and disclaimers

For standard products, the warranty period is applied within 1 year from the date of use or within 18 months after delivery, whichever comes first.
During the warranty period, if a failure or damage is clearly attributable to our company, we will provide a replacement/necessary replacement part, and we will not bear any additional loss. Warranty here means the warranty for our products, and any other damage caused by the failure of the product is excluded from the scope of the warranty.

Specifications

Fluid : filtered compressed air
Ambient and fluid temp. : -5~60℃ (with no freezing)
Proof pressure : 1.5MPa
Max. Operating pressure : 1.0MPa
Min. Operating pressure : 0.05MPa
Mounting : bracket mounting, panel mounting
Operating method : relief(standard), non-relief(option)

Bowl/bowl guard material
~~Standard : polycarbonate
~~Metal(option) : aluminum

Drain type
~~Standard : manual drain
~~Option : auto drain(differential pressure type / float type)

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Functions

<div class="cms-symbol-block">
<div class="image light-mode-images"><img src="https://cdn.prod.website-files.com/6577e4ddb18c5363e98a478a/65a606002fb07002b7695fae_symbol__KAW.png" class="manual-symbol-img"><div class="cms-symbol-text">Filter regulator</div></div>
<div class="image dark-mode-images"><img src="https://cdn.prod.website-files.com/6577e4ddb18c5363e98a478a/65a605ff39648a39d517ced9_symbol__KAW_dark.png" class="manual-symbol-img"><div class="cms-symbol-text">Filter regulator</div></div>
</div>

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Product configuration

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How to assemble the module

Assembly precautions

<div class="ico_caution">When assembling, pay attention to the direction of fluid supply. (supply side → output side)</div>

Modular basic order : filter → regulator → lubricator
When assembling multiple filters, assemble them in order from the largest to the smallest.
e.g. KAF(5 μm) → KAFM(0.3 μm) → KAFU(0.01 μm)

Assembly method

Fasten the seal in the seal fastening groove between the products to be assembled or by using a spacer.
Seal fastening groove : 301 body
Spacer attach : 101, 201, 401, 601 body
After positioning both products, fix the front and rear module brackets.
Assemble the bracket fixing bolts from the front to the rear side of the bracket.

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Installation and disassembly

Precautions before installation

<div class="ico_danger">Installation and disassembly of a pressurized product may cause personal injury and/or property damage.</div>

<div class="ico_danger ico_2ndline">Before installation, be sure to release the pressure inside the product and piping.</div>

Ensure free space around the product for maintenance and safe operation.
Do not install in a location with high humidity or temperature. Doing so may cause performance degradation or malfunction.
Avoid dropping and external impacts when transporting and installing the product.
Connect the pneumatic pipe after completing the installation.
When connecting only the pneumatic pipe, without a separate mounting device, consider installing a separate pipe support to prevent excessive moment load or vibration on the pipe side. Otherwise, a malfunction or damage may occur.
Before installing the piping, flush or clean the piping sufficiently to remove any foreign substances. Even when fastening piping or fittings, make sure that chips from the piping screws or sealing material do not move into the machine. These may cause malfunction.

Pneumatic piping

Check the flow direction and place the product. Check the IN and OUT or arrows on the product body.
Fasten the threaded part of the pipe or fitting to the pneumatic port.
- Hold the female thread side and apply the proper torque.
- Insufficient tightening torque may lead to loosening or an improper seal. Excessive tightening torque may cause damage to screws, etc.
After completely sealing the pneumatic port, connect the pneumatic tube.

Drain piping

Install vertically with the drain outlet facing down. It cannot be used in a lateral or upward orientation.
For auto drain discharge piping, the auto drain kits (AD201F, AD301N, AD401N) use a ∅6 outer diameter (∅4 inner diameter) tube, and the length must be within 5 meters.

Disassembly

<div class="ico_danger">Before disassembly, be sure to release the pressure inside the product and pipe.</div>

Exhaust air from the entire system and product.
Press and release the lock on the pipe or fitting, then pull out the hose line.
Loosen the fitting on the connecting flange and turn it out.

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Regulator pressure adjustment

Precautions before pressure adjustment

Set the pressure while checking the inlet pressure and outlet pressure.
Set the set pressure 0.1 MPa or lower than the inlet pressure before use.
Operate the pressure control handle manually. Use of tools, etc. may cause damage to the handle.
If the pressure difference between the supply side and the output side is large, pulsation may occur.
In this case, use with a small pressure difference between the supply side and the output side.
When releasing the pressure (turn counterclockwise), check the pressure drop at the outlet or gauge, and operate the handle only until the pressure becomes “0”.
If you turn the handle too far, the handle may lock.

How to adjust the pressure

Pull the handle to release the lock. (a blue band appears under the handle.)
Turn the handle clockwise to increase the outlet pressure to the desired set pressure.
At a pressure lower than the target set pressure, gradually increase the pressure to reach the desired set pressure.
To lock the handle, press down the pressure control handle. (blue band under is hidden.)

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Maintenance

Air source

Please use clean air.
If the compressed air contains chemicals, organic solvents, synthetic oil, or corrosive gas, it may cause damage to parts or malfunction.
Air containing a large amount of moisture or foreign substances can cause malfunction, so install an air dryer or an after cooler on the inlet side of the product.

Maintenance and inspection

Regularly inspect the bowl for contamination, cracks, damage, and other deterioration. Use a neutral detergent for cleaning. If the contamination is severe, replacement is recommended.
In case of cracks, damage, or other deterioration, replace it.

Drain release

Open and close the drain valve manually. Use of tools may cause damage.
Release the drain before the level of the drain reaches the baffle.
~~Manual drain : turn the drain valve handle counterclockwise to drain.
~~Float-type auto drain : when the water level in the drain reaches the appropriate level, it is automatically discharged.
You can force a discharge by pushing the lower outlet.

Filter replacement

When to Replace the Filter Element
~~Replace the filter element after 2 years of use or when the outlet pressure drop exceeds 0.1MPa.
~~Replace when the green part of the differential pressure indicator turns completely red.

Cleaning

Clean the exterior of the product periodically with a soft cloth.
Allowable detergents : soapy water (maximum 60°C), neutral detergent (without aromatic compounds)

Failures and measures

Air leakage

Air leak from the gap between the bowl and body

In case the bowl packing is damaged‍

- Replace the bowl O-ring.

- Spread grease on the bowl O-ring and then fasten it.

Air leakage

Air leak from the bowl

‍In case the bowl is damaged

- Replace the bowl assembly.

- Switch to a metal bowl.

Air leakage

Air leak from the drain cock

In case foreign matter has been introduced to the drain valve‍

- Open the drain cock for several seconds to discharge foreign matter.

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In case the drain valve O-ring is damaged‍

- Replace the bowl assembly.

Air leakage

Air leak from the exhaust air hole of the bonnet

In case the diaphragm is damaged

- Replace the diaphragm.

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In case the piston packing is damaged

- Clean or replace the piston assembly and spread grease on the piston packing and sliding surface.

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In case foreign matter has been introduced to the exhaust seat

- Detach the valve guide and then clean the valve and valve seat.
- Replace the diaphragm.

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In case the surface of the valve seat is damaged

- Replace the valve assembly.

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In case back pressure at exit in excess of the set pressure is generated

- Modify the pneumatic circuit to prevent back pressure.

Air leakage

Air leak from the gap between the bonnet and body

In case the bonnet screws are loosened

- Fasten the bonnet screws again.

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In case the diaphragm is damaged

- Replace the diaphragm.

Breakage

Damage to the bowl or drain parts

In case corrosive gas is contained in compressed air

- Remove the cause of gas mixing, replace the damaged parts.

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In case parts are damaged due to external impact

- Remove the cause of external impact, replace the damaged parts.

Drain

Drain discharge not possible

In case the drain valve outlet is clogged with solid foreign matter, etc.

- Replace the bowl assembly.

Drain

Excessive discharge of drain in the pipe on the exit side

In case the drain level exceeds the baffle height and overflows

- Open the drain valve to discharge drain and then replace the element.

Flow

Excessive or unstable pressure drop

In case flow consumption at exit exceeds the product’s specifications

- Replace it with a product with greater flow.

Flow

Oil not flowing

Clogging of element

- Replace the element.

Pressure

Pressure adjustment not possible

In case the pneumatic pipe is installed in the opposite direction

- Install the pipe by following the correct IN/OUT direction.
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In case the surge spring or valve spring is broken‍

- Replace the part.

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In case foreign matter has been introduced to the valve seat

- Detach the valve guide and then clean the valve and valve seat.

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In case the valve seat is damaged

- Replace the valve assembly.

Pressure

Pressure setting not becoming “0” even after the handle is loosened

In case foreign matter is introduced into the valve seat

- Detach the valve guide and then clean the valve and valve seat.

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In case the valve seat or valve spring is damaged

- Replace the damaged part.

References

Video

Catalog

The contents in this manual are subject to change without notice.
For additional information, please visit our web site or contact us.

Doc# :

PUM-WK-KAW-2301