Original operating manual
Assembly and operating manual
PMP
Portal module
Imprint
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved. Any reproduction, processing, distribution (making available to third parties),
translation or other usage - even excerpts - of the manual is especially prohibited and
requires our written approval.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 389313
Version: 03.00|14/02/2019|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear Customer,
thank you for trusting our products and our family-owned company, the leading
technology 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. KG
Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
Tel. +49-7133-103-0
Fax +49-7133-103-2399
info@de.schunk.com
schunk.com
2
03.00 | PMP | Assembly and operating manual | en | 389313
Table of contents
Table of contents
1 General.................................................................................................................... 5
1.1 About this manual ................................................................................................5
1.1.1 Presentation of Warning Labels ...............................................................5
1.1.2 Definition of Terms...................................................................................6
1.1.3 Applicable documents ..............................................................................6
1.1.4 Sizes ..........................................................................................................6
1.2 Warranty .............................................................................................................. 6
1.3 Scope of delivery ..................................................................................................6
1.4 Accessories ........................................................................................................... 7
1.4.1 Variable end stop...................................................................................... 7
1.4.2 Intermediate stops AS/ZA.........................................................................7
1.4.3 Bellows .....................................................................................................7
1.4.4 Cable track................................................................................................ 7
1.4.5 Columns and mounting material ..............................................................7
1.4.6 T-nuts........................................................................................................ 7
2 Basic safety notes ................................................................................................... 8
2.1 Intended use......................................................................................................... 8
2.2 Not intended use.................................................................................................. 8
2.3 Constructional changes ........................................................................................8
2.4 Spare parts ........................................................................................................... 8
2.5 Environmental and operating conditions .............................................................9
2.6 Personnel qualification......................................................................................... 9
2.7 Personal protective equipment.......................................................................... 10
2.8 Notes on safe operation ..................................................................................... 10
2.9 Transport ............................................................................................................ 10
2.10 Malfunctions....................................................................................................... 11
2.11 Disposal .............................................................................................................. 11
2.12 Fundamental dangers......................................................................................... 11
2.12.1 Protection during handling and assembly ..............................................11
2.12.2 Protection during commissioning and operation ...................................12
2.12.3 Protection against dangerous movements.............................................12
2.12.4 Protection against electric shock............................................................13
2.13 Information about special dangers..................................................................... 13
3 Technical Data ........................................................................................................14
03.00 | PMP | Assembly and operating manual | en | 389313
3
Table of contents
4 Assembly ................................................................................................................15
4.1 Mechanical connection ...................................................................................... 15
4.2 Compressed air supply ....................................................................................... 17
4.3 Setting the speed................................................................................................ 18
4.4 Adjustment of the shock absorber strocke ........................................................ 19
4.5 End position - sets .............................................................................................. 20
4.5.1 End position adjustment "X" ..................................................................20
4.5.2 Variable end stop VE...............................................................................22
4.5.3 Damping adjustment “Z” ........................................................................22
4.6 Intermediate stop AS/ZA ....................................................................................23
4.6.1 Stop collar AS …. .....................................................................................23
4.6.2 Intermediate stop ZA..............................................................................24
4.6.3 Handling..................................................................................................25
4.7 Cable track.......................................................................................................... 26
4.7.1 Cable track horizontal KSH... ..................................................................26
4.7.2 Vertical KSV... cable drag chain ..............................................................27
5 Commissioning .......................................................................................................28
6 Troubleshooting .....................................................................................................29
6.1 Module does not move?..................................................................................... 29
6.2 Power / speed / power of the module is declining?........................................... 29
6.3 End position signal not present? ........................................................................ 29
6.4 Module impacts on end position? .....................................................................29
6.5 Service load vibrates in end position?................................................................ 30
7 Maintenance ..........................................................................................................31
7.1 Notes .................................................................................................................. 31
7.2 Maintenance and lubrication intervals............................................................... 31
7.3 Lubricants/Lubrication points (basic lubrication) ..............................................32
7.4 Dismantling the module ..................................................................................... 32
7.5 Assembling the module...................................................................................... 33
8 Assembly / spare parts ...........................................................................................34
8.1 PMPS/F 16 ..........................................................................................................34
8.2 PMPS/F 25 ..........................................................................................................35
9 Translation of original declaration of incorporation ................................................37
10 Annex to Declaration of Incorporation....................................................................38
4
03.00 | PMP | Assembly and operating manual | en | 389313
1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working is
the observance of all safety instructions in this manual.
Illustrations in this manual are provided for basic understanding
and may differ from the actual product design.
In addition to these instructions, the documents listed under
Applicable documents [}6] are applicable.
1.1.1 Presentation of Warning Labels
General
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.
03.00 | PMP | Assembly and operating manual | en | 389313
5
General
1.1.2 Definition of Terms
The term "product" replaces the product name on the title page in
this manual.
1.1.3 Applicable documents
• General terms of business*
• Catalog data sheet of the purchased product *
• Assembly and operating manuals of the accessories *
The documents marked with an asterisk (*) can be downloaded on
our homepage schunk.com
1.1.4 Sizes
This operating manual applies to the following sizes:
• PMP 16
• PMP 25
1.2 Warranty
If the product is used as intended, the warranty is valid for 24
months from the ex-works delivery date under the following
conditions:
• Observe the specified maintenance and lubrication intervals
• Observe the ambient conditions and operating conditions
Parts touching the workpiece and wear parts are not included in
the warranty.
1.3 Scope of delivery
The scope of delivery includes
• Portal module PMP in the version ordered
• Assembly and Operating Manual
6
03.00 | PMP | Assembly and operating manual | en | 389313
1.4 Accessories
A wide range of accessories are available for this product
For information regarding which accessory articles can be used
with the corresponding product variants, see catalog data sheet.
1.4.1 Variable end stop
The stroke and its position along the entire stroke length of the
portal module can be adjusted using the variable VE end stops
Variable end stop VE [}22].
For further information, consult the latest catalog.
1.4.2 Intermediate stops AS/ZA
The intermediate stop consists of a AS... stop guide which is
mounted on the traversing slide and of the actual ZA stops. These
can be controlled independently and any number can be
distributed along the axis.
General
The intermediate stop can be supplied for all types and sizes of the portal module Intermediate stops AS/ZA [}21].
1.4.3 Bellows
The module is optionally available with a bellow. This increases the
protection against penetrating materials. This option is only
available for fixed stroke variants Assembly / spare parts [}34].
For further information, consult the latest catalog.
1.4.4 Cable track
For guiding electric and pneumatic lines
The cable track is available for "horizontal slide" and "vertical
slide" versions. Several attachment variants are possible Cable track [}26].
1.4.5 Columns and mounting material
Columns, adapter plates and mounting materials are available for
the portal modulesMechanical connection [}15].
For further information, consult the latest catalog.
1.4.6 T-nuts
For mounting the linear module on the machine / system.
Overview of T-nuts
Designation Type/ID number
T-nut for PMP S/F NT-M5 / 0313607
03.00 | PMP | Assembly and operating manual | en | 389313
7
Basic safety notes
2 Basic safety notes
2.1 Intended use
The product is exclusively designed for linear movement of useful
loads into any desired position.
• The product may only be used within the scope of its technical
data, Technical Data [}14].
• When implementing and operating components in safetyrelated parts of the control systems, the basic safety principles
in accordance with DIN EN ISO 13849-2 apply. The proven safety
principles in accordance with DIN EN ISO 13849-2 also apply to
categories 1, 2, 3 and 4.
• The product is intended for installation in a machine/system.
The applicable guidelines must be observed and complied with.
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 Not intended use
It is not intended use if the product is used, for example, as a
pressing tool, stamping tool, lifting gear, guide for tools, cutting
tool, clamping device or a drilling tool.
• Any utilization that exceeds or differs from the appropriate use
is regarded as misuse.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
• Use only original spare parts or spares authorized by SCHUNK.
8
03.00 | PMP | Assembly and operating manual | en | 389313
Basic safety notes
2.5 Environmental and operating conditions
•
Make sure that the product is used only in the context of its
defined application parameters, Technical Data [}14].
• Make sure that the product is not exposed to excessive
vibrations and/or strokes.
• Make sure that the environment is free from splash water and
vapors as well as from abrasion or processing dust. Exceptions
are products that are designed especially for contaminated
environments.
• Make sure that the environment is clean and the ambient
temperature corresponds to the specifications per the catalog.
• Ensure that no strong magnetic fields impair the function of the
product.
Contact your SCHUNK partner if the product is to be used in
strong magnetic fields.
2.6 Personnel qualification
Trained electrician
Qualified personnel
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
• All work may only be performed by qualified personnel.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person
Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
03.00 | PMP | Assembly and operating manual | en | 389313
9
Basic safety notes
2.7 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
•
Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
2.8 Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Avoid any manner of working that may interfere with the
function and operational safety of the product.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product to any corrosive media. This does
not apply to products that are designed for special environments.
• Eliminate any malfunction immediately.
• Observe the care and maintenance instructions.
• Observe the current safety, accident prevention and environmental protection regulations regarding the product's application field.
2.9 Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
• Secure the product against falling during transportation and
handling.
• Stand clear of suspended loads.
10
03.00 | PMP | Assembly and operating manual | en | 389313
2.10 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
2.11 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and environmental harm.
• Follow local regulations on dispatching product components for
recycling or proper disposal.
Basic safety notes
2.12 Fundamental dangers
General
• Observe safety distances.
• Never deactivate safety devices.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• If the energy supply is connected, do not move any parts by
hand.
• Do not reach into the open mechanism or movement area of
the product during operation.
2.12.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
•
For all work, secure the product against accidental operation.
• Observe the relevant accident prevention rules.
• Use suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
03.00 | PMP | Assembly and operating manual | en | 389313
11
Basic safety notes
2.12.2 Protection during commissioning and operation
2.12.3 Protection against dangerous movements
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
• Stand clear of suspended loads and do not step into their
swiveling range.
• Never move loads without supervision.
• Do not leave suspended loads unattended.
Falling or violently ejected components
Falling and violently ejected components can cause serious injuries
and even death.
• Take appropriate protective measures to secure the danger
zone.
• Never step into the danger zone during operation.
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely solely on the response of the monitoring function to
avert danger. Until the installed monitors become effective, it
must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum possible
movement energy. EMERGENCY STOP switches must be easily
and quickly accessible. Before starting up the machine or
automated system, check that the EMERGENCY STOP system is
working. Prevent operation of the machine if this protective
equipment does not function correctly.
12
03.00 | PMP | Assembly and operating manual | en | 389313
2.12.4 Protection against electric shock
Possible electrostatic energy
Components or assembly groups may become electrostatically
charged. When the electrostatic charge is touched, the discharge
may trigger a shock reaction leading to injuries.
• The operator must ensure that all components and assembly
groups are included in the local potential equalisation in
accordance with the applicable regulations.
• While paying attention to the actual conditions of the working
environment, the potential equalisation must be implemented
by a specialist electrician according to the applicable
regulations.
• The effectiveness of the potential equalisation must be verified
by executing regular safety measurements.
2.13 Information about special dangers
Basic safety notes
WARNING
Risk of injury caused by crushing and impacts when moving the
unit or attachments!
Risk of injury due to attachments breaking or becoming loose!
WARNING
Risk of injury from objects falling and being ejected!
Falling and ejected objects during operation can lead to serious injury or death.
• Take appropriate protective measures to secure the danger
zone.
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
• Before starting any work on the product: Switch off the power
supply and secure against restarting.
• Make sure, that no residual energy remains in the system.
WARNING
Risk of injury when the machine/system moves unexpectedly in
the case of a loss of power supply or control system
malfunction.
Use of a holding brake on the linear axis.
03.00 | PMP | Assembly and operating manual | en | 389313
13
Technical Data
3 Technical Data
Size 16 – 25
Ambient temperature [°C] 5 - 60
IP rating 40
Noise emission [dB(A)] ≤ 70
Pressure medium Compressed air, compressed air
quality according to ISO
8573-1:7 4 4
Min. pressure [bar] 3
Max. pressure [bar] 10
Nominal working pressure [bar] 6
Repeatability [mm] ± 0.02
More technical data is included in the catalog data sheet.
Whichever is the latest version.
NOTICE
The gantry modules may not under any circumstances have
been operated with oiled air before operation with unoiled air.
14
03.00 | PMP | Assembly and operating manual | en | 389313
4 Assembly
4.1 Mechanical connection
Assembly
Evenness of the
mounting surface
Mounting
The values apply to the whole mounting surface to which the
product is mounted.
Requirements for evenness of the mounting surface (Dimensions in mm)
Edge length Permissible unevenness
< 100 < 0.02
> 100 < 0.05
Grooves fasten the module underneath on the profile, the load
can be mounted and fastened on the slide using bore holes and
threads.
Position dimensions, etc. ☞ Catalog.
PMPS/F 16 connection geometries
PMPS/F 25 connection geometries
03.00 | PMP | Assembly and operating manual | en | 389313
15
Assembly
PMPS/F 16 / 25 connection geometries
PMPS/F 16 PMPS/F 25
A [mm] M6 / 11 (2x) M8 / 16 (6x)
W [mm] Ø5F7 / 10 (2x) Ø5F7 / 8 (2x)
C X M6 / 12 (4x)
D [mm] 5 8
E [mm] 11.77 20.5
F [mm] 1.8 3.5
G [mm] 4.55 7.95
Fitting example PMPS/F on pillar profile modular system, horizontal and vertical
Additional information on the pillar profile modular system and
mounting elements for attachment ☞ Catalog.
16
03.00 | PMP | Assembly and operating manual | en | 389313
4.2 Compressed air supply
NOTICE
Possible damage to the linear module!
If the module moves too hard against the end positions, the
linear module might be damaged.
• A linear movement alway must reach the end position without
jerk or bounce.
• Therefore flow control valves and shock absorbers must be
used, Setting the speed [}18] and Adjustment of the shock
absorber strocke [}19].
• Please observe the diagrams and information in the catalog
pages.
NOTE
• Use connecting wires with the same or a larger cross-section as
the connection thread.
• Observe the requirements for the air supply Technical Data
[}14].
Assembly
Compressed air connections PMPS/F .... Axes
Thread diameter of the air connections
Air connection thread M5 G 1/8"
03.00 | PMP | Assembly and operating manual | en | 389313
PMP 16 PMP 25
17
Assembly
4.3 Setting the speed
NOTICE
Risk of damage to the product!
If the end position is approached too hard, the product may be
damaged.
• Adjust exhaust throttle valve and shock absorber so that the
movement is braked smoothly.
Ø Close exhaust throttle valve completely.
Ø Open exhaust throttle valve until the product starts to move.
Ø Continue to open the exhaust throttle valve incrementally until
the movement decelerates smoothly.
✓ If the speed is too low, the product will brake too soon and
the end position will be reached too slowly.
✓ If the speed is too high, the product will impact against the
end position and the shock absorber will be overloaded.
NOTE
A smooth motion may also be too slow in many use-cases.
Further settings can be made via the shock absorbers, Adjustment
of the shock absorber strocke [}19].
18
03.00 | PMP | Assembly and operating manual | en | 389313
4.4 Adjustment of the shock absorber strocke
Movement
Target position
End position
Target time
Time T
Damping
Movement
Target position
End position
Target time
Time T
Damping
Movement
Target position
End position
Target time
Time T
Damping
The shock absorber stroke is too long and the end position is
reached too slowly.
Assembly
The shock absorber stroke is too short and the unit arrives in the
end position too abruptly.
Optimal shock absorber stroke.
03.00 | PMP | Assembly and operating manual | en | 389313
19
Assembly
4.5 End position - sets
For stroke limiting, damping and query of the end positions the
following components are available:
• VE (Variable end stop)
• LMST-...(shock absorber - stop collar)
• NI 30 (proximity switch)
Hereinafter the assembly of LMST- and NI 30 in the portal module
with and without variable end stop VE is shown.
Portal module with and without variable end stop VE
4.5.1 End position adjustment "X"
The end positions can be finely adjusted by the shock absorbers stop collar LMST
the maximum possible setting range X is included in the catalog
modular assembly automation
20
03.00 | PMP | Assembly and operating manual | en | 389313
4.5.1.1 Intermediate stops AS/ZA
The stop slide AS-... is mounted on the carriage of the portal
actuator and, depending on the design, is suitable for approaching
the intermediate position from one side or both sides.
Assembly
Installation of AS and ZA
03.00 | PMP | Assembly and operating manual | en | 389313
21
Assembly
4.5.2 Variable end stop VE
The stroke and its location along the entire stroke of the portal
module can be adjusted by the variable end stops. For the
assembly remove the cover caps and the fastening screws of the
profiled rail guide in the selected area.
NOTICE
Ensure that the slots residual in the nots don´t move.
After placing the variable end stop with the supplied centering
sleeves it must be screwed together with the profiled rail guides.
Further information ☞ catalog modular assembly automation
4.5.3 Damping adjustment “Z”
The adjustment screw of the damper adjustment mechanism can
be used to adjust the stroke of the shock absorber and thereby the
damping curve to the kinetic energy occur-ring.
The counternut is loosened and the appropriate setting value is
adjusted by turning the adjustment screw.
The permissible setting values Z are given in the SCHUNK standard
catalog modular assembly automation.
damping adjustment dimension "Z"
22
03.00 | PMP | Assembly and operating manual | en | 389313
4.6 Intermediate stop AS/ZA
The intermediate stop consists of an stop slide AS... which is
mounted on the traversing slide and the actual ZA stops. These can
be controlled independently and any number can be distributed
along the axis.
Assembly
Installation of AS and ZA
4.6.1 Stop collar AS ….
The stop collar AS-... is mounted at the guide carriage of the portal
module.
• Depending on the model suitable for one-or two-sided to
approach the intermediate position.
• The stop collar (Pos.5) can be used for precision adjustment of
the intermediate position within a ±3mm range.
• With an appropriate version and setting, the intermediate
position can be approached from both sides without a loss of
position.
• Independently of this, it is also possible to match the end
position damping to the specific mass by adjusting the shock
absorber (11).
• The cover plate (6 and 7) is prepared for installation of a
proximity switch NI 30 that interrogates the precision position
of the stop slide
03.00 | PMP | Assembly and operating manual | en | 389313
23
Assembly
: Section drawing stop collar AS
In accordance with the section drawing above, all parts can be
ordered individually.
Ordering numbers are as indicated in the following example
• Part-No.: AS 25-02
4.6.2 Intermediate stop ZA
The intermediate stop ZA-... is located by means of the slots in the
support rail.
• It can be moved steplessly.
• It is thereby possible to approach several intermediate positions
CAUTIONObserve minimum distance.
• The position at which the portal actuator (2) is actually located
is determined by the proximity switch NI 40 (14a). Query of the
interactive position by the proximity switch NI40 (14b) is
optionally possible.
Section drawing and installation of the sensors ZA...
24
03.00 | PMP | Assembly and operating manual | en | 389313
In accordance with the section drawing all parts can be ordered
individually.
Ordering numbers are as indicated in the following example:
• Part-No: 2 ZA 25-02
As standardized wear part sets, seal sets are available under the
following ordering numbers:
• ZADI 16 for intermediate stop ZA 16
• ZADI 25 for intermediate stop ZA 25
4.6.3 Handling
Assembly
Controlling
determination of the
position / sensors
Further movement from the intermediate position is possible at
the portal of corresponding control module via a 5/3-way valve
without repeating stroke (center position = both chambers
ventilated). Commissioning [}28].
To determine the position of several intermediate positions in
which the portal module is currently a installation of the proximity
switch NI 30 is intended.
It will be fixed with the clamping screw (20).
A switch cam will be requested at the stop slide.
Achieving a precise end position is sensed by the sensors NI30 on
the stop slide.
Thus any intermediate position and end position can be requested
exactly.
03.00 | PMP | Assembly and operating manual | en | 389313
25
Assembly
4.7 Cable track
There are different possibilities to mount the cable tracks on the
module.
In the following chapter there is always only one variant mapped
exemplarily.
Detailed information about the attachment variants you can get
form of the contact person.
4.7.1 Cable track horizontal KSH...
Cable track horizontal KSH...
In accordance with the drawing all wear parts and individual parts
are available as single items.
Ordering numbers are as indicated in the following example
• Part-No1: KSH...-01
NOTE
Always quote the stroke or the Id.-No. of the axis at part 05
Assembly / spare parts [}34]
26
03.00 | PMP | Assembly and operating manual | en | 389313
4.7.2 Vertical KSV... cable drag chain
Vertical KSV... cable drag chain
Assembly
All parts can be ordered individually in accordance with the figure.
Order numbers as given in the following example:
• • Part no. 1: KSV...-01
NOTE
For part 05, always specify the stroke or the axis Id-No.
Assembly / spare parts [}34].
03.00 | PMP | Assembly and operating manual | en | 389313
27
Commissioning
5 Commissioning
NOTICE
Before commissioning !
Please read these instructions carefully. Only with the knowledge
of this manual errors can be prevented, and trouble-free
operation is ensured.
NOTICE
Possible damage to the linear module!
If the module moves too hard against the end positions, the
linear module might be damaged.
• A linear movement alway must reach the end position without
jerk or bounce.
• Therefore flow control valves and shock absorbers must be
used, Setting the speed [}18] and Adjustment of the shock
absorber strocke [}19].
• Please observe the diagrams and information in the catalog
pages.
• Check technical specifications Technical Data [}14].
• Do not use the linear module until you have determined that it
is in perfect operating condition, after having checked for
compliance with all permissible operating parameters.
• For operation, use only a 5/3-directional control valve which
ventilates both chambers of the drive cylinder in center
position. This ensures, each time the system is started up, that
both cylinder chambers are filled equally and thus prevents the
slide from shooting out.
• Regulate the operating speed of the cylinder with regulator
valves Compressed air supply [}17]. Starting slow, increase the
speed until the desired operating speed is reached.
• Do not load the portal module beyond the operating range
limit. Excessive loading can cause damage or result in guide unit
inaccuracies. The maximum permissible loads are listed in the
catalog.
28
03.00 | PMP | Assembly and operating manual | en | 389313
Troubleshooting
6 Troubleshooting
6.1 Module does not move?
Possible cause Corrective action
Pressure drops below minimum. Check air supply.Compressed air supply
[}17]
Compressed air lines switched. Check compressed air lines.
Mechanical damage Check mechanical parts
6.2 Power / speed / power of the module is declining?
Possible cause Corrective action
Pressure drops below minimum. Check air supply., Compressed air supply
[}17]
Compressed air lines are leaking Check compressed air lines.
Rodless cylinder is leaking Check cylinder for leaks and replace if
necessary, Dismantling the module [}32]
Guide carriage or rail is defective Send the product to SCHUNK with a repair
order.
Guide carriage or rail is very dirty Clean guide rails, relubricate guide carriage
and rails, Maintenance and lubrication
intervals [}31]
6.3 End position signal not present?
Possible cause Corrective action
Sensor is adjusted inaccurately to the stop. Adjust sensor or if necessary change sensor.,
End position - sets [}20] Intermediate stops
AS/ZA [}21]
Proximity switch defective or set incorrect. Change sensor.
Cable breakage. Replacing the sensor cable.
6.4 Module impacts on end position?
Possible cause Corrective action
Damping wrong adjustet. Adjusting damping., Damping adjustment
“Z” [}22] Stop collar AS …. [}23]
Shock absorber defective. Change the shock absorber., Damping
adjustment “Z” [}22] Stop collar AS ….
[}23]
Stroke speed too high. Check / reduce stroke speed with ventilation
valves.
Change defective exhaust ait throttle if
necessary.
03.00 | PMP | Assembly and operating manual | en | 389313
29
Troubleshooting
6.5 Service load vibrates in end position?
Possible cause Corrective action
Stroke speed too high. Check / reduce stroke speed with ventilation
valves.
Change defective exhaust ait throttle if
necessary.
Bad damping. Adjusting damping., Damping adjustment
“Z” [}22], Stop collar AS …. [}23]
Unfavorable installation. Check construction.
PMPS/F type too small Use larger PMPS/F type
30
03.00 | PMP | Assembly and operating manual | en | 389313
Maintenance
7 Maintenance
7.1 Notes
The following recommendations apply if the unit is operated as
intended in compliance with the specified operating parameters,
operating conditions and settings.
Original spare parts
Use only original spare parts of SCHUNK when replacing spare and
wear parts.
7.2 Maintenance and lubrication intervals
NOTICE
Material damage due to hardening lubricants!
Lubricants harden more quickly at temperatures above 60°C,
leading to possible product damage.
• Reduce the lubricant intervals accordingly.
interval Component Activity
every 3 months
/ 500km
regularly rodless cylinder Checking for leaks
Guide rails /
Carriage
Clean it with an oil-soaked cloth
Remove all incrustations of dust and grease residues
Visual inspection for traces of wear.
Mechanical testing on backlash and ease of movement
of the guides.
Grease the intended lubrication points Lubricants/
Lubrication points (basic lubrication) [}32]
03.00 | PMP | Assembly and operating manual | en | 389313
31
Maintenance
7.3 Lubricants/Lubrication points (basic lubrication)
Lubrication points carriage
SCHUNK recommends the lubricants listed.
During maintenance, treat all greased areas with lubricant. Thinly
apply lubricant with a lint-free cloth.
Lubricant point Lubricant
Carriage Isoflex-Topas NCA 52
Guide rails
Fa. Klüber
7.4 Dismantling the module
NOTICE
For disassembly and assembly of the module for the wealth of
technical knowledge is required. Personnel qualification [}9]
The single handed maintenance or removal of deficiencies to
the module by the customer will void the warranty and
responsibility for any resulting warranty and consequential
damages.
• It is recommended to repair damaged and defective modules
in the factory. Contact your SCHUNK contact person.
32
03.00 | PMP | Assembly and operating manual | en | 389313
Maintenance
7.5 Assembling the module
Assemble the module as shown in chapter "Assembly" Assembly /
spare parts [}34].
NOTICE
Assembly measures
• Select suitable tightening torque values for screws when
assembling the module, in accordance with the generally
accepted guidelines for screw connections
• Observe specified lubricant and greasing areas Lubricants/
Lubrication points (basic lubrication) [}32].
• Secure all screws using a suitable chemical screw lock.
03.00 | PMP | Assembly and operating manual | en | 389313
33
Assembly / spare parts
8 Assembly / spare parts
Wearing parts and individual components are available individually according to the following sectional drawings PMPS/F 16 [}34] /
PMPS/F 25 [}35].
Order numbers are composed as follows:
• PMPS16 part no. 4: PMPS 16-04
• PMPF16 part no. 4: PMPF 16-04
• PMPS25 part no. 4: PMPS 25-04
• PMPF25 part no. 4: PMPF 25-04
Always order the cylinder (30) without piston rod as a complete
component.
Always state the module stroke or the Id-No. when placing orders.
Please contact your SCHUNK contact if damage should occur to the
heavy-duty guide (01).
8.1 PMPS/F 16
PMPS 16
34
03.00 | PMP | Assembly and operating manual | en | 389313
Assembly / spare parts
PMPF 16
* Glued to the base part, order together
**stroke- dependent, always indicate the stroke or the Id.-No. to the order
8.2 PMPS/F 25
PMPS 25
03.00 | PMP | Assembly and operating manual | en | 389313
35
Assembly / spare parts
PMPF 25
* Glued to the base part, order together
** stroke- dependent, always indicate the stroke or the Id.-No.
to the order
36
03.00 | PMP | Assembly and operating manual | en | 389313
Translation of original declaration of incorporation
9 Translation of original declaration of incorporation
in terms of the Directive 2006/42/EG, Annex II, Part 1.B of the European Parliament and of
the Council on machinery.
Manufacturer/
Distributor
SCHUNK GmbH & Co. KG Spann- und Greiftechnik
Bahnhofstr. 106 – 134
D-74348 Lauffen/Neckar
We hereby declare that on the date of the declaration the following partly completed
machine complied with all basic safety and health regulations found in the directive
2006/42/EC of the European Parliament and of the Council on machinery. The declaration
is rendered invalid if modifications are made to the product.
Product designation: Portal module / PMP / pneumatic
ID number 0314141, 0314142, 0314151, 0314152
The partly completed machine may not be put into operation until conformity of the
machine into which the partly completed machine is to be installed with the provisions of
the Machinery Directive (2006/42/EC) is confirmed.
Applied harmonized standards, especially:
EN ISO 12100:2010 Safety of machinery - General principles for design -
Risk assessment and risk reduction
The manufacturer agrees to forward on demand the relevant technical documentation for
the partly completed machinery in electronic form to national authorities.
The relevant technical documentation according to AnnexVII, Part B, belonging to the
partly completed machinery, has been created.
Person authorized to compile the technical documentation:
Robert Leuthner, Address: see manufacturer's address
Lauffen/Neckar, February 2019 p.p. Ralf Winkler, Manager for development of
gripping system components
03.00 | PMP | Assembly and operating manual | en | 389313
37
Annex to Declaration of Incorporation
10 Annex to Declaration of Incorporation
according 2006/42/EG, Annex II, No. 1 B
1.Description of the essential health and safety requirements pursuant to 2006/42/EC,
Annex I that are applicable and that have been fulfilled with:
Product designation Portal module
Type designation PMP
ID number 0314141, 0314142, 0314151, 0314152
To be provided by the System Integrator for the overall machine ⇓
Fulfilled for the scope of the partly completed machine ⇓
Not relevant ⇓
1.1 Essential Requirements
1.1.1 Definitions X
1.1.2 Principles of safety integration X
1.1.3 Materials and products X
1.1.4 Lighting X
1.1.5 Design of machinery to facilitate its handling X
1.1.6 Ergonomics X
1.1.7 Operating positions X
1.1.8 Seating X
1.2 Control Systems
1.2.1 Safety and reliability of control systems X
1.2.2 Control devices X
1.2.3 Starting X
1.2.4 Stopping X
1.2.4.1 Normal stop X
1.2.4.2 Operational stop X
1.2.4.3 Emergency stop X
1.2.4.4 Assembly of machinery X
1.2.5 Selection of control or operating modes X
1.2.6 Failure of the power supply X
38
03.00 | PMP | Assembly and operating manual | en | 389313
Annex to Declaration of Incorporation
1.3 Protection against mechanical hazards
1.3.1 Risk of loss of stability X
1.3.2 Risk of break-up during operation X
1.3.3 Risks due to falling or ejected objects X
1.3.4 Risks due to surfaces, edges or angles X
1.3.5 Risks related to combined machinery X
1.3.6 Risks related to variations in operating conditions X
1.3.7 Risks related to moving parts X
1.3.8 Choice of protection against risks arising from moving parts X
1.3.8.1 Moving transmission parts X
1.3.8.2 Moving parts involved in the process X
1.3.9 Risks of uncontrolled movements X
1.4 Required characteristics of guards and protective devices
1.4.1 General requirements X
1.4.2 Special requirements for guards X
1.4.2.1 Fixed guards X
1.4.2.2 Interlocking movable guards X
1.4.2.3 Adjustable guards restricting access X
1.4.3 Special requirements for protective devices X
1.5 Risks due to other hazards
1.5.1 Electricity supply X
1.5.2 Static electricity X
1.5.3 Energy supply other than electricity X
1.5.4 Errors of fitting X
1.5.5 Extreme temperatures X
1.5.6 Fire X
1.5.7 Explosion X
1.5.8 Noise X
1.5.9 Vibrations X
1.5.10 Radiation X
1.5.11 External radiation X
1.5.12 Laser radiation X
1.5.13 Emissions of hazardous materials and substances X
1.5.14 Risk of being trapped in a machine X
1.5.15 Risk of slipping, tripping or falling X
1.5.16 Lightning X
03.00 | PMP | Assembly and operating manual | en | 389313
39
Annex to Declaration of Incorporation
1.6 Maintenance
1.6.1 Machinery maintenance X
1.6.2 Access to operating positions and servicing points X
1.6.3 Isolation of energy sources X
1.6.4 Operator intervention X
1.6.5 Cleaning of internal parts X
1.7 Information
1.7.1 Information and warnings on the machinery X
1.7.1.1 Information and information devices X
1.7.1.2 Warning devices X
1.7.2 Warning of residual risks X
1.7.3 Marking of machinery X
1.7.4 Instructions X
1.7.4.1 General principles for the drafting of instructions X
1.7.4.2 Contents of the instructions X
1.7.4.3 Sales literature X
The classification from Annex 1 is to be supplemented from here
forward.
2 Supplementary essential health and safety requirements for certain
categories of machinery
2.1 Foodstuffs machinery and machinery for cosmetics or pharmaceutical
products
2.2 Portable hand-held and/or guided machinery X
2.2.1 Portable fixing and other impact machinery X
2.3 Machinery for working wood and material with similar physical
characteristics
3 Supplementary essential health and safety requirements to offset
X
hazards due to the mobility of machinery
4 Supplementary essential health and safety requirements to offset
X
hazards due to lifting operations
5 Supplementary essential health and safety requirements for machinery
intended for underground work
X
X
X
X
6 Supplementary essential health and safety requirements for machinery
presenting particular hazards due to the lifting of persons
40
03.00 | PMP | Assembly and operating manual | en | 389313
X
Loading...