assembly and operating manual dl12 profinet

Assembly and Operating ManualDL12 PROFINETControl and Signal Module

Imprint

201.00 | DL12 PROFINET | Assembly and Operating Manual | en | 1354496

ImprintCopyright:This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights re-served. Any reproduction, processing, distribution (making available to third parties),translation or other usage - even excerpts - of the manual is especially prohibited and re-quires our written approval.

Technical changes:We reserve the right to make alterations for the purpose of technical improvement.

Document number: 1354496

Version: 01.00 | 29/05/2018 | en

© SCHUNK GmbH & Co. KGAll rights reserved.

Dear Customer,thank you for trusting our products and our family-owned company, the leading techno-logy supplier of robots and production machines.Our team is always available to answer any questions on this product and other solutions.Ask us questions and challenge us. We will find a solution!Best regards,Your SCHUNK team

SCHUNK GmbH & Co. KGSpann- und GreiftechnikBahnhofstr. 106 – 134D-74348 Lauffen/NeckarTel. +49-7133-103-0Fax [email protected]

Table of contents


3

Table of contents1 Technical Data ......................................................................................................... 4

2 Overview ................................................................................................................. 62.1 Master Module and Tool Module......................................................................... 7

3 Installation .............................................................................................................. 83.1 Electrical Connections .......................................................................................... 83.2 Installing DL-K Control/Signal Module................................................................ 133.3 Remove the DL-K Control/Signal Module........................................................... 143.4 Installing DL12-A Control/Signal Module ........................................................... 143.5 Remove the DL-A Control/Signal Module........................................................... 153.6 PROFINET Interface ............................................................................................ 153.7 Utility Schematic................................................................................................. 15

4 Description ............................................................................................................. 164.1 Master Module................................................................................................... 16

4.1.1 PROFINET Interface Information ............................................................ 164.1.2 Integrated Ethernet Switch .................................................................... 214.1.3 System Failure and Bus Failure LEDs ...................................................... 224.1.4 Ethernet 1 and Ethernet 2 LEDs.............................................................. 234.1.5 Reset-To-Factory Push-Button................................................................ 24

4.2 Arc Prevention Circuit......................................................................................... 254.2.1 Arc Prevention Circuit Behavior during Coupling ................................... 254.2.2 Arc Prevention Circuit Behavior during Uncoupling ............................... 27

4.3 Tool Module ....................................................................................................... 284.4 Safety System ..................................................................................................... 29

5 Operation ............................................................................................................... 325.1 Inputs.................................................................................................................. 325.2 Error Conditions ................................................................................................. 345.3 Recommended Sequence of Operation ............................................................. 37

6 Maintenance and care ............................................................................................ 406.1 Pin Block Inspection and cleaning ...................................................................... 416.2 Seal Replacement ............................................................................................... 436.3 DL Device Replacement Procedures................................................................... 44

6.3.1 Replace DL module with a new “out-of-the-box” DL module ................ 446.3.2 Replace DL module with an already-commissioned DL module............. 44

7 Trouble shooting..................................................................................................... 46

8 Recommended Spare Parts ..................................................................................... 47

9 Drawings................................................................................................................. 48

Glossary.................................................................................................................. 54

Technical Data


1 Technical DataDL12-K PROFINETInterface Connections

Auxiliary Power: 5-Pin Minifast (7/8”) MalePROFINET: 4-Pin D-Coded M12 FemaleIntegrated Tool Changer I/O:• 4x M8, 3-pin female connectors supporting

Tool Changer Locked, Unlocked, and Ready-to-Lock proximity sensors.

Integrated Connection to Valve Adapter Dia-gnostic Sensors:• 1x M8, 3-pin female connectors supporting

Valve Adapter proximity sensor• 1x M8, 4-pin female connectors supporting

Valve Adapter pressure sensorIntegrated Connection to JU4/JU5 Valve Ad-apter:• 1x 4-pin Block supporting Latch and Unlatch

signalsElectrical Rating Power Pass-Through:

• US1+ and US2+ Power: 10 A, 20–29 VDC Note: Arc prevention is applied to US1 andUS2 power.

Signal Pass-Thru: 3A, 30 VDC maximumCurrent Draw US1:

Coupled, safety switch on and activated: 0.28 ACoupled, safety switch deactivated: 0.24 ACoupled, safety switch disconnected: 0.22 AUncoupled: 0.14 AUS2:Latching and Unlatching are the same: 0.48 A(peak)

Enclosure IP65 (in coupled state)Temperature 0 to 49 °C.

Technical Data


5

DL12-A PROFINETFactory DefaultConfiguration

(5) Independent Tool-ID switches, each reading a(0–9) position (all factory set to Tool Position 1)

Interface Con-nections

Auxiliary Power: 5-Pin Minifast (7/8”) MalePROFINET: 4-Pin D-Coded M12 FemaleConnection to Switch:• M12, 5-pin female connector supporting con-

nection to RFID based Safety SwitchElectrical Rating Power Pass-Through:

• US1+ and US2+ Power: 10A, 20-29 VDCSignal Pass-Thru: 3 A, 30 VDC maximum

Enclosure IP65 (in coupled state)Temperature 0 to 49 °C

Overview


2 OverviewThe DL modules enable the customer to control and communicatewith the Tool Changer through a network using a PROFINET inter-face. A PROFINET node is established on the Master module, butnot on the Tool. Control of the Tool Changer is realized throughthe Master Node along with the reporting of various Tool ChangerI/O. The Tool module supports Tool-ID reported through the Mas-ter and functions as a pass-through for PROFINET network andpower to downstream equipment.The DL module is to be used in combination with the valve adapterwith dual double-solenoid valves, for Latch/Unlatch control of theTool Changer. When used in combination with the valve adapter,the DL achieves PL d safety reliability in accordance with ISO stand-ard 13849-1. The user is required to provide a pneumatic supplysource to the Tool Changer. Please refer to the appropriatemanual for specific module and Tool Changer requirements.The DL-K/DL-A modules are designed with a Safety circuit to allowthe Tool Changer to be operated in the safest manner possible. Inaddition to supporting the standard Tool Changer input signals(Locked, Unlocked, and Ready-to-Lock proximity sensors) the mod-ules also support advanced diagnostic and fault reporting. Refer toSafety System and Operation [} 32] for more information onthese attributes.A standard 5-Pin Push-Pull connector is provided on the Masterand Tool modules for interfacing with Auxiliary Power. The powersource for US1 and US2 Power must be a 24VDC certified powersupply or equivalent voltage controlled power supply and must beprotected by a user installed external 10 A fuse. A standard con-nector is provided on the Master and Tool modules for interfacingwith PROFINET. When the Tool Changer is coupled, the Master andTool modules pass signals via a spring-loaded pin block. A flexibleboot surrounds the pin block to seal the connection from moistureand liquid while coupled, Master Module and Tool Module [} 7].

Overview


7

2.1 Master Module and Tool ModuleSF, Ethernet 2, BF,

Ethernet 1 LED's,and Reset Switch

19-Pin Signal Spring Contactsand Rubber V-ring Seal

19-Pin Signal Contacts

Power Connector5-Pin Female Minifast

Valve Signal Pin Block

Common LedgeMounting Feature

Valve Adapter Pressure Sensor Connector4-Pin Female

Valve Adapter Proximity Sensor Connector3-Pin Female

PROFINET Connector4-Pin D-coded Female

0-99999 Tool IDTSI, M12 5-Pin Female Contacts

7-Pin Power Contacts

7-Pin Power Spring Contactsand Rubber V-ring Seal

RTL, Lock, and Unlock(4) 3-Pin Female Contacts

Power Connector5-Pin Minifast Male

PROFINET Connector4-Pin D-coded Female

DL PROFINET Master (K) and Tool (A) Modules

Master Module (DL-K)

The DL-K module has an integrated 4-Pin Valve signal pin block toprovide the latch and unlatch signals to the solenoid valves. Themaster module is equipped with M8 3-Pin connectors for the RTL1,RTL2, Lock, and Unlock sensor connections.The DK-K module has integrated M8 3-Pin valve adapter proximitysensor and M8 4-Pin valve adapter pressure sensor connectors aspart of the safety functionality.The DL-K Module also incorporates an Arc Prevention Circuit whichextends the life of all electrical power contacts by eliminatingarcing caused by inductive loads and high inrush current duringcoupling/uncoupling. Refer to Arc Prevention Circuit [} 25] for ad-ditional information regarding the Arc Prevention Circuit.The DL-K module provides status LED’s to visually indicate their op-eration. A reset button provides the ability to return to factory de-fault settings.

Tool Module (DL-A) The DL-A module requires a JR4-T Spacer Module to align the DL Masterand Tool modules and mounts to the Tool body of the Tool Changer.The DL-A module employs a series of thumbwheel switches forsetting of the Tool-ID input. This allows the customer to distinguishbetween the different Tools that are being used in a robotic cell oron a production line. The Tool-ID is reported through the Mastermodule bitmap. See PROFINET Interface Information for PROFINETbitmap and detailed I/O information. A M12 5-pin connectorprovides connection to the non-contact safety switch that is integ-rated into the safety circuit.

Installation


3 Installation

WARNINGDo not perform maintenance or repair on Tool Changer or mod-ules unless the Tool is safely supported or placed in the toolstand, all energized circuits (e.g. electrical, air, water, etc.) areturned off, pressurized connections purged and power dis-charged from circuits in accordance with the customer’s safetypractices and policies.Injury or equipment damage can occur with Tool not placed andenergized circuits on.• Place the Tool safely in the tool stand, turn off and discharge

all energized circuits, purge all pressurized connections, verifyall energized circuits are deenergized before performing main-tenance or repair on Tool Changer or modules.

The control/signal modules are typically installed by SCHUNK priorto shipment. The steps below outline the field installation or re-moval as required. The DL-K Master Module is mounted to theJR4-M valve adapter module on flat A of the Tool Changers MasterPlate. The DL-A Tool Module is mounted to the JR4-A Spacer mod-ule on flat A of the Tool Changer Tool Plate.

3.1 Electrical ConnectionsDie Master- und Werkzeugmodule DL verfügen über einen 5-poli-gen Schnellstromanschluss und einen M12 PROFINET Anschluss.Die Pinbelegungen können den nachstehenden Abbildungen undTabellen entnommen werden.

NOTEDie Spannungsquelle für die US1- und US2-Spannung muss einerzertifizierten 24VDC-Stromversorgung oder einer äquivalentenSpannung entsprechen, die durch die Stromversorgung kontrol-liert wird, und muss zudem durch eine vom Benutzer installierteexterne 10A-Sicherung geschützt sein.

Installation


9

Power connector

Pin Signal1 0 VDC Safe2 0 V DC I/O3 GND4 24 V DC I/O5 24 V DC Safe

Profinet connector

Pin Signal1 TX+2 RX+3 TX-4 RX-

Installation


The DL9 Master Modules has four M8 3-Pin female connectors forRTL1, RTL2, Locked, and Unlocked connections. The Master mod-ule has two connectors to interface with the valve adaptor, an M83-Pin female connector to interface with the Proximity sensor andan M8 4-Pin female connector to interface with the Pressuresensor. A M12 5-Pin connector on the Tool module is used to con-nect the Euchner Safety Switch.

M8 3-Pin female connectors for RTL1, RTL2, Locked, and Unlocked

Pin Signal1 US1+3 US1-4 Input

M8 3-Pin Female Valve Adapter Proximity Sensor

Pin Signal1 US1+3 US1-4 Input

Installation


11

M8 4-Pin Female Valve Adapter Pressure Sensor

Pin Signal1 +5V2 Pressure Output+3 Pressure Output-4 GND 5V

M12 5-Pin Female Euchner Safety Switch Connector

Pin Signal1 US1+2 SSO13 US1-4 SSO25 SSFAULT (not required, electric-

ally not connected)

Installation


The Latch and Unlatch signals to the JR4 Valve Adapter are trans-mitted through a 4-Pin internal pin block to prevent damage orother environmental factors that could cause the signals to short.

1Latch

4US2

Unlatch 2

Unlatch1

Pin Internal Pin Block

Pin Signal1 Latch2 Unlatch23 Unlatch14 US2-

Installation


13

3.2 Installing DL-K Control/Signal Module

NOTEIf module being installed is not new “out of the box” and has beenpreviously commissioned refer to Replace DL module with analready-commissioned DL module [} 44] for instructions.

Tool Changer

Valve Adapter on Head Side (JR4 shown)M5 Socket Head Cap Screws

Connect to "S2"Connect to "S1"

DL12-K

RTL, Lock and UnlockSensor Connectors

Use Ledge Mounting Feature to Proberty Align Module

Power Connector

Ethernet Connector

Ø It may be necessary to clean the mounting surface on the valveadapter prior to installing the module in order to remove anydebris that may be present.

Ø Using the ledge feature as a guide place the DL-K Control/SignalModule on the Valve Adapter mounting surface. Align the con-trol/signal module with the valve adapter using the dowels inthe bottom of the ledge feature.

Ø If fasteners do not have pre-applied adhesive, apply Loctite242® to the supplied M6 SHCS fasteners. Install the two M6socket head screws securing the Control/Signal Module to theValve Adapter and tighten to 8 Nm.

Ø Connect the pressure sensor and proximity sensor cables to theconnectors on the DL-K Module.

Ø Connect the Euchner Safety switch cable to the connector onthe DL-K Module.

Ø Connect the RTL1, RTL2, Lock, and Unlock sensor cables to theconnectors on the DL-K Module.

Ø Connect the M12 PROFINET cable and the 5-Pin Power cable tothe connectors on the DL-K Module.

Ø The new module will automatically get the name and IP addressof the old module assigned.

Ø After a few seconds it should be operating on the network.

Installation


3.3 Remove the DL-K Control/Signal ModuleØ Remove the pressure and proximity sensor cables from the DL-K

Control/Signal Module piggy-backed on the valve adapter.Ø Disconnect the sensor cables (RT1, RT2, Lock, and Unlock) from

the DL-K Control/Signal Module.Ø Disconnect the M12 PROFINET and 5-Pin power cables from the

DL-K Control/Signal Module.Ø Support the Control/Signal Module and remove the two M6

SHCS and lower the module until it clears the guide pin, setmodule aside.

3.4 Installing DL12-A Control/Signal Module

2x M6 Socket Head Cap Screws

DL12-A

Power Connection

PROFINET Connection Tool-ID Safety Switch Connection

Use Ledge Mounting Feature to Proberly Align Module

Valve Adapter on Tool Side (JR4 shown)

Tool Changer

Module Installation and Removal DL-T Control/Signal Module

Ø It may be necessary to clean the mounting surface on theSpacer Module prior to installing the module in order to removeany debris that may be present.

Ø Using the ledge feature as a guide place the DL-A Control/SignalModule on the Spacer Module mounting surface. Align the con-trol/signal module with the Spacer Module using the dowels inthe bottom of the ledge feature.

Ø If fasteners do not have pre-applied adhesive, apply Loctite242® to the supplied M6 SHCS fasteners. Install the two M6socket head screws securing the Control/Signal Module to theSpacer and tighten to 8 Nm.

Ø Connect the M12 PROFINET cable and the 5-Pin Power cable tothe connectors on the DL-A Module.

Installation


15

3.5 Remove the DL-A Control/Signal ModuleØ Disconnect the M12, the 5-Pin power cables and the Euchner

Safety Switch cable from the DL-A Control/Signal Module.Ø Support the Control/Signal Module and remove the two M6

SHCS and lift up on the module until it clears the guide pin, setmodule aside.

3.6 PROFINET InterfaceThe PROFINET interface parameters and I/O bitmaps employed inthe DL modules are found in chapter PROFINET Interface Informa-tion of the manual. These should be thoroughly understood prior tooperating the Tool Changer. A detailed operational sequence isprovided in chapter Recommended Sequence of Operation [} 37].

3.7 Utility SchematicRefer to Drawings [} 48] of this manual for customer interfaceand wiring details for the DL-K/DL9-A modules.

Description


4 Description4.1 Master Module

4.1.1 PROFINET Interface Information

The following table lists the PROFINET interface parameters em-ployed in the DL-K Master module.PROFINET Interface Parameters

Parameter DescriptionDCP supportedFast Startup supportedUsed Protocols (subset) UDP, IP, ARP, ICMP (Ping)Topology recognition LLDP, SNMP V1, MIB2, physical deviceVLAN- and priority tagging yesContext Management by CL-RPCMinimum cycle time 2msBaud rate 100 MBit/sData transport layer Ethernet II, IEEE 802.3

A GSDML file for the Master node is available by e-mail. Referencethe part number: DL12-M Node GSDML file 9031-20-1071 Robot input and output bitmaps for the Master node are providedin the follwing tabeles "I/O Bitmap, Robot Inputs from SWO-L-DL-KModule" and "I/O Bitmap, Robot Outputs to SWO-L-DL-K Module".

Description


17

I/O Bitmap, Robot Inputs from SWO-L-DL12-K Module

Byte Bit# Designation Description/Function0 0 Locked Tool Changer is locked

1 Unlocked Tool Changer is unlocked2 Latch Enabled Tool Changer is ready to Latch3 Unlatch Enabled Tool Changer is ready to Unlatch4 RTL1 Ready-to-Lock Proximity switch1 I/P5 RTL2 Ready-to-Lock Proximity switch2 I/P6 TOOL_PRESENT Bit indicating Master and Tool are in electrical

contact.7 Tool Power Is On Indicates that Arc Prevention Circuit is turned ON

and power is provided to the Tool1 0 US1_Power_Present US1 supply voltage on robot side within the allow-

able range of 20.4 to 28.8 V1 US2_Power_Present US2 supply voltage on robot side within the allow-

able range of 20.4 to 28.8 V2 SSO_1 Input from safety switch that indicates it is safe to

unlatch the tool. Should always agree with SSO_23 SSO_2 Input from safety switch that indicates it is safe to

unlatch the tool. Should always agree with SSO_14 SS Pulse Missing Is high if the SSO inputs are jumpered or shorted

high.5 UNSAFE_LATCH User attempted to latch when unsafe.6 Unsafe Unlatch Unlatch Rejected Due to Unsafe Condition

Present7 SYSTEM_IS_UNSAFE Any APx_COMM_ERROR, APx_MISMATCH_ERROR,

APx_ SAFETY_ERROR, SSO_FAULT sets this bit.2 0 * V1RELAY Indicates that safety switch has activated safety

relay 1. Should agree with SSO_1.1 * V2RELAY Indicates that safety switch has activated safety

relay 2. Should agree with SSO_2.2 Lock/Unlock Sensor Fault Lock & Unlock Inputs True at the same time or

swapped lock & unlock sensors or bad sensors orno latch/unlatch motion.

3 ERROR_ON_LATCH Overload or short circuit on Latch Output4 ERROR_ON_UNLATCH1 Overload or short circuit on Unlatch1 Output5 ERROR_ON_UNLATCH2 Overload or short circuit on Unlatch2 Output6 TOOL-ID_ERROR Tool ID Communication Timeout7 EVERYTHING IS OK Any APx_COMM_ERROR, APx_MISMATCH_ER-

ROR, APx_ SAFETY_ERROR sets this bit.

Description


Byte Bit# Designation Description/Function3 0 VALVE_ERROR Valve or pressure sensor defect. Logical OR of

APx_VALVE_ ERROR bits.1 * CROSS_MONITORING_

ERRORSafety System detected mismatch. Logical OR ofthe APx_ INP_MISMATCH, APx_OUTP_MIS-MATCH, and AP2_COMM_ ERROR bits.

2 PRESSURE_TOO_HIGH Pressure sensor reports an unlatch pressurehigher than the maximum system rating.

3 PRESSURE_TOO_LOW Pressure sensor report an unlatch pressure lowerthan the minimum system rating.

4 Tool ID Switch1 Bit1 N/A5 Tool ID Switch1 Bit2 N/A6 Tool ID Switch1 Bit4 N/A7 Tool ID Switch1 Bit8 N/A

4 0 Tool ID Switch2 Bit1 N/A1 Tool ID Switch2 Bit2 N/A2 Tool ID Switch2 Bit4 N/A3 Tool ID Switch2 Bit8 N/A4 Tool ID Switch3 Bit1 N/A5 Tool ID Switch3 Bit2 N/A6 Tool ID Switch3 Bit4 N/A7 Tool ID Switch3 Bit8 N/A

5 0 Tool ID Switch4 Bit1 N/A1 Tool ID Switch4 Bit2 N/A2 Tool ID Switch4 Bit4 N/A3 Tool ID Switch4 Bit8 N/A4 Tool ID Switch5 Bit1 N/A5 Tool ID Switch5 Bit2 N/A6 Tool ID Switch5 Bit4 N/A7 Tool ID Switch5 Bit8 N/A

6 0 * Minor Revision Bit0 uC firmware revision1 * Minor Revision Bit1 uC firmware revision2 * Minor Revision Bit2 uC firmware revision3 * Minor Revision Bit3 uC firmware revision4 * Major Revision Bit0 uC firmware revision5 * Major Revision Bit1 uC firmware revision6 * Major Revision Bit2 uC firmware revision7 * Major Revision Bit3 uC firmware revision

Description


19

Byte Bit# Designation Description/Function7 0 * Raw Locked Sensor Direct mirror of locked proximity sensor.

1 * Raw Unlocked Sensor Direct mirror of unlocked proximity sensor.2 * Valve Proximity Sensor Shows status of valve position.3 * AP2_Comm_Error AP1 lost communication to AP24 * AP1_VALVE_ ERROR Valve 2 opening or closing at the wrong time.5 * AP1_OUTP_ MISMATCH AP1 detects that AP2 has come to a different de-

cision than AP1 regarding a safety-critical motion,or AP1 sees Unlatch_ valve_control_2 is differentthan expected.

6 * AP1_INP_ MISMATCH AP1 detects that AP2 reports different input val-ues than AP1 sees.

7 * MEMORY_FAILURE N/A8 0 * (Reserved) N/A

1 * (Reserved) N/A2 * (Reserved) N/A3 * (Reserved) N/A4 * Firmware Version Mismatch N/A5 * (Reserved) N/A6 * (Reserved) N/A7 * (Reserved) N/A

9 0 * AP2_Mismatch_ Error N/A1 * AP2_Comm_Error AP1 lost communication to AP22 * AP2_Memory_ Failure N/A3 * AP2_VALVE_ ERROR Position sensor does not meet expectations4 * ERROR_ON_UNLATCH2 Overload on Unlatch 2 output was detected.5 PRESSURE_ SENSOR_ DIS-

CONNECTEDInternal bit indicating that the pressure sensor isdisconnected and/or that there are broken wiresin the sensor cable

6 * Memory_Tests_ Complete N/A7 * Safe_to_Unlatch_ AP2 N/A

10 0 * AP2_SSO_2 N/A1 * V1Relay N/A2 * V2Relay N/A3 * AP2_SSFAULT N/A4 * Unlatch_Valve_ Control_2 N/A5 * Valve_Position N/A6 * AP2_Version_Error N/A7 * AP2_Safety_Error N/A

Description


Byte Bit# Designation Description/Function11 0 * Pressure Reading Bit 8 N/A

1 * Pressure Reading Bit 9 N/A2 *

Unused

N/A3 * N/A4 * N/A5 * N/A6 * N/A7 * N/A

12 0 * Pressure Reading Bit 0 N/A1 * Pressure Reading Bit 1 N/A2 * Pressure Reading Bit 2 N/A3 * Pressure Reading Bit 3 N/A4 * Pressure Reading Bit 4 N/A5 * Pressure Reading Bit 5 N/A6 * Pressure Reading Bit 6 N/A7 * Pressure Reading Bit 7 N/A

13 0 *

Unused Unused

1 *2 *3 *4 *5 *6 *7 *

14 0 *Major Version Number ofAP2 [0:4

AP2 Firmware Revision Number

1 *2 *3 *4 *

Minor Version Number ofAP2 [0:4]

5 *6 *7 *

15 * (Reserved) (Reserved)* ) These bits should be mapped for SCHUNK diagnostic use.

Description


21

I/O Bitmap, Robot Outputs to SWO-L-DL12-K Module

Byte Bit# Designation Description/Function0 0 Latch Request Lock

1 Unlatch Request Unlock2 Unused - Does not need to be mapped3 Clear Errors Reset errors, allow affected I/O to be reactivated4 Soft Start Enable Enables the soft start functionality5 Unused - Does not need to be mapped6 Direct Power Control Enable Arc Prevention Override7 Unused - Does not need to be mapped

1 to7

Unused - Does not need to be mapped

4.1.2 Integrated Ethernet Switch

The DL-K Master Module provides an integrated 2-port Ethernetswitch which supports the following:• Transmission rate 100 MBit/s• Interface type 100 BASE-TX, isolated• Half duplex/Full duplex supported .• Auto-Negotiation supported• Auto-Crossover supported

Description


4.1.3 System Failure and Bus Failure LEDs

When the module are coupled and functioning properly, the DL-KLEDs should display as shown in the figure with some blinking.

LED Display of Properly Functioning Coupled Modules

The System Failure (SF) status LED is identified on the module as“SF”. It provides device status for power and proper operation.Refer to the following table for an outline of this LED’s operation.The Bus Failure (BF) status LED is identified on the module as “BF”.It provides PROFINET status information. Refer to the followingtable for an outline of this LED’s operation.

DL-K SF status LED

Status SF LED NoteNo Power Off No power applied. Check if voltage is 24 VDC.Operational Green Normal operationFault Red One of the following faults has occurred:

- Internal Diagnostic ErrorFault Red blinking Reset To Factory Push Button was pressed or one of the

following faults has occurred:- Communication error with tool module- Input power failure

DL-K BF status LED

Status SF LED NoteOff Line Off Device not on line. Device may not have an IP address or

may be powered off.Operational Green Normal operationNot OK RED No configurationNot OK Red blinking No data exchange.

Description


23

4.1.4 Ethernet 1 and Ethernet 2 LEDs

The Ethernet LEDs provide information about link status and activ-ity on the ports of the integrated Ethernet switch.• The Ethernet 1 LED displays the status of the robot-side Ether-

net port (refer to "Master Module Ethernet 1 LED").• The Ethernet 2 LED displays the status of the Tool-side Ethernet

port (refer to "Master Module Ethernet 2 LED").Master Module Ethernet 1 LED

Status SF LED NoteNo Link Off The Master module has no connection to the Ethernet.Link Green The Master is connected to the Ethernet but there is cur-

rently no data exchange activity.Active RX/TX Blinking Amber There is sporadic data exchange activity with the Ether-

net.PROFINET con-nection estab-lished

Amber There is continuous data exchange activity with the Ether-net.

Master Module Ethernet 2 LED

Status SF LED NoteNo Link Off There is no Ethernet device connected to the tool module.Link Green There are one or more Ethernet devices connected to the

Tool module but there is currently no data exchangeactivity.

Active RX/TX Blinking Amber There is sporadic data exchange activity with the Ether-net.

PROFINET con-nection estab-lished

Amber There is continuous data exchange activity with the Ether-net.

Description


4.1.5 Reset-To-Factory Push-Button

A push-button, located under the LED window cover between theE2 and BF LED allows the user to perform a “Reset-To-Factory”function which clears the PROFINET Name Of Station and the mod-ule’s IP address. This is useful when already configured devices getswapped or a broken device gets replaced by an already con-figured device. See Section DL Device Replacement Procedures [} 44] for a detailed device replacement procedure.After the push-button was pressed the SF LED will blink red, indic-ating that with the next power cycle the Name of Station and IPaddress will be cleared.Make sure to re-apply the LED window cover after access to thepush-button is not needed anymore.

Description


25

4.2 Arc Prevention CircuitThe DL Module incorporates SCHUNK’s exclusive Arc PreventionCircuit. The Arc Prevention Circuit extends the life of all electricalpower contacts by eliminating arcing caused by inductive loadsand high inrush current during coupling/uncoupling. The Arc Pre-vention Circuit makes it possible to couple/uncouple withoutswitching power off and prevents damage to the contacts.In the DL Module, the Arc Prevention Circuit controls the ON/OFFstatus of the following two power signals:• Input and Logic power US1+• Output power US2+The behavior of the Arc Prevention circuit is more fully describedin the following sections.

4.2.1 Arc Prevention Circuit Behavior during Coupling

The behavior of the Arc Prevention circuit during coupling can bemore clearly understood by referring to the figure below "Power-On Timing", which shows the power-on timing diagram for the ArcPrevention Circuit. Starting at the top of the diagram, the LATCHcommand is issued thus initiating locking of the Master and Tool.Soon after locking is initiated, electrical contact between Masterand Tool Pin Contacts occurs (this time is designated t1 in the dia-gram). The magnitude of time t1 is a function of many factors in-cluding the weight of the EOAT, the distance between the Masterand Tool when the LATCH command is issued, how well the Mas-ter and Tool are aligned during pick-up, etc.As soon as electrical contact is made and the LATCH command isissued, the Arc Prevention Circuit will turn on US1 and US2 power.The time delay between when the electrical contacts become fullyengaged to when power is actually available to the EOAT (time t2in the diagram) is less than 100ms.Important: The Arc Prevention Circuit will only allow power to passto the Tool after the LATCH command has been issued and theMaster and Tool module’s electrical contacts are fully engaged.

Description


Latch command

electrical contactbetween master and tool

US1, US2 power

t = Tool Changer Lock Time1t = Power Switch ON-delay2

Power-On Timing

4.2.1.1 Soft Start during CouplingHigh current spikes can cause voltage drops on the power supplyand potentially may lead to network faults. The Arc Prevention Cir-cuit has an SCHUNK exclusive Soft Start feature that pulses thepower on gradually in the beginning, preventing the large currentspike that would otherwise occur if there were only one hard onsignal. This results in a series of much smaller current spikes andprevents significant voltage drops on the network power. The fig-ure below shows how the Soft Start feature effectively reduces thevoltage drop on network power.

V(supply) V(supply)

V(load) V(load)

Soft Start Feature

Description


27

4.2.2 Arc Prevention Circuit Behavior during Uncoupling

The behavior of the Arc Prevention Circuit during uncoupling canbe more clearly understood by referring to the figure below, whichshows the power-off timing diagram for the Arc Prevention Circuit.Starting at the top of the diagram, the UNLATCH command is is-sued thus initiating uncoupling of the Master and Tool.Immediately after the UNLATCH command is issued, the Arc Pre-vention Circuit will turn off US1 and US2 power. The power-offtime delay between the UNLATCH command and the switching offof power (designated t3 in the diagram) is less than 50ms.Some time after power is turned off and the Master and Tool be-gin to separate, electrical contact between Master and Tool PinContacts will be lost. This occurs with a delay, designated t4 in thediagram, after the UNLATCH command is issued. The magnitude oftime t4 is a function of many factors, including the weight of theEOAT, the friction between Master and Tool alignment pins, etc.but is usually not shorter than 100ms.

UNLATCH command

electrical contact between master and tool

US1, US2 Spannung

t = Power Switch Off Delay3t = Tool Changer Unlock Time4

Arc Prevention Circuit Power-Off Timing

Description


4.3 Tool ModuleThe Tool module utilizes a patented, rapid communication methodto report the Tool-ID information from the pushbutton switches tothe Master module as soon as the Tool Changer is coupled. Typic-ally the Tool-ID information is available to the Master within250ms from the time the changer is coupled.Five pushbutton switches are provided on the Tool module for set-ting of a Tool-ID number.If the plastic window and seal above the Tool-ID switches are re-moved, ensure the seal and window are re-positioned correctly toprevent a leakage path to the module inside.The Tool ID is available to the Master within 250ms from the timethe changer is coupled; otherwise a Tool-ID_Error shall be set inthe bit map. If a Tool is not present the Tool ID is set to FFFFF. Ifthe Master and Tool are coupled and the Tool ID fails to be repor-ted, a Tool-ID_Error shall be set.

SW5 SW5

Decrease (-) Digit

Set Tool ID to an Unique 1-Digit Number for each ToolIncrease (+) Digit

Window

4x M3 Captive Head Screws

DL9 Tool Module, Tool-ID Switch Settings

For details of how the Tool-ID is reported: PROFINET Interface In-formation [} 16]

Description


29

4.4 Safety SystemThe DL-K module in conjunction with the JR4/JU4 valve adapter isdesigned with special features to achieve a PL d safety reliabilitylevel in accordance with ISO standard 13849-1. The safety systemis designed to avoid unintentional Tool release, integrating theEuchner contact-less safety switch, two pneumatically intercon-nected solenoid valves, dual relays, and two cross-monitoring pro-cessors into the safety circuit.The two cross-monitoring processors in the DL-K mModule will de-termine, based on the status of all the safety-related inputs andoutputs, when it is safe to execute an Unlatch command. The pro-cessors are linked by hardwired I/O, if one processor detects acondition that differs from the other processor, its control logicwill declare a fault preventing the unlatch output. When the Toolis positioned safely in the tool stand or storage location, the Euch-ner safety switch outputs will close the V1 and V2 relays allowingthe Unlatch command to pass from the Application Processors tothe solenoid valves.A second set of contacts on the V1 and V2 relays also provide dia-gnostics to the Application Processors. The JR4/JU4 Valve Adapteris equipped with two double-solenoid valves. Pressure and proxim-ity sensor outputs provided by the Valve Adapter are evaluated bythe Application Processors for diagnostic purposes.

Description


PROFINET I/O

PROFINETInterface

Application Prozessor 1 (AP1)

Current Limiter

Application Prozessor 2 (AP2)

UNLATCH VALVE 1

UNLATCH VALVE 2

Input Power

Output Power

DL Master module

To AP1and AP2

V1 Relay24V

24V

to AP1and AP2

V2 Relay

DL Tool Module

ARCPrevention

PCB

EuchnerContact-less Safety Switch

Input PowerSafety Output,

Channel 1

Safety Output,Channel 2

Tool Stand Mounted Actor

Unlocked Sensor

Locked Sensor

RTLSensors

Tool Stand

RTL1 & 2

Tool-ID PCB

1 2 3 4 5RS485

+/-

Locking Mechanism Air Cylinder

Tool Changer

UNLOCK AIR

LOCK AIR

PROFINET I/O

Input PowerOutput Power

Electrical Contacts

To Applications Processors

Valve 1 Valve 2

To Applications Processors

Air InputValve Adapter w/ Dual Double-Solenoid Valves

LATC

H (A

P1)

LATC

H (A

P1)

Pow

er-o

nCr

oss-

Mon

itorin

g

Pressure Sensor

Proximity Sensor

The safety switch (not included with module) is mounted to theDL-A module using a mounting bracket that can be supplied bySCHUNK. The actuator is mounted to the tool stand using an ad-justable mounting bracket. The safety switch is connected to theDL-K module by a five conductor M12 cable. Refer to the JR4/JU4/JU5/JT7 Valve adapter manual for detailed information on the dualdouble solenoid valve functionality.

Description


31

CAUTIONIt is required to use a PL e rated contact-less safety switch suchas the Euchner CES-AP with the DL module.Use of unapproved switches will void the PL d safety rating.• Contact SCHUNK before using another safety rated switch.

Valve ModuleJRU-K Shown

Master Module

Valve Module SpacerJR4-A Shown

Tool Module

Non-Contact SwitchInterconnecting Cable

Tool Stand

Switch Actuator

Non-ContactSafety Switch

Safety Switch (Modules Shown for Reference Only)

Operation


5 OperationA thorough understanding of the advanced diagnostic and fault re-porting capability is required to proficiently operate this product.The following information is provided to help define the behaviorof the DL-K/DL-A modules.

5.1 InputsThe following describes the most critical inputs from the SCHUNKMaster module.

Locked A proximity sensor input indicating that the coupling mechanism isin the Lock position. The “LOCKED” bit in the PROFINET bitmap willonly be set high if the following conditions are true:• LOCKED sensor input is 1• UNLOCKED sensor input is 0• TOOL PRESENT input is 1• RTL1 and RTL2 inputs are 1

RTL1 and RTL2 Proximity sensor inputs that indicate the tool changer master isclose to the tool. It is recommended that these inputs be used toindicate when it is okay to couple the tool changer. These proxim-ity sensors are installed in the Master body and sense targets inthe Tool body that indicate the Master is adjacent to the tool(within ~ 0.06” or 1.5mm).

SSO 1 and SSO 2 Discrete inputs from the Euchner safety switch, which are highwhen the tool changer is in the stand.

Tool Present An input indicating the master module is electrically connected tothe tool.

Unlocked A proximity sensor input indicating that the coupling mechanism isin the Unlocked position. The bit “UNLOCKED” in the PROFINETbitmap will only be set high if the following conditions are true:• UNLOCKED sensor input is high• LOCKED sensor input is low

US1 Power Present An input indicating the presence of Input and Logic Power (US1) atthe SCHUNK master module. US1 power must be between 20.4and 28.8 otherwise the tool changer will NOT unlatch.

US2 Power Present An input indicating the presence of Output Power (US2) at theSCHUNK master module. US1 power must be between 20.4 and28.8 otherwise the tool changer will NOT unlatch.

V1 Relay and V2 Relay

V1 Relay is a normally open relay driven to closure by Channel 1 ofthe Euchner Safety Switch (SSO1). Similarly, the V2 Relay is drivento closure by Channel 2 of the Euchner Safety Switch (SSO2). Bothof these inputs must be high when the Tool Changer is in the toolstand, otherwise the tool changer will NOT unlatch.

Operation


33

EVERYTHING IS OK This is an overall status bit that indicates if there is an error condi-tion that will block an unlatch request. This bit is high as long asthere are no errors.

Tool Power Is On The Tool Power Is On bit indicates that the Arc Prevention circuithas turned power on to the tool side.

Unlatch Enabled The Unlatch Enabled bit indicates when the preconditions for un-latching the tool changer have been met. The preconditions in-clude:• No Errors• US1 and US2 Power within operating range• Air pressure within operating range• UNLOCKED bit is 0• LATCH bit is 0• The Tool is in the tool stand as indicated by SSO1, SSO2, V1RE-

LAY, and V2RELAY bits being 1

Operation


5.2 Error ConditionsThe following describes the reported error conditions and explainshow to reset the condition.

AP2 COMM ERROR This bit indicates that the two Application Processors in the Mastermodule have stopped communicating.The error condition can be reset with a power cycle.

CROSS MONITORINGERROR

The two Application Processors monitor the various safety-relatedinputs and outputs. If the processors are not in agreement on thestatus of these inputs and outputs the CROSS_MONITORING_ER-ROR bit will be set.The error condition can be reset with a power cycle.

ERROR ON LATCH This bit indicates that a short circuit or overload condition on theLATCH output has been detected.The error condition can be reset with the “Clear Errors” bit.

ERROR ON UNLATCH1 This bit indicates that a short circuit or overload condition on theUNLATCH output to Valve 1 has been detected.The error condition can be reset with the “Clear Errors” bit.

ERROR ON UNLATCH2 This bit indicates that a short circuit or overload condition on theUNLATCH output to Valve 2 has been detected.The error condition can be reset with a power cycle.

Lock/Unlock SensorFault

This error bit will be set if the Locked and Unlocked Sensors are onat the same time. If the condition is not true anymore then the bitshall be reset.

PRESSURE TOO HIGH The Valve Adapter operating pressure is 4,1 to 6,9 bar. If the mod-ule detects that the air pressure is too high then the PRESSURETOO HIGH bit will be set. The error can be reset with the “Clear Er-rors” bit or by supplying air at the correct pressure.

PRESSURE TOO LOW The Valve Adapter operating pressure is 60 to 100 psi. If the mod-ule detects that the air pressure is too low then the PRES-SURE_TOO_LOW bit will be set.The error can be reset with the “Clear Errors” bit or by supplyingair at the correct pressure.

RTL1/RTL2 Mismatch The DL Control Module shall check for a mismatch of the sensor in-puts RTL1 and RTL2 immediately after it receives an UNLATCHcommand. In case of a mismatch it shall set the “RTL1/RTL2 Mis-match Error” bit. This error bit shall be reset when a new UNLATCHcommand is received (UNLATCH command removed and re-applied) and the mismatch condition is removed with the “ClearErrors” output bit.

SSFAULT This error bit indicates that the safety switch has detected a faultcondition. This condition is continually monitored and will disablethe Unlatch and turn off Unlatch immediately.The error condition can be reset with a power cycle.

Operation


35

TOOL-ID ERROR The Tool ID shall be available to the Master within 250ms from thetime the changer is coupled; otherwise a TOOL-ID ERROR is set inthe bit map. If the Master and Tool are coupled and the Tool IDfails to be reported, a TOOL-ID ERROR is set. The error conditioncan be reset with a rising edge of TOOL PRESENT or power cycle.

UNSAFE LATCH A LATCH command shall only be performed if the following condi-tions are true: •• LATCH command is received• UNLATCH bit is 0• US1 and US2 Power Present is1• LOCKED sensor input is 0• PRESSURE_TOO_LOW and PRESSURE_TOOL_HIGH are 0• The RTL inputs are 1• SYSTEM_IS_UNSAFE bit is 0If the LATCH command is received and the above conditions arenot all met, the UNSAFE_LATCH error bit shall be set.

UNSAFE UNLATCH The UNSAFE_UNLATCH bit will be set when the user sends an un-safe unlatch command, refer to Section "Unlatch Enabled" inchapter "Inputs" for safe unlatch conditions. This condition is mon-itored immediately after UNLATCH command and will disable theUnlatch and turn off Unlatch immediately. If UNLATCH is inadvert-ently held high during a power cycle the UNSAFE_UNLATCH errorwill be generated. This error bit will be reset when a new UN-LATCH command is received (UNLATCH command removed andreapplied) and the UNLATCH_ENABLE conditions are met or withthe rising edge of the “Clear Errors” output bit.

VALVE ERROR If the module detects an error in the function of either valve, aVALVE_ERROR bit shall be set. Reference the JR4 Valve Adapter In-stallation and Operation Manual for potential valve failure modes.Valve errors set the SYSTEM_IS_UNSAFE bit so a power cycle is re-quired to clear.

PRESSURE DISCON-NECTED

The PRESSURE_DISCONNECTED bit indicates that the pressuresensor is disconnected and/or that there are broken wires in thesensor cable.If the pressure sensor is left disconnected then a SYSTEM_IS_UN-SAFE error will be generated. The error condition can be reset witha power cycle.

SYSTEM IS UNSAFE Any safety-related error (Application Processor communication er-rors, input/output mismatch errors, safety switch error, valve er-ror, etc.) will set the SYSTEM_IS_UNSAFE error. If the SYS-TEM_IS_UNSAFE error bit is set the UNLATCH and LATCH outputsshall be frozen. Refer to following Table for the errors that will trig-ger a SYSTEM_IS_UNSAFE error.The error condition can be reset with the Clear Errors bit.

Operation


Error Conditions

Error Bit Error Description TRIGGERS SYS-TEM_IS_UNSAFEERROR

Reset with

AP2_COMM_ERROR Communication failurebetween Application Pro-cessor 1 and 2

Yes Clear Errors Bit

CROSS_MONITOR-ING_ERROR

Application Processorsafety-related inputs andoutputs do not match


ERROR_ON_LATCH Short circuit detection onLATCH output

No (Yes only duringUnlatch)

Clear Errors Bit

ERROR_ON_UN-LATCH1

Short circuit detection onUNLATCH output to Valve1.


Clear Errors Bit

ERROR_ON_UN-LATCH2

Short circuit detection onUNLATCH output to Valve1.


Clear Errors Bit

LOCK/UNLOCKSensor Fault

LOCKED and UNLOCKEDSensor on at the sametime


Correct error orClear Errors Bit

PRESSURE_DISCON-NECTED

Pressure Sensor not con-nected


PRES-SURE_TOO_HIGH

Air supply to Valve Ad-apter too high


Clear Errors Bit

PRES-SURE_TOO_LOW

Air supply to Valve Ad-apter too low


Clear Errors Bit

RTL1/RTL2 mis-match

RTL1/RTL2 senor inputsdo not match

No Rising edge of UN-LATCH or Clear Er-rors Bit

TOOL_ID_ERROR TOOL-ID timeout error No Rising edge ofTOOL_ PRESENT;Clear Errors Bit

UNSAFE_LATCH Latch requested underunsafe conditions

No Rising edge ofLATCH or Clear Er-rors Bit

UNSAFE_UNLATCH Unlatch requested underunsafe conditions

No Rising edge of UN-LATCH or Clear Er-rors Bit

VALVE_ERROR Valve module pressureand/or position error


Operation


37

5.3 Recommended Sequence of Operation1. Start: The robot and Tool Changer master are free of the stand

or storage location, the Tool Changer is uncoupled and the ToolChanger locking mechanism is fully retracted (unlocked condi-tion). The tool is by itself in the Tool Stand. No error or faultconditions exist.a. The RTL1 and RTL2 inputs are 0.b. The Unlocked inputs are 1.c. The Locked inputs are 0.d. The SSO_1, SSO_2, V1RELAY, and V2RELAY inputs are 0.e. The SCHUNK tool and any downstream PROFINET device(s)

are offline.f. The US1_Power_Present (Input Power) and

US2_Power_Present (output Power) inputs are true andmust remain so at all times.

g. Tool-ID invalid (all 1: 0xFFFF)h. The Unlatch output is false and the Latch output is 0.i. Unlatch Enabled is 0.j. Everything is OK bit is 1.

2. Robot and master move into the tool, are parallel and within1.5 mm to 3.8 mm of the tool (i.e., the module contact pins aretouching, but the RTL sensors have not yet sensed the targetson the tool).

3. Robot and master move within 0.06” of the tool and safetyswitch is within range.a. The RTL1 and RTL2 inputs are true, indicating that it is ok to

couple the tool.b. The SSO_1, SSO_2, V1RELAY, and V2RELAY are true.c. The Tool Present input goes true, indicating that the mas-

ter and tool are in close proximity of each other.d. Communication is initiated with the SCHUNK tool and

downstream nodes. When the Tool Present input goes trueTool-ID becomes available within 100–150ms.

e. Shortly thereafter, communications should be establishedwith the downstream devices.

f. Unlatch Enabled is true.g. Everything is OK bit is true.

4. Couple the Tool Changer.a. The Latch output is made true.b. The Unlocked input goes false a short time later, indicating

piston travel. Subsequently, the Locked input goes true, in-dicating that the coupling operation is complete.

c. Once the Locked input goes true, a short time later theLatch output is made false.

Operation


d. Power becomes available on the Tool and the Tool Poweris On bit becomes true.

e. Unlatch Enabled is true.f. Everything is OK bit is true.g. Robot moves away from the tool stand with the Tool

Changer coupled.a. The Safety Switch becomes deactivated, and the SSO_1,

SSO_2, V1RELAY, and V2RELAY inputs go off.b. Unlatch Enabled is off.c. Everything is OK bit is on.

5. Normal operationa. The following inputs are off:

I. UnlockedII. SSO_1III. SSO_2IV. V1RELAYV. V2RELAYVI. Unlatch Enabled

b. The following inputs are on:I. LockedII. US1 Power (Input Power)III. US2 Power (Output Power)IV. RTL1 and RTL2V. Tool Power is OnVI. Tool PresentVII. Everything is OK bit is on.

c. The following outputs are 0:I. Unlatch

d. The following outputs are 1:I. Latch

6. Robot moves into the Tool Stand with the Tool Changercoupled. Everything is OK bit is 1.a. When the tool is returned to the stand, the Safety Switch

becomes activated and the SSO_1, SSO_2, V1RELAY, andV2RELAY inputs go 1.

b. Unlatch Enabled becomes1, indicating that it is safe to un-couple the Tool Changer.

7. Uncouple the Tool Changer.a. The Unlatch output is made 1.b. The Tool Power is On bit becomes 0.c. Communication is lost with downstream device(s).

Operation


39

d. The Locked input goes 0 a short time later and sub-sequently the Unlocked input goes 1, indicating that theuncoupling operation is complete.

e. Once the Unlocked input goes 1, a short time later the Un-latch output is made 0.

f. Unlatch Enabled is 1.g. Everything is OK bit is 1.

8. Robot and master move away from the tool, are parallel andbetween 0.06” to 0.15” of the tool.a. The Safety Switch becomes deactivated, and the SSO_1,

SSO_2, V1RELAY, and V2RELAY inputs go off.b. Unlatch Enabled is off.c. Everything is OK bit is on.)

9. Normal operationa. The following inputs are off:

I. Unlatch EnabledII. LockedIII. RTL1 and RTL2IV. Tool PresentV. SSO_1VI. SSO_2VII. V1RELAYVIII. V2RELAYIX. Tool Power is On

b. The following inputs are on:I. UnlockedII. US1 Power (Input Power)III. US2 Power (Output Power)IV. Everything is OKV. Tool-ID invalid (all 1→ 0xFFFF)

c. The following outputs are off:I. Latch

d. The following outputs are on:I. Unlatch

Maintenance and care


6 Maintenance and careOnce installed the operation of the control modules is generallytrouble free. The modules are not designed to be field serviced asall point-to-point wiring connections are soldered. Component re-placement is limited to the V-Ring seal on the Master.

WARNINGDo not perform maintenance or repair on Tool Changer or mod-ules unless the tool is safely supported or docked in the toolstand and all energized circuits (e.g. electrical, air, water, etc.)have been turned off.Injury or equipment damage can occur with tool not docked andenergized circuits on.• Dock the tool safely in the tool stand and turn off all energized

circuits before performing maintenance or repair on ToolChanger or modules.

If the Tool Changer is being used in dirty environments (e.g., weld-ing or deburring applications), care should be taken to limit the ex-posure of the Tool Changer. Idle Tool assemblies should becovered to prevent debris from settling on the mating surface.Also, the Master assembly should be exposed for only a shortperiod of time during Tool change and down time.Under normal conditions, no special maintenance is necessary,however it is recommended that periodic inspections be per-formed to assure long-lasting performance and to assure that un-expected damage has not occurred. Perform the following visualinspection monthly:Ø Inspect mounting fasteners to verify they are tight and if loose,

then tighten to the proper torque.Ø Cable connections should be inspected during maintenance

periods to ensure they are secure. Loose connections should becleaned and re-tightened as appropriate. Inspect cable sheath-ing for damage, repair or replace damaged cabling. Loose con-nections or damaged cabling are not expected and may indicateimproper routing and/or strain relieving.

Ø Inspect the Master and Tool pin blocks for any pin damage,debris or darkened pins. Refer to Pin Block Inspection and clean-ing.

Ø Inspect V-Ring seals for wear, abrasion, and cuts. If worn ordamaged, replace. Refer to Seal Replacement [} 43].



41

6.1 Pin Block Inspection and cleaningØ For a Tool Changer, if the Tool Changer is installed place the

Tool safely in the tool stand. Uncouple the Tool Changer or Util-ity Coupler to allow clear access to the Master and Tool plates.

Ø Turn off and de-energize all energized circuits (e.g. electrical,air, water, etc.).

Tool Module Pin Block Master Module Pin Block

Weld Debris

Blackened PinsNote: Pin blocks shown are for illustration purposes only

Inspect Master and Tool Pin Blocks

Ø Inspect the Master and Tool pin blocks for any debris ordarkened pins.

Ø If debris or darkened pins exist, remove debris using a vacuum,and clean using a nylon brush.

NOTEDo not use an abrasive media, cleaners, or solvents to clean thecontact pins.Using abrasive media, cleaners, or solvents will cause erosion tothe contact surface.• Clean contact surfaces with a vacuum or non-abrasive media

such as a nylon brush.



Stuck Pins Severe Pin Block Damage

Note: Pin blocks shown are forillustration purposes

only

Stuck Pin and Pin Block Damage

Ø Inspect the Master and Tool pin blocks for stuck pins or severepin block damage.

Ø If stuck pins or severe pin block damage exists, contact SCHUNKfor possible pin replacement procedures or module replace-ment.

Ø If repairs are complete, return circuits to normal operation.



43

6.2 Seal ReplacementReplace the V-Ring seal:Ø To remove the existing seal, pinch edge of seal with fingers and

gently pull the seal away from the pin block on the Master.Ø Pull the seal off the pin block.Ø To install a new seal, stretch the new seal over the shoulder of

the pin block.Ø Push the seal’s hub down against the pin block using finger tip.

Stretch seal over shoulder of pinblock and push seal hub down

against the pin block with finger tip

V-Ring SealV-Ring Seal

Pinch edge of seal withfingers and gently pullaway from pin block

V-Ring seal Replacement



6.3 DL Device Replacement ProceduresThe device replacement procedures are based on the following as-sumptions:• The topology of the PROFINET network was properly defined

with the PROFINET engineering tool.• The PROFINET controller supports automatic device replace-

ment.

6.3.1 Replace DL module with a new “out-of-the-box” DL module

Ø Remove the “old” module from the Tool Changer, refer to In-stallation [} 8] for removal procedure.

Ø Install new module on Tool Changer, refer to Installation [} 8]for installation procedure.

6.3.2 Replace DL module with an already-commissioned DL module

Tool Changer

Valve Adapter on Head Side (JR4 shown)M5 Socket Head Cap Screws

Connect to "S2"Connect to "S1"

DL12-K

RTL, Lock and UnlockSensor Connectors

Use Ledge Mounting Feature to Proberty Align Module

Power Connector

Ethernet Connector

Module Installation and Removal DL-K Control/Signal Module

Ø Remove the “old” module from the Tool Changer.Ø It may be necessary to clean the mounting surface on the JR4

valve adapter prior to installing the module in order to removeany debris that may be present.

Ø Using the ledge feature as a guide place the DL-K Control/SignalModule to the JR4 Valve Adapter mounting surface. Align thecontrol/signal module with the valve adapter using the dowelsin the bottom of the ledge feature.



45

Ø If fasteners do not have pre-applied adhesive, apply Loctite242® to the supplied M6 SHCS fasteners. Install the two M6socket head screws securing the Control/Signal Module to theValve Adapter and tighten to 4.5 - 7.9 Nm.

Ø Connect the pressure sensor and proximity sensor cables to theconnectors on the DL-K Module.

Ø Connect the Euchner Safety switch cable to the connector onthe DL-K Module.

Ø Connect the RTL1, RTL2, Lock, and Unlock sensor cables to theconnectors on the DL-K Module.

Ø Connect the 5-Pin Power cable to the connectors on the DL-KModule.

System Failure (SF) LEDEthernet (E2) LED

Tool-Side Ethernet PortReset Button(Reset to Factory Settings)Bus Failure (BF) LED

Ethernet (E1) LEDRobot-Side Ethernet Port

2x M3 Captive Head Screws

Window

Reset Button

Ø Loosen two M3 Pan Head Captive Screws and remove LED win-dow.

Ø Locate Reset Button between BF and E2 LED.Ø Use a non-conductive tool (e.g. plastic stylus) to press on the

Reset Button -> the SF LED will change from GREEN to blinkingRED, indicating that the DL6 module will clear its name and IPaddress after the next power-cycle.

Ø Re-install the LED window and tighten the M3 Pan Head CaptiveScrews.

Ø Disconnect the 5-Pin Power cable to the connectors on the DL-KModule.

Ø Connect the RJ45 Ethernet cable and the 5-Pin Power cable tothe connectors on the DL-K Module.

Ø The “new” module will automatically get the name and IP ad-dress of the old module assigned.

Ø After a few seconds it should be operating on the network.Ø The SF LED should be GREEN.

Trouble shooting


7 Trouble shootingRefer to table below for troubleshooting information:

Symptom Possible Cause / CorrectionUnit will not lock or unlock

Verify that ball bearings are moving freely. Clean and lubricate asneeded (see Tool Changer Manual Maintenance Section).Check air supply, pressure must be between 4,2 und 6,9 psi to op-erate.Check that exhaust port is properly vented (check muffler).If unlocking, Unlatch Enabled bit is high.Verify that the PROFINET network is operating and communicat-ing properly.Verify that the US1 and US2 Power present bit is HIGH.Verify that the Master and Tool are within the specified No-Touchzone when attempting to lock.Everything is OK bit is high.Verify that when the tool is in the stand the SSO1 and SSO2 inputsare high.Verify that the Safety switch is functioning and properly adjusted.Verify that the valve is operating properly.

Sensors not operatingproperly (but PROFINET is oper-ating correctly)

Verify that cables are connected correctly (Refer to the ToolChanger Manual).Ensure that the Tool Plate is securely held to the Master Plate andthat nothing is trapped between their surfaces, and that there isno air trapped in the Unlock (U) air port.

Loss of PROFINET Com-munication

Check/Replace PROFINET cabling up-stream and down-stream ofTool Changer modules.Inspect PROFINET Module contact pins for debris/wear.Verify that the US1 Power Present is connected and available (US1Power Present and US2 Power Present bits are HIGH).

No Power on the Tool-side

Verify that the Latch command has been issued by the robot.Verify that the Tool Power is On bit is HIGH.Verify that the Tool Present bit is HIGH.

Loss of Auxiliary Poweron the Tool-side

Loss of US1 (Logic) power on the Master-side will cause loss ofUS2 (Auxiliary) power to the Tool. The Arc Prevention Circuit relieson US1 power to operate.Restore US1 power to the Master to restore US2 power to theTool.

Recommended Spare Parts


47

8 Recommended Spare PartsDescription Part NumberSWO-L-DL12-K 1356677SWO-L-DL12-A 1356678

See Drawings [} 48] for spare parts directly associated with theDL-K/DL-A modules.

Drawings


9 Drawings

Drawings


49

Drawings


Drawings


51

Drawings


Drawings


53

Glossary


Glossary

Application Processor 1A board inside the DL12 module whichcontrols solenoid outputs, monitorsfunction of the unlatch valves for pres-sure and position, safety checking anddiagnostics, reports sensor status, pro-tects outputs against short circuit over-load, detects and reports status of the24 V power supply, and provides crossmonitoring of the pressure processorboard.

Application Processor 2A board inside the DL module whichcontrols Unlatch Valve 2, reports thepressure inside the valve module, andprovides cross monitoring of the Ap-plication Processor 1.

BF LEDBUS Failure LED; this is a standardProfibus status LED, similar to the Devi-ceNet Network Status LED.

Clear ErrorsAn output supplied to the SCHUNKmaster DeviceNet node to clear all ap-plicable error conditions

CL-RPCConnection Less Remote ProcedureCall.

DCPPROFINET Discovery and ConfigurationProtocol.

EOATEnd Of Arm Tool (end effector).

Error on Latch OutputAn input indicating a short circuit over-load condition exists with the LatchOutput.

Error on Unlatch OutputAn input indicating a short circuit over-load condition exists with the UnlatchOutput.

Ethernet Network SwitchEthernet network switches are elec-tronic devices that connect multipleEthernet cables to an Ethernet networkwhile directing the flow of traffic.

GSDML FileA special kind of XML-based Device De-scription File used by PROFINET

Latch (Lock)The output supplied to the SCHUNKMaster module to couple the ToolChanger.

LLDPLink Layer Discovery Protocol

Lock/Unlock Sensor FaultAn input indicating that the Locked andUnlocked inputs are high at the sametime.

LockedA proximity sensor input indicating thatthe coupling mechanism is in theLocked position.

Glossary

PROFINETA communication system for IndustrialEthernet designed and developed byPROFIBUS International.It uses somemechanisms similar to those of thePROFIBUS field bus

RTL (Ready To Lock)A proximity sensor input that senseswhen the SCHUNK Tool is in close prox-imity.

SF LEDSystem Failure LED; this is a standardProfibus status LED, similar to the Devi-ceNet Module Status LED;it has a redpart and a green part.

SNMPSimple Network Management Protocol

SSO1 and SSO2Inputs from a safety switch, which arehigh when the tool changer is in thestand.

Tool Power is OnThe “Tool Power is ON” bit is set highwhen the Arc Prevention Circuit has ac-tivated power on the tool side. If thisbit is low there will be neither Input/Logic Power nor Output power avail-able on the tool.

Tool PresentA hard connect input (sourced from theTool) indicating the Master and Tool areelectrically connected to each other.

Tool-IDAn input from the Master node report-ing the values from the Tool-ID switchon the Tool module.

Unlatch EnableIndicates it is safe to proceed with anunlatch request.

UnlockedA proximity sensor input indicating thatthe coupling mechanism is in the Un-locked position.

Unsafe UnlatchAn input indicating that an Unlatchcommand was received which wouldresult in an unsafe tool release and wastherefore not processed.

US1 Power PresentAn input indicating the presence of In-put and Logic Power (US1) at theSCHUNK master module.

US2 Power PresentAn input indicating the presence ofOutput Power (US2) at the SCHUNKmaster module.

V1Relay and V2RelayInputs from relays which should mirrorthe status of SSO1 and SSO2.


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assembly and operating manual dl12 profinet

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