product manual - robot system products · 6 m0711-1 ver. 2.4 1 introduction robot system products...

2 M0711-1 ver. 2.4

M0711-1 ver. 2.4 3

The information in this document is subject to change without prior notice and should not be regarded as an undertaking from Robot System Products AB. Robot System Products AB

assumes no responsibility for errors that may occur in this document.

Robot System Products AB bears no responsibility for damage that is incurred by the use of this document, or the software or hardware described in this document.

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without authorization. Infringement hereof will be subject to action in accordance with the applicable laws.

Further copies of this document can be obtained from Robot System Products AB at current prices.

© Robot System Products AB

Robot Systems Products AB Isolatorvägen 4 SE-721 37 Västerås Sweden

4 M0711-1 ver. 2.4

CONTENTS

1 INTRODUCTION ...................................................................................................... 6

1.1 Safety ......................................................................................................................... 7

1.1.1 General ............................................................................................................................... 7 1.1.2 Explanation of warnings ..................................................................................................... 7

1.2 Description of RSP tool changers ............................................................................... 8

1.3 Complementary Equipment ........................................................................................ 8

2 TECHNICAL SPECIFICATIONS .............................................................................. 9

2.1 Description of tool changers and tool attachments ..................................................... 9

2.1.1 Coordinate System Definition ........................................................................................... 10 2.1.2 Tool Changer TC1000-8, Article: P0701A ........................................................................ 11 2.1.3 Tool Attachment, TA1000-8. Article no: P0702A ............................................................. 12 2.1.4 Tool Changer TC1000-8E, Article: P0703A ..................................................................... 13 2.1.5 Tool Attachment, TA1000-8E. Article no: P0704A ........................................................... 15 2.1.6 Tool Changer TC1000-1EV, Article: P0764 ..................................................................... 16 2.1.7 Tool Changer TC1000-1EV, Article: P0767 ..................................................................... 18 2.1.8 Tool Attachment, TA1000-1E. Article no: P0765 ............................................................. 20 2.1.9 Pneumatic diagram Pne0206-001 for P0701A and P0703A ............................................ 21 2.1.10 Pneumatic diagram Pne0206-104 for P0764 and P0767 .............................................. 22 2.1.11 Circuit diagram E0206-001 for P0703A ......................................................................... 23 2.1.12 Circuit diagram E0206-100 for P0764 ............................................................................ 24 2.1.13 Circuit diagram E0206-104 for P0767 ............................................................................ 25 2.1.14 Circuit diagram E0206-099 for P0765 ............................................................................ 26

2.2 Options to tool changers and tool attachments ......................................................... 27

2.2.1 Robot adaptation kit ......................................................................................................... 27 2.2.2 Hose bracket kit ................................................................................................................ 27 2.2.3 Connection kits and cables .............................................................................................. 27

3 INSTALLATION ..................................................................................................... 28

3.1 Tightening torques .................................................................................................... 28

3.2 Recommended tools for installation .......................................................................... 28

3.3 Installation of tool changer on robot .......................................................................... 29

3.4 Installation of tool attachment to the gripper/tool ....................................................... 30

3.5 Recommended software function (TC1000-1EV) ...................................................... 31

3.6 Limitation of Robot movements ................................................................................ 34

3.7 Hints ......................................................................................................................... 34

4 MAINTENANCE AND SERVICE ............................................................................ 35

4.1 Maintenance chart .................................................................................................... 35

4.1.1 Required products ............................................................................................................ 35 4.1.2 Recommended tools for maintenance ............................................................................. 36 4.1.3 Wear parts ........................................................................................................................ 36 4.1.4 Activities and intervals on tool changer ............................................................................ 37 4.1.5 Activities and intervals on tool attachment ....................................................................... 37

M0711-1 ver. 2.4 5

4.2 Visual inspection ...................................................................................................... 38

4.2.1 Inspection of the tool changer .......................................................................................... 38 4.2.2 Inspection of the tool attachment ..................................................................................... 38

4.3 Cleaning ................................................................................................................... 39

4.3.1 Cleaning and lubrication of tool changer .......................................................................... 39 4.3.2 Cleaning and lubrication of tool attachment ..................................................................... 41

4.4 Replacement of wear parts ....................................................................................... 42

4.4.1 Replacement of signal pins (TC1000-8E and TC1000-1EV only).................................... 42 4.4.2 Replacement of air coupling (TC1000-1EV and TA1000-1E) ......................................... 42 4.4.3 Replacement of air sealing ............................................................................................... 43 4.4.4 Replacement of O-ring ..................................................................................................... 43 4.4.5 Replacement of guide pins (TC1000) .............................................................................. 44 4.4.6 Replacement of valve unit (TC1000-1EV only) ................................................................ 44

4.5 Complete service of tool changer ............................................................................. 45

4.6 Replacement of tool changer .................................................................................... 46

4.7 Manual unlocking of tool changer (TC1000-1EV only) .............................................. 48

4.7.1 Manual unlocking when control system failed .................................................................. 48 4.7.2 Manual unlocking when valve unit failed working ............................................................ 49

5 SPARE PARTS ..................................................................................................... 52

5.1 Part list for tool changer P0701A and P0703A .......................................................... 52

5.2 Part list for tool changer P0764 ................................................................................ 54

5.3 Part list for tool changer P0767 ................................................................................ 56

5.4 Part list for tool attachment P0702A and P0704A ..................................................... 58

5.5 Part list for tool attachment P0765 ............................................................................ 59

6 DISPOSAL AND RECYCLING .............................................................................. 60

6 M0711-1 ver. 2.4

1 INTRODUCTION

Robot System Products is a front-rank provider of peripheral products for high performance robot applications. We provide complete system solutions for your robot installations, aiming to improve your productivity with the most reliable and cost-effective tooling on the market. Continuously we explore emerging technologies, working with leading edge design.

Robot System Products has a wide range of standard robot peripheral products:

• Tool changers

• Swivels

• Swivels with integrated tool changers

• Grippers

• Hose Packages

• Valve units

• Tool systems

• Tool stands

Robot System Products’ tool changers are constructed to maximize the flexibility and reliability of your robot fleet. Through our patented locking device TrueConnect™ robustness and high safety are combined with low weight and compactness. With our swivels you can provide compressed air, water, electrical and data signals as well as weld and servo power to your tools with robot motion capabilities fully maintained. Our swivels with tool changers unites the TrueConnect™ tool changing mechanism with our swivel technology, combining the best out of two technologies.

Robot System Products’ product lines are available for all major robot brands and come with complete documentation. 3D-models for simulation are available for download at: www.rsp.eu.com

http://www.rsp.eu.com/

M0711-1 ver. 2.4 7

1.1 Safety

1.1.1 General

The integrator installing the tool changer into the system must follow the safety demands stated in standards and provisions applicable in the country where the tool changer system is installed. The products are all prepared for CE-certification.

The user of the Robot System Products tool changer is responsible that law and directives applicable in respective countries, with regards to safety, are adhered to. The user is also responsible to guarantee that all safety devices are installed correctly.

WARNING! Never carry out service work on a robot that has not been taken out of operation. See safety information for the robot.

WARNING! Only perform work on grippers or tools attached to the tool changer if the air pressure is safely switched off.

WARNING! Be aware that tool changers and tool attachments are heavy and may cause personal injury and equipment damage if dropped.

NOTE! The tool changer shall always be in locked position, also when empty, to avoid unexpected locking if air pressure is lost.

1.1.2 Explanation of warnings

The warnings in this document are specific to the products in this manual. It is expected that the user also pay attention to certain notifications from the robot manufacturer and/or the manufacturers of other components used in the installation.

WARNING! The warning sign will make you aware that a situation could result in potential serious injury or damage to equipment.

NOTE! The note sign will alert you about something important to consider.

8 M0711-1 ver. 2.4

1.2 Description of RSP tool changers

Our tool changers enable robots to handle and switch between multiple tools. They are built to ensure reliable and smooth operation, being compact with low weight and robust design and incorporating many safety features. Depending on model and options, electrical signals, weld and servo power, data, water and compressed air are transferred from the robot side to the tool.

The patented locking device TrueConnect™ has a minimum of play and gives a practically, through the lifespan, absolute positioning repeatability. The principle behind the locking mechanism is the uniform distribution of load obtained by pressing looking balls into spherical grooves. In consequence, substantially larger positional tolerances are accepted during docking.

1.3 Complementary Equipment

Complementary equipment is described in separate documents.

Article Note

Valve unit Mounted at the rear of the upper arm. Shuts off the air

automatically during tool changing.

Cable and Hose Package Complete packages for most robots on the market ready to be

mounted without any modifications.

Connection kits In order to make electrical installation easier, connection kits

are available for the tool changer.

3D-models Available in Solid Works® and STEP-format.

M0711-1 ver. 2.4 9

2 TECHNICAL SPECIFICATIONS

2.1 Description of tool changers and tool attachments

This document presents the Robot System Products TC1000-8 and TC1000-8E tool changers including tool attachments dedicated for material handling. Likewise presented are adaptation kits, connection kits to facilitate electrical installation and a tool stand kit.

The tool changer TC1000-8 transfers compressed air to the tool. It can be equipped with transfer of electrical signals, via spring loaded signal pins, to the tool attachment. The electrical version is designated ’E’. The tool changers TC1000-8 and TC1000-8E cannot transport fluids.

The spring loaded signal pins of TC1000-8E are placed and protected at the centre of the tool changer. The contact surface of the tool attachment and the signal pins are not in connection until at the very end of the docking cycle when the tool attachment is already properly aligned. This guarantees a minimum of wear of the contact surfaces.

The electrical unit is primarily intended for transfer of sensor signals from grippers. In addition it can be used for checking the presence and identifying tools by using signal jumpers and binary coding of signals on the tool attachment.

For other bolt circles adaptation plates between the tool changer and the turning disc on the robot may be needed. Such adaptation plates are available from RSP.

TC1000-8E

10 M0711-1 ver. 2.4

2.1.1 Coordinate System Definition

A tool changer adds load to the robot. If the arm and tool loads are not stated correctly during programming the behaviour of the robot and the wear of the equipment will be affected. Information about weight and centre of gravity can, in accordance with the co-ordinate system stated below, be found in the technical specification tables of the tool changer.

NOTE!

For the tool changer and tool changer with tool attachment, the origo is in the centre of the robot mounting flange.

M0711-1 ver. 2.4 11

2.1.2 Tool Changer TC1000-8, Article: P0701A

Tool changer TC1000-8 transfers 8 pneumatic channels to the tool attachment. To be used together with tool attachment P0702A.

Technical data

Working temperature +10°C−+60°C

Bolt pattern ISO9409-1-200-12-M16

Maximum tool load

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±10 000 Nm

Weight and centre of gravity

TC1000-8

With TA1000-8

Weight

Mass centre X / Y / Z

Weight


19.7 kg

-0.2 / -0.1 / 66.0 mm

27.6 kg

0.0 / -0.1 / 82.7 mm

Air ducts Pneumatic diagram

Total number of ducts

Dedicated air ducts

Max air pressure

Air flow

Connections, robot side

Air quality

Pne0206-001 (see section 2.1.9)

10

Open TC marked Open (6−10 bar)

Close TC marked Close (6−10 bar)

10 bar

2 400 l/min

8 x G 1/2"

2 x G 1/8" (Open, Close)

Oil-clean and waterless filtered air, with max 25µm

particle content

12 M0711-1 ver. 2.4

2.1.3 Tool Attachment, TA1000-8. Article no: P0702A

Tool attachment TA 1000-8 transfers 8 pneumatic channels to the tool. To be used together with tool changer P0701A.

Technical data



Weight 7.9 kg

Maximum tool load

(M16-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±10 000 Nm

Maximum tool load

(M14-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±7 500 Nm

Air ducts Number of ducts

Connection, tool side

8

G 1/2”

Note! Tools can be mounted to the tool attachment using twelve M16-screws, alternatively the tool attachment can be mounted to the tool using twelve M14-screws.

M0711-1 ver. 2.4 13

2.1.4 Tool Changer TC1000-8E, Article: P0703A

Tool changer TC1000-8E transfers 8 pneumatic channels and 20 electrical signals to the tool attachment. To be used together with tool attachment P0704A.

14 M0711-1 ver. 2.4

Technical data



Maximum tool load

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±10 000 Nm


TC1000-8

With TA1000-8

Weight


Weight


19.8 kg

-0.2 / -0.1 / 66.0 mm

27.7 kg

-0.2 / -0.1 / 82.6 mm


Total number of ducts

Dedicated air ducts

Max air pressure

Air flow

Connections, robot side

Air quality


10

Open TC marked Open (6−10 bar)

Close TC marked Close (6−10 bar)

10 bar

2 400 l/min

8 x G 1/2"

2 x G 1/8" (Open, Close)


particle content

Electric channels Circuit diagram

Total number of signals

Dedicated signals

Max current

Max voltage

Connections

E0206C-001 (see section 2.1.11)

21

2 x 24 V

2 x 0 V

TC Uncoupled (+24V)

TC Coupled (+24V)

2 A

60 V

3-module Harting 10B

M0711-1 ver. 2.4 15

2.1.5 Tool Attachment, TA1000-8E. Article no: P0704A

Tool attachment TA 100-8E transfers 8 pneumatic channels and 19 electrical signals to the tool. To be used together with tool changer P0703A.

Technical data



Weight 7.9 kg

Maximum tool load

(M16-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±10 000 Nm

Maximum tool load

(M14-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±7 500 Nm

Air ducts Number of ducts


8

G 1/2”

Electrical signals Circuit diagram

Total number of signals


E0206C-001 (see section 2.1.11)

19


Note! Tools can be mounted to the tool attachment using twelve M16-screws, alternatively the tool attachment can be mounted to the tool using twelve M14-screws.

16 M0711-1 ver. 2.4

2.1.6 Tool Changer TC1000-1EV, Article: P0764

Tool changer TC1000-1EV transfers 1 pneumatic channel with automatic shut off, 8 pneumatic channels without automatic shut off, 4 bus channels and 10 electrical signals to the tool attachment. To be used together with tool attachment P0765.

M0711-1 ver. 2.4 17

Technical data



Maximum tool load

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±10 000 Nm


TC1000-1EV

With TA1000-EV

Weight


Weight


22.7 kg

13.6 / 3.1 / 63.5 mm

32.7 kg

18.1 / 1.3 / 81.3 mm


Number of ducts

Dedicated air ducts

Max air pressure

Air flow

Connection, robot side

Air quality


9 totally

1 for tool change function (6-10 bar)

10 bar

2 000 l/min

G 1/2"


particle content


Number of signals

Dedicated signals

Max current

Max voltage

Connections

E0206-100 (see section 2.1.12)

16 totally

1 x 24 V

1 x 0 V

TC Opened (+24V)

TC Coupled (+24V)

Open TC

Close TC

2 A

60 V


Bus

Number of pins

Connections

4 total

M12 D-code (Profinet)

18 M0711-1 ver. 2.4

2.1.7 Tool Changer TC1000-1EV, Article: P0767

Tool changer TC1000-1EV transfers 1 pneumatic channel with automatic shut off, 8 pneumatic channels without automatic shut off, 4 bus channels and 10 electrical signals to the tool attachment. To be used together with tool attachment P0765.

M0711-1 ver. 2.4 19

Technical data



Maximum tool load

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±10 000 Nm


TC1000-1EV

With TA1000-EV

Weight


Weight


22.7 kg

13.6 / 2.8 / 63.4 mm

32.7 kg

18.1 / 1.1 / 81.2 mm


Number of ducts

Dedicated air ducts

Max air pressure

Air flow

Connection, robot side

Air quality


9 totally

1 for tool change function (6-10 bar)

10 bar

2 000 l/min

G 1/2"


particle content


Number of signals

Dedicated signals

Max current

Max voltage

Connections

E0206-104 (see section 2.1.13)

16 totally

1 x 24 V

1 x 0 V

TC Opened (+24V)

TC Coupled (+24V)

Open TC

Close TC

2 A

60 V

Souriau UT0W01626PH

Bus

Number of pins

Connections

4 total


20 M0711-1 ver. 2.4

2.1.8 Tool Attachment, TA1000-1E. Article no: P0765

Tool attachment TA 100-1E transfers 1 pneumatic channel with automatic shut off, 8 pneumatic channels without automatic shut off, 4 bus channels and 10 electrical signals to the tool. To be used together with tool changer P0764 and P0767.

Technical data



Weight 10.0 kg

Maximum tool load

(M16-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±10 000 Nm

±10 000 Nm

Maximum tool load

(M14-screws)

Fz (static)

Mx/My (dynamic)

Mz (dynamic)

±10 000 N

±7 500 Nm

±7 500 Nm

Air ducts Number of air ducts


9 totally

G 1/2”

Electrical signals Circuit diagram

Number of signals


E0206-099 (see section 2.1.14)

10 totally


Bus

Number of pins

Connections

4 total


Note! Tools can be mounted to the tool attachment using twelve M16-screws,

alternatively the tool attachment can be mounted to the tool using twelve M14-screws.

M0711-1 ver. 2.4 21

2.1.9 Pneumatic diagram Pne0206-001 for P0701A and P0703A

22 M0711-1 ver. 2.4

2.1.10 Pneumatic diagram Pne0206-104 for P0764 and P0767

M0711-1 ver. 2.4 23

2.1.11 Circuit diagram E0206-001 for P0703A

24 M0711-1 ver. 2.4

2.1.12 Circuit diagram E0206-100 for P0764

M0711-1 ver. 2.4 25


26 M0711-1 ver. 2.4


M0711-1 ver. 2.4 27

2.2 Options to tool changers and tool attachments

2.2.1 Robot adaptation kit

The flange of the tool changer shaft has fastening holes in accordance with ISO9409-1-200-12-M16. Adaptation plates are available for other bolt circles, they are mounted between the tool changer and the robot flange. The order number is customer specific, depending on the robot.

Example of robot adaptation kit (P6913)

2.2.2 Hose bracket kit

Hose bracket kits are available for certain robot models and bolt circles. The order number is customer specific.

Example of hose bracket kit (P0769)

2.2.3 Connection kits and cables

Item Description Part number Pcs

1 Electrical connection kit for P0703 and P0764 (Female 3-

module Harting):

P8009 1

1 Electrical connection kit for P0704 (23P Souriou), straight: P8001 1

1 Electrical connection kit for P0704 (23P Souriou), angled: P8001-1 1

1 Cable kit for P0704, (23P Souriou and cable 2 meter, free end) P8112-20 1

1 Electrical connection kit for P0767 (26S compact Souriou): P8025 1

1 Electrical connection kit for P0765 (Male 3-module Harting): P8011 1

28 M0711-1 ver. 2.4

3 INSTALLATION

3.1 Tightening torques

Tightening torques for mounting (screw class 8.8)

Dimension Torque

M4 3 Nm

M5 6 Nm

M6 10 Nm

M8 24 Nm

M10 47 Nm

M12 82 Nm

M16 200 Nm

3.2 Recommended tools for installation

Tools Applications

Complete set of Allen keys For dismounting and mounting.

Torque wrench For all socket head cap screws

Torx key For dismounting and mounting

M0711-1 ver. 2.4 29

3.3 Installation of tool changer on robot

Action Note

1 Safety Read the safety section (1.1)

2 Service position Place the robot in service position

3 Power off Switch the power off and lock the

circuit breaker

NOTE! Read the safety chapter for

the robot.

4 Mount guide pins

Press the enclosed guide pins into

the robot flange.

Alternatively, if adaptation plate is

used:

Mount the adaptation plate on the

robot flange (see tightening torques

above). Press the enclosed guide

pins into the adaptation plate.

5 Fit tool changer

Lift the tool changer to the robot

flange (or adaptation plate). Make

sure that the guide pin is fitted to the

guide hole in the tool changer.

WARNING! The tool changer may

cause personal injury and equipment

damage if dropped.

6 Mount tool changer

Fit the tool changer with the enclosed

screws. Use an Allen key for

tightening (see tightening torques

above).

7 Connect air hoses Connect air hoses to the hose fittings

and make sure that they are tightly

attached with securing straps.

NOTE! Pneumatic diagrams are

found in sections 2.1.9 and 2.1.10.

8 Connect signals Connect electrical connectors

9 Power on Unlock circuit breaker and switch

power on.

30 M0711-1 ver. 2.4

3.4 Installation of tool attachment to the gripper/tool

Action Note

1 Safety Read the safety section (1.1).

2 Mount guide pins

Press two guide pins into the hole on the tool.

3 Fit the tool attachment

Lift and fit the tool attachment, using the guide

pins, into its appropriate guide hole.

4 Mount the tool attachment

Mount the tool attachment using a torque

wrench with either M14 or M16 screws:

o M14-screws are put in from the tool

attachment side to threaded M14-holes

in the gripper/tool.

o M16-screws are put in from the

gripper/tool side to the threaded M16-

holes in the tool attachment.

See tightening torques above.

5 Connect air hoses Connect the air hoses according to markings.

NOTE! Pneumatic diagrams are found in

sections 2.1.9 and 2.1.10.

6 Connect signal

Connect signal contact to the gripper/tool.

M0711-1 ver. 2.4 31

3.5 Recommended software function (TC1000-1EV)

The risk assessment for this tool changer (locking control function and monitoring) requires that the software logic described below is adhered to by the system integrator installing the tool changer.

Valve control with two monostable 3/2-valves

o The right valve, called TC Close, will in passive position allow the air pressure to move

the piston in the direction locking the tool. In active position the air will be allowed to be evacuated from the cylinder without impacting the piston.

o The left valve, called TC Open, will in active position let the air pressure move the piston in the direction unlocking the tool. In passive position the air will be evacuated from this side of the cylinder, allowing the tool to be locked.

o As a consequence both valves must be activated to open the tool changer.

o The “Open TC 2” signal shall be interlocked with both a tool attachment (TA) present jumper and a tool stand switch indicating the following safe conditions for opening the tool changer:

* When there is no tool attachment mounted, the tool changer can be opened.

* When there is a tool attachment mounted, it is only possible to open the tool changer when it is positioned in the tool stand.

Piston status monitoring sensor

There are two sensors supervising the location of the piston.

o Signal “TC Opened” is high when the piston is in open position.

o Signal “TC Coupled” is high when the TC is connected to the TA present jumper.

V1.14 TC Open valve (NC)

V1.12 TC Close valve (NO)

Signal “TC Opened”

“Open TC 2” signal “Open TC 1” signal

32 M0711-1 ver. 2.4

Signal logic for picking up a tool

o Open the tool changer (set signals “Open TC 1” and “Open TC 2” to high).

o The signal “TC Opened” should be high and “TC Coupled” low. This means that the tool changer is opened and that the tool changer is allowed to move to the tool attachment.

o When the tool changer is in position for picking up the tool attachment, the tool changer should be closed (set signals “Open TC 1” and “Open TC 2” low).

o When signal “TC Coupled” is high and “TC Opened” low the tool changer is connected to the tool attachment and the tool changer can start to move.

o When the closed tool changer has been lifted 10mm, the signal from the switch or sensor mounted on the tool stand should be checked to confirm that the tool remains in the tool changer.

Set “Open TC 1” and “Open TC 2” to high

Is “TC Opened” high and “TC Coupled” low?

Move robot to tool stand

Is robot in position in tool stand?

Reset “Open TC 1” and “Open TC 2”

Is “TC Coupled” high and “TC Opened” low?

Move robot up 10 mm

Is tool stand indicating “No tool in stand”?

Continue work cycle

Signal logic for leaving a tool in tool stand

o Opening of tool changer should only be possible when tool is positioned in a tool stand. A switch or sensor mounted on the tool stand should give a signal that allows the tool changer to open.

o Set signals “Open TC 1” and “Open TC 2” to high when the tool attachment is positioned in the tool stand.

o When signal “TC Opened” is high and “TC Coupled” low, the tool changer is opened and the tool changer can start to move.

o When the opened tool changer has been lifted 10mm, the signal from the switch or sensor mounted on the tool stand should be checked to confirm that the tool remains in the tool stand.

No

No

Wait

Yes

Yes

No

Yes

No

Yes

Wait

Wait

Stop

M0711-1 ver. 2.4 33

Move the robot to the tool stand position

Is robot in position in tool stand?

Is tool stand indicating “Tool in stand”?

Set “Open TC 1” and “Open TC 2” to high

Is “TC Opened” high and “TC Coupled” low?

Move robot up 10 mm

Is tool stand indicating “No tool in stand”?

Continue work cycle

Breaking-conditions

o If signal “TC Coupled” disappears, when tool attachment is in tool changer, the robot should be stopped.

o If signal “TC Opened” disappears, when tool changer is going to pick up the tool attachment, the robot should be stopped.

No

No

Yes

Yes

Yes

No

No

Wait Yes

Wait

Wait

Stop

34 M0711-1 ver. 2.4

3.6 Limitation of Robot movements

There can be some limitations on the movement of axis 5 for some robot models. Contact Robot System Products for more information.

3.7 Hints

Programming

The following will ensure a correct docking position.

Action

1 Attach a spare tool attachment (without the external air module) to the tool changer.

2 Position the spare tool attachment above the tool attachment that is mounted on the

tool.

3 The right position is found when the tool attachments are parallel, centered and the

engraved arrows are on the same line.

4 Save the position. The robot can move to this position with high speed.

5 Dismount the spare tool attachment.

6 Go back to the saved position and move the tool changer (in axis 6 direction) the

remaining distance to the tool attachment (mounted on the tool).

7 Save the position. The robot should move to this position with low speed.

Sparking

WARNING! Electrical signals and power must be switched off and disconnected when docking the tool attachment. This is to prevent sparking between signal pins and tool attachment.

Electrical installation

Connection kits for the tool changer and tool attachment are available (see section 2.2.3).

Tool stand

NOTE! To guarantee reliability and a long service-life for the tool changer, the tool stand must be stable, both in terms of its design and attachment.

Tool Identification

Jumpers on signals at the tool attachment can be used to give information about which tool attachment that is docked in the tool changer.

M0711-1 ver. 2.4 35

4 MAINTENANCE AND SERVICE

4.1 Maintenance chart

The tool changer and tool attachment must be maintained regularly to ensure proper function. The specified intervals are approximate and valid under normal conditions. Under extreme conditions, such as dirty environments or extreme robot movements, the intervals should be shortened.

Consider the table as a guide and update as your production experience of each system increases.

WARNING! Risk of getting squeezed between piston and ball holder when the piston is taking closed position.

NOTE! Only perform work on grippers or tools attached to the tool changer if the air pressure is safely switched off.

NOTE! Tool changers must only be dismantled and repaired by Robot System Products during the warranty period. Otherwise the warranty will not be valid.

4.1.1 Required products

Product Specification Note

Grease,

3HXG1000-413

Magnalube-G, Teflon

grease

Sealing and air couplings.

Grease I0876 MolykoteBR2Plus Locking balls and guide pins.

Cleaning agent Denatured alcohol or

similar

Signal pins at tool changer and

signal contacts at tool

attachment.

Cleaning agent Denatured alcohol or

similar

For tool changer and tool

attachment.

Cloth Lint free cloth For cleaning.

NOTE! Chemical resistance protective gloves are recommended when using grease or cleaning agents such as denatured alcohol. Safety goggles are recommended when working with cleaning agents such as denatured alcohol.

36 M0711-1 ver. 2.4

4.1.2 Recommended tools for maintenance

Tools Applications

Complete set of Allen keys For dismounting and mounting.

Pair of pliers For dismounting the signal pins.

Screw driver For removing the air sealings.

Plastic mallet For mounting the air sealings.

27mm socket wrench For dismounting and mounting air coupling.

13mm open end wrench For dismounting and mounting the guide pins.

Torque wrench For all socket head cap screws.

4.1.3 Wear parts

Wear parts should be replaced before considerable damage occurs. The interval depends on the number of tool changes and its working environment. Generally, the more contaminated environment, the closer maintenance intervals.

The following parts are considered as wear parts:

o Air sealings

o Air couplings

o Signal pins

o O-rings

o X-rings

o Guide pins

M0711-1 ver. 2.4 37

4.1.4 Activities and intervals on tool changer

Equipment Maintenance

activity

Interval Description

Tool changer Inspection 2 weeks Visual inspection of tool changer (see section

4.2.1).

Tool changer Cleaning 1 month Cleaning of tool changer, interval depending on

the environment (see section 4.3.1).

Guide pins Clean and

lubricate

1 month Wipe the pins clean and add new lubrication (see

section 4.3.1).

Air couplings Clean and

lubricate

1 month Wipe the couplings clean and add new lubrication

(see section 4.3.1).

Signal pins Replace 18

months

Wear parts, interval is depending on number of

tool changes and the environment (see section

4.4.1).

Air couplings Replace 18

months



4.4.2).

Air sealings Replace 18

months



4.4.3).

O-ring Replace 18

months



4.4.4).

Guide pins Replace 18

months

Wear parts, interval is depending on the docking

position, number of tool changes and the

environment (see section 4.4.5).

Tool changer Service 5 years Complete service, to be done by Robot System

Products (see section 4.5).

4.1.5 Activities and intervals on tool attachment

Equipment Maintenance

activity

Interval Description

Tool attachment Inspection 2 weeks Visual inspection of tool attachment (see section

4.2.2).

Tool attachment Cleaning 1 months Cleaning of tool attachment, interval depending

on the environment (see section 4.3.2).

Air couplings Clean and

lubricate

1 months Wipe the couplings clean and add new lubrication


Air couplings Replace 18

months

Wear and tear parts, interval is depending on

number of tool changes and the environment


38 M0711-1 ver. 2.4

4.2 Visual inspection

4.2.1 Inspection of the tool changer

Visually check the following:

Check Note

Air sealings Not worn, damaged or dirty

Signal pins Not damaged or dirty

O-ring Not damaged or dirty

Air coupling Not damaged or dirty

Guide pins No wear

Cables No wear, no damage

All parts No wear

All parts No damage

All parts No dirt

4.2.2 Inspection of the tool attachment

Visually check the following:

Check Note

Surface for air sealing Not damaged or dirty

Signal contact surface Not worn or dirty

Air coupling Not damaged or dirty

Holes for guide pins No wear

Cables Not squeezed or damaged

All parts No wear

All parts No damage

All parts No dirt

M0711-1 ver. 2.4 39

4.3 Cleaning

4.3.1 Cleaning and lubrication of tool changer

Action Note

1 Clean locking balls

Wipe the locking balls with a cloth.

2 Check locking balls

Check each ball to make sure it

moves freely. Additional cleaning

may be necessary to free any

balls stuck in place.

3 Lubricate looking balls

Apply a small amount of grease

(Molykote BR2Plus) on the locking

balls.

NOTE! It is important that this is

done or there might else be a risk

that the tool attachment jams.

4 Clean water/air-couplings

Wipe the couplings with a cloth.


(Magnalube-G) on the contact

surfaces.

40 M0711-1 ver. 2.4

5 Clean signal pins

Clean only the contact surfaces!

NOTE!

Avoid cleaning solvent in the

spring housing.

6 Clean guide pins

Wipe the guide pins with a cloth.


(Molykote BR2Plus) on the guide

pins.

7 General cleaning Clean the swivel with tool changer

in general.

M0711-1 ver. 2.4 41

4.3.2 Cleaning and lubrication of tool attachment

Action Note

1 Clean the grooves

Clean the grooves for the locking

balls and apply a small amount of

grease (Molykote BR2Plus).

NOTE! It is important that this is

done or else there is a risk that

the tool attachment jams.

2 Clean water/air-couplings

Wipe the couplings with a cloth.


(Magnalube-G) on the contact

surfaces.

3 Clean surface of signal contact

Wipe the contact surface with a

cloth.

4 Lubricate guide pin bushings

Apply small amount of grease

(Molykote BR2Plus) inside the

guide pin bushings.

42 M0711-1 ver. 2.4

4.4 Replacement of wear parts

4.4.1 Replacement of signal pins (TC1000-8E and TC1000-1EV only)

Replace a signal pin when the spring jams, or become bent.

Action Note

1 Power off Switch the power off and lock the circuit

breaker.

2 Remove signal pins

Pull out the signal pins with a pair of pliers.

NOTE! There are totally 20 signal pins.

3 Replace signal pins

Fit the new signal pins by pushing them

into the sleeves.

NOTE! The signal pins must be

individually pressed fully into the sleeves

using a small screw driver!

4 Power on Unlock the circuit breaker and switch the

power on.

4.4.2 Replacement of air coupling (TC1000-1EV and TA1000-1E)

Action Note

1 Remove air coupling

Remove the air coupling with a 27mm

socket wrench.

2 Clean surface Clean the surface around the air

coupling.

3 Mount new air coupling Put small amount of grease (Magnalube-

G) on the water/air contact surface.

NOTE! Tightening torque 20Nm.

M0711-1 ver. 2.4 43

4.4.3 Replacement of air sealing

4.4.4 Replacement of O-ring

Replace O-ring when it starts to wear.

Action Note

1 Remove O-ring

Remove the O-ring on the ball

holder at the tool changer.

2 Clean surface Clean the surface at the O-ring

location.

3 Apply grease Add a small amount of grease

(Magnalube-G) on the new O-

ring.

4 Mount new O-ring

Action Note

1 Remove air sealings

Remove the air sealings with a

screw driver.

NOTE! There are totally 8 air

sealings.

2 Clean sealing holes Wipe clean the sealing holes.

Remove all remaining parts of

the air sealings.

3 Tap in air sealing Tap in the new air sealings with

a plastic mallet.

44 M0711-1 ver. 2.4

4.4.5 Replacement of guide pins (TC1000)

Action Note

1 Clean area Clean the area around the

guide pins.

2

Dismount guide pins

Dismount the guide pins.

NOTE! Use a 13mm open end

wrench.

3 Mount the new guide pins

4.4.6 Replacement of valve unit (TC1000-1EV only)

Action Note

2 Release screws

Release and remove the two screws

holding the cover.

3 Remove cover

Remove the cover from the integrated

valve.

M0711-1 ver. 2.4 45

4 Remove valve unit

Remove the two screws holding the valve

unit and remove the unit.

5 Mount new valve unit

Replace the valve unit and mount with the

two screws.

NOTE! Maximum tightening torques 2 Nm!

6 Mount cover

Mount the cover of the integrated valve.

7 Fasten screws

Fasten the two screws holding the cover.

4.5 Complete service of tool changer

We recommend a complete service on tool changers to be carried out every 5 years. This will ensure proper function and increase the lifespan of the tool changer considerably. We further recommend that the maintenance shall be carried out by qualified RSP personnel. Please contact us for a quotation.

The 5 year tool changer service at Robot System Products includes inspection and cleaning of the full unit, replacement of all wear parts including sealings and signal pins.

46 M0711-1 ver. 2.4

4.6 Replacement of tool changer

Recommended tools

Tools Applications

Complete set of Allen keys For dismounting and mounting of tool changer

Torque wrench For all socket head cap screws

Action Note

1 Safety Read the safety section (1.1).

2 Dismount tool Leave tool, with tool attachment

mounted, in tool stand.

3 Service position Place the robot in service position.

NOTE! The tool change function

shall be in locked position.

4 Power off Switch the power off and lock the

circuit breaker.

NOTE! Read the safety chapter for

the robot.

5 Pneumatic air off NOTE! The pressure in the

pneumatic system must be released

before dismounting begins.

6 Release electrical connectors

Dismount the air hoses from the tool

changer.

NOTE! Make sure that no dirt will

enter into the air hoses.

7 Dismount air hoses (TC1000-1EV only)

Dismount the air hoses from the tool

changer.

NOTE! Make sure that no dirt will

enter into the air hoses.

M0711-1 ver. 2.4 47

8 Remove screws

Remove the screws holding the tool

changer to the robot flange.

WARNING! The tool changer is

heavy and may cause personal

injury and equipment damage if

dropped.

NOTE! Be careful not to damage

the signal pins at the tool side of the

tool changer.

NOTE! A guide pin is mounted

between the tool changer and the

robot flange.

9 Dismount tool changer

10 Clean the robot flange

11 Mount replacement tool changer

Follow instructions in section 3.3.

48 M0711-1 ver. 2.4

4.7 Manual unlocking of tool changer (TC1000-1EV only)

In conjunction with faults where the automation or control system stops working, it may be necessary to manually operate the main cylinder of the tool changer to release the tool.

WARNING! Do not remove the hoses before parking the tool in a tool stand or on a table. If the locking function of the tool changer is released, the tool may drop and cause serious personal injury and equipment damage.

4.7.1 Manual unlocking when control system failed

Action Note

1 Safety Read the safety section (1.1) and

the safety chapter for the robot.

2 Park the tool Park the tool on a tool stand or

table.

NOTE! Make sure that the tool

attachment and tool are fully

supported by the tool stand or

table.

3 Pneumatic air on Air system pressure shall be on.

4 Release tool attachment

Press both manual control

switches at the same time, with

thin shaft screwdrivers or similar,

at the rear of the valve unit.

WARNING! The tool will be

immediately released when the

two switches are pressed. As

the tool and tool attachment is

heavy it may cause personal

injury and equipment damage if

dropped.

5 Remove tool attachment Move the robot (in manual mode)

in order to remove the tool

changer from the tool

attachment.

NOTE! Both manual control

switches have to be pressed

during the movement of the

robot.

WARNING! When the control

switches are released the tool

changer will immediately go to

locked position.

M0711-1 ver. 2.4 49

4.7.2 Manual unlocking when valve unit failed working

Action Note

1 Safety Read the safety section (1.1) and

the safety chapter for the robot.

2 Park the tool Park the tool on a tool stand or

table.

NOTE! Make sure that the tool

attachment and tool are fully

supported by a tool stand or table

3 Release connectors Release connectors from the tool

changer in order to prevent short

circuit and sparking.

4 Pneumatic air off Relieve the system pressure.

NOTE! The pressure in the

pneumatic system must be fully

released before dismounting

begins.

5 Remove cover

Release and remove the two M5-

screws and the cover of the

integrated valve.

6 Remove valve

Release and remove the two M6-

screws and the valve.


the O-rings at the rear of the

connection plate.

7 Remove valve adapter

Release and remove the four M5-

screws and the valve adapter.


the O-rings at the rear of the valve

adapter.

50 M0711-1 ver. 2.4

8 Insert fitting

Insert a hose fitting (G1/8” thread)

in the hole marked “OPEN”.

9 Release tool attachment Release the tool attachment by

compressing air (6-10 bar) in the

air duct “OPEN”. The exhaust air

will be evacuated via the duct

“CLOSE”.

WARNING! The tool will be

released when “OPEN” is

pressurized. Be careful! As the

tool and tool attachment is heavy

it may cause personal injury and

equipment damage if dropped.

10 Remove tool attachment Move the robot (in manual mode)

in order to remove the tool changer

from the tool attachment.

NOTE! The air duct “OPEN” has to

be maintained pressurized during

movement of the robot.

WARNING! Be careful! As the tool

and tool attachment is heavy it

may cause personal injury and

equipment damage if dropped.

11 Dismount hose fitting

Release pressure and dismount

the hose fitting from the air duct

“OPEN”.

WARNING! When pressure is

released the tool changer will

immediately go to locked position.

M0711-1 ver. 2.4 51

12 Mount valve adapter


(Magnalube-G) on the O-rings at

the rear of the valve adapter and

mount with four M5-screws.

13 Mount valve

Put a small amount of grease

(Magnalube-G) on the O-rings at

the connection plate and mount

the valve using two M6-screws.

NOTE! Replace valve if broken.

14 Mount Cover

Mount the cover for the integrated

valve using two M5-screws.

52 M0711-1 ver. 2.4

5 SPARE PARTS

5.1 Part list for tool changer P0701A and P0703A

M0711-1 ver. 2.4 53

Item Description Part number Wear parts Pcs

1 Securing screw MC6S M16x100 12

2 Guide pin P0206-069 X 2

3 Spring P0206-010 1

4 Air Sealings P0206-005 X 8

5 O-ring I0245 X 1

6 Locking ball 2213874-20 12

7 X-ring I0242 1

8 X-ring I0243 1

9 O-ring I0244 1

10 X-ring I0246 1

11 O-ring I0245 1

12 Cover P0206-003B 1

13 Screw 21212519-289 4

54 M0711-1 ver. 2.4

5.2 Part list for tool changer P0764

M0711-1 ver. 2.4 55




3 O-ring I0245 X 3

4 X-ring I0242 1

5 X-ring I0243 1

6 O-ring I0244 1

7 Screw MC6S 4x10 4

8 Sensor I0055 1

9 O-ring I0165 2

10 Valve unit I0449 1

11 Air coupling I0202 1


13 Locking ball 2213874-20 12

14 Signal pin I0042 X 20

15 X-ring I0246 1

16 O-ring I0024 8

17 Connector Harting and M12 D-code P8021 1

18 Guide pin 21112021-512 2

The guide pins, signal pins, air couplings, O-rings, X-rings and air sealings are also considered as wear parts, see section 4.1.3.

56 M0711-1 ver. 2.4

5.3 Part list for tool changer P0767

M0711-1 ver. 2.4 57




3 O-ring I0245 X 3

4 X-ring I0242 1

5 X-ring I0243 1

6 O-ring I0244 1

7 Screw MC6S 4x10 4

8 Sensor I0055 1

9 O-ring I0165 2

10 Valve unit I0449 1



13 Locking ball 2213874-20 12

14 Signal pin I0042 X 20

15 X-ring I0246 1

16 O-ring I0024 8

17 Connector Souriau and M12 D-code P8019 1

18 Guide pin 21112021-512 2

The guide pins, signal pins, air couplings, O-rings, X-rings and air sealings are also considered as wear parts, see section 4.1.3.

58 M0711-1 ver. 2.4

5.4 Part list for tool attachment P0702A and P0704A


1 Connector A0206-033 1

2 Connection plate A0206-035 1

3 O-ring I0840 1

4 Plunge P0206-015 1

5 Cover P0206-016 1

6 O-ring I0241 1

7 Screw MC6S 5x20 6

M0711-1 ver. 2.4 59

5.5 Part list for tool attachment P0765


1 Connector Harting P8020 1

2 Connector M12 D-code (Profinet) A0206-107 1


4 O-ring I0840 1

5 Screw MC6S 5x20 6

6 O-ring I0241 1

7 Connection plate A0206-035 1

8 Plunge P0206-045 1

60 M0711-1 ver. 2.4

6 DISPOSAL AND RECYCLING

Taking care of spent equipment

Used equipment must be taken care of in an environmentally-friendly way.

When disposed of, a major share of the material, or its energy content, can be recycled. The quantities possible to recycle vary depending on technical resources and practises in respective country. Non-recyclable components shall be handed over to an authorized environmental waste treatment facility for destruction or disposal.

Electronics

Electronic equipment shall be sent to an authorized recycling company or sorted into different component materials and treated as such.

Metals

Metals can, in general, be melted down, recycled and used in new products. They shall be sorted according to type and surface coating and handed over to an authorized recycling facility.

Metal components of steel and aluminium are substantial in size and easy to identify. Copper is primarily used in transmission of power for spot welding. Silver or gold plating of contact surfaces may occur.

Plastics

Thermoplastics can, in general, be re-heated and recycled without any major loss of quality. They shall be handed over to an authorized recycling facility. POM occurs in swivel housings, etc. PTFE in some sealings.

Rubber

Rubber shall be handed over to an authorized environmental waste treatment facility either for recycling, disposal or destruction. Rubber occurs in O-rings.

Other material

All other material shall be sorted and handed to an authorized environmental waste treatment facility in accordance with national legislation.

M0711-1 ver. 2.4 61

62 M0711-1 ver. 2.4

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