Linear unit, pneumatic KHM 40

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1 Translation of original operating manual Linear unit, pneumatic KHM 40 Assembly and Operating Manual Superior Clamping and Gripping

2 Imprint Imprint Copyright: This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely supplied to our customers and operators of our products and forms part of the product. This documentation may not be duplicated or made accessible to third parties, in particular competitive companies, without our prior permission. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: Edition: /10/2013 en SCHUNK GmbH & Co. KG All rights reserved. Dear customer, congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for the highest precision, top quality and best service. You are going to increase the process reliability of your production and achieve best machining results to the customer's complete satisfaction. SCHUNK products are inspiring. Our detailed assembly and operation manual will support you. Do you have further questions? You may contact us at any time even after purchase. Kindest Regards Yours SCHUNK GmbH & Co. KG Spann- und Greiftechnik Bahnhofstr D Lauffen/Neckar Tel Fax info@de.schunk.com KHM 40 en

3 Table of contents Table of contents 1 About this manual Warnings Key words Symbols Applicable documents Basic safety notes Intended use Not intended use Environmental and operating conditions Product safety Protective equipment Constructional changes, attachments, or modifications Personnel qualification Using personal protective equipment Notes on particular risks Warranty Scope of delivery Accessories Sensors Technical data Assembly and connection Mounting the linear unit Reduction of stroke Air connection Lifting plate Inductive proximity switch IN Troubleshooting Linear unit does not move? Linear unit is not performing the entire stroke? Lifting unit opens or closes with a jerk? Piston force decreasing? Maintenance and Care Notes Maintenance and care intervals Lubricants/Lubrication points (basic lubrication) KHM 40 en 3

4 Table of contents 9.4 Disassembling the linear unit Servicing and assembling the module Assembly drawings Seal kit Accessories kit Translation of original declaration of incorporation KHM 40 en

5 About this manual About this manual This instruction is an integral part of the product and contains important information for a safe and proper assembly, commissioning, operation, maintenance and help for easier trouble shooting. Before using the product, read and note the instructions, especially the chapter "Basic safety notes". Warnings The following key words and symbols are used to highlight dangers Key words DANGER WARNING CAUTION NOTICE Dangers for persons. Non-compliance will inevitably cause irreversible injury or death. Dangers for persons. Non-compliance may cause irreversible injury or death. Dangers for persons. Non-observance may cause minor injuries. Information about avoiding material damage Symbols Warning about a danger point Warning about hand injuries General mandatory sign to prevent material damage 1.2 Applicable documents General terms of business Catalog data sheet of the purchased product The documents listed here, can be downloaded on our homepage KHM 40 en 5

6 Basic safety notes Basic safety notes Intended use The module is exclusively designed for linear movement of useful loads into any desired position. The module is intended for installation in a machine/system. The requirements of the applicable guidelines must be observed and complied with. The module may be used only in the context of its defined application parameters ( 6, Page 11). The module is intended for industrial use. To use this unit as intended, it is also essential to observe the technical data and installation and operation notes in this manual and to comply with the maintenance intervals. 2.2 Not intended use It is not an intended use if the module is used, for example, as a pressing tool, stamping tool, lifting gear, guide for tools, cutting tool, clamping device or a drilling tool. 2.3 Environmental and operating conditions The module may be used only within its defined application parameters. Ensure that the environment is clean. Observe the lubrication intervals ( 9.2, Page 22). Ensure that the environment is free of splashing water and vapors, and also of abrasive dust and process dust. This does not apply to modules designed especially for unclean environments. Do not subject the module to excessive vibrations and/or mechanical shocks. Strong magnetic fields can impair the function of the module. If the product is to be used in strong magnetic fields, contact your SCHUNK partner. Ensure that the environment is free from ferromagnetic particles or chips KHM 40 en

7 Basic safety notes 2.4 Product safety Dangers arise from the module, if: the module is not used in accordance with its intended purpose. the module is not installed or maintained properly. the safety and installation notes are not observed. Avoid any manner of working that may interfere with the function and operational safety of the module. Wear protective equipment. NOTE More information are contained in the relevant chapters Protective equipment Provide protective equipment per EC Machinery Directive Constructional changes, attachments, or modifications Additional drill holes, threads, or attachments that are not offered as accessories by SCHUNK may be attached only with permission of SCHUNK. 2.5 Personnel qualification The assembly, initial commissioning, maintenance, and repair of the module may be performed only by trained specialist personnel. Every person called upon by the operator to work on the module must have read and understood the complete assembly and operating manual, especially the chapter "Basic safety notes" ( 2, Page 6). This applies particularly to personnel only used occasionally, such as maintenance personnel KHM 40 en 7

8 Basic safety notes 2.6 Using personal protective equipment When using this product, observe the relevant industrial safety regulations and use the personal protective equipment (PPE) required! Use protective gloves, safety shoes and safety goggles. Observe safe distances. Minimal safety requirements for the use of equipment. 2.7 Notes on particular risks Generally valid: Remove the energy supplies before installation, modification, maintenance, or adjustment work. Make sure that no residual energy remains in the system. Do not move parts by hand when the energy supply is connected. Do not reach into the open mechanism or the movement area of the module. Perform maintenance, modifications, and additions outside of the danger zone. For all work, secure the unit against accidental operation. Take a precautionary approach by maintenance and disassembly. Only specially trained staff should disassemble the module KHM 40 en

9 Basic safety notes WARNING Risk of injury from objects falling and being ejected The danger zone must be surrounded by a safety fence during operation. WARNING Risk of injury in the event of a power failure! Modules can still move independently if the power supply fails. Secure the end positions of the module with SCHUNK dampers. WARNING During operation, components of the module may heat up! Before starting any assembly / disassembly or repair work, allow the module to cool down KHM 40 en 9

10 Accessories 3 Warranty The warranty is valid for 24 months from the delivery date to the production facility under the following conditions: Intended use in 1-shift operation Observe the mandatory maintenance and lubrication intervals Observe the environmental and operating conditions Parts touching the work piece and wear parts are not part of the warranty. 4 Scope of delivery The scope of delivery includes: Linear unit, pneumatic KHM in the ordered model. Accessory pack Accessories A wide range of accessories are available for this module. For information about which accessories can be used with the appropriate product version catalog. Sensors Overview of the compatible sensors Designation Inductive proximity switches Type IN Exact type designation of the compatible sensors see catalog. If you require further information on sensor operation, contact your SCHUNK contact person or download information from our homepage. For mounting the sensors, mounting kits are partly necessary KHM 40 en

11 Technical data 6 Technical data KHM Noise emission [db(a)] 70 Nominal working pressure [bar] IP rating 40 Repeatability [mm] Ambient temperature [ C] Min. Max. Pressure medium 0.05 (for intermediate position 0.15 mm) 5 60 Compressed air, standard for quality of the compressed air according to ISO : Further technical data can be found in the catalog data sheet. The most recent version applies KHM 40 en 11

12 Assembly and connection Assembly and connection Mounting the linear unit WARNING Do not reach between the lifting plate and the housing when doing assembly work, connecting, adjusting or testing. Base area Fig. 1 Base area 1 1x fixing bore Ø6H7 for cylindrical pin Ø6m6 x x centering hole Ø60H7 3 8x threaded holes M6 x 14 mm Lateral surface Fig. 2 Lateral surface 1 front 4 rear 2 / 3 4x threaded holes M6 x 14 mm 2x fixing bores Ø8H12 for clamping sleeve Ø8 x KHM 40 en

13 Assembly and connection 7.2 Reduction of stroke The rod-side reduction of stroke is built in at the factory. Reequipping from the rod-side to the piston-side reduction of stroke can be done at the factory. Fig. 3 1 for reduction of stroke Adjusting the rod-side reduction of stroke: 1 Pressurize the»up«connection with 6 bar air pressure. 2 Using a hexagon socket wrench ( 6) turn the base of the linear unit in the direction of: -»Shorter«(torque approx. 12 Nm) -»Longer«(torque 6 Nm) until the desired stroke adjustment has been reached. The adjustment is self-securing KHM 40 en 13

14 Assembly and connection 7.3 Air connection Connections for hose-free direct connection Seal the unused connections with suitable dummy plugs (M4, M5). 1 2 Connections»Up«and»Down«2 4 Connections for further pneumatically actuated tools or grippers (P1... P4). Fig KHM 40 en

15 Assembly and connection In the event of a radial load on the linear unit and use of 2 internal air feed-throughs Fig. 5 1 Case A For air feed-throughs, please use P 3 + P 4. 2 Case B For air feed-throughs, please use P 3 + P 4. Front left for connection with screws 4 connections»up«,»down«, P 1 and P 2 (M5). Front right for connection with screws 2 connections P 3 and P 4 (M5). Fig. 6 1 Front left KHM 40 en 15

16 Assembly and connection 7.4 Mounting: Connection: Lifting plate 4 threaded holes M6 4 threaded holes M6 x 14 4 bore holes with countersink for M6 DIN fixing bores Ø6H7 4 air connections P 1, P 2, P 3, P 4 for hose-free pressure medium feed-through Fig. 7 1 Adapter 5 4 threaded holes M6 x 14 2 O-ring Ø 6 x threaded holes 3 2 fixing bores 7 KHM 4 4 bore holes with countersink KHM 40 en

17 Assembly and connection 7.5 Inductive proximity switch IN 80 Fig. 8 Connection example for IN 80 1 brown 2 black 3 blue The inductive proximity switches used are equipped with reverse polarity protection and are short-circuit-proof. Make sure that you handle the proximity switches properly: Do not pull on the cable. Do not allow the sensor to dangle from the cable. Do not overtighten the mounting screw or mounting clip. Please adhere to a permitted bend radius of the cable. ( catalog) Avoid contact of the proximity switches with hard objects and with chemicals, in particular nitric acid, chromic acid and sulphuric acid. The inductive proximity switches are electronic components, which can react sensitively to high-frequency interference or electromagnetic fields. Check to make sure that the cable is fastened and installed correctly. Provide for sufficient clearance to sources of highfrequency interference and their supply cables. Parallel switching of several sensor outputs of the same type (npn, pnp) is permissible, but does not increase the permissible load current. Note that the leakage current of the individual sensors (ca. 2 ma) is cumulative KHM 40 en 17

18 Assembly and connection Fig. 9 1 Attachment screw 5 Proximity switch 2 Proximity switch 6 Clamping nut 3 Clamping nut 7 Range of stroke 4 30 mm 4 Monitoring bolt 8 Range of stroke mm KHM 40 en

19 Assembly and connection The KHM 40 linear unit requires two proiximty switches (closers). The proximity swtiches are used to monitor the two end positions (strokes from mm). 1 Set the linear unit to the»up«position. 2 Set the monitoring bolt onto the range of stroke of your choice. To do so, undo the attachement screw in the lifting plate. 3 Carefully install the proximity switch into the T-slot. The proximity switches must not project further than the nut in the T- Slot when installed. 4 Fix the proyimity switches into place using the clamping nut. 5 Undo the upper proximity switch and shift it to the desired switching position. 6 Carefully turn the proximity switch into the T-slot until it touches the switching lug. Then turn back the proximity switch by 1mm and attach it using the clamping nut. 7 Move the linear unit to position»down«and proceed in the same way with the other proximity switch. 8 Connect the proximity switch and test the function KHM 40 en 19

20 Troubleshooting Troubleshooting Linear unit does not move? Possible cause Corrective action Pressure drops below minimum. Check the air supply. ( 7.3, Page 14) Compressed air lines switched Proximity switch defective or set incorrect. Unused air connections not closed. Flow control valve closed. Component is broken, e.g. through overloading Check compressed air lines. Repair the proximity switch. Close the unused air connections. Open the flow control valve. Replace component or send the module with a repair order to SCHUNK. Ensure that the module was only used within its defined application parameters. 8.2 Linear unit is not performing the entire stroke? Possible cause Pressure drops below minimum. Mounting surface is not even enough Component is broken, e.g. through overloading Corrective action Check the air supply. ( 7.3, Page 14) Check the levelness of the bolting surface. ( 7.1, Page 12) Send the module to SCHUNK with a repair order or disassemble module. 8.3 Lifting unit opens or closes with a jerk? Possible cause Too little grease in the mechanical guiding areas of the module Compressed air lines are blocked Mounting surface is not even enough Flow control valve is missing or not set correctly Corrective action Clean the module and relubricate it. ( 9, Page 22) Check the compressed air lines for crushing or damage. Check the levelness of the bolting surface. Install and adjust flow control valve KHM 40 en

21 Troubleshooting 8.4 Piston force decreasing? Possible cause Compressed air can escape Too much grease in the mechanical motion spaces of the module Pressure drops below minimum. Corrective action Check seals, if necessary disassemble module and replace seals. Clean the module and relubricate it. Check the air supply. ( 7.3, Page 14) KHM 40 en 21

22 Maintenance and Care Maintenance and Care Notes When replacing parts of the completely linear unit, send a repair order to SCHUNK. Maintenance and seal replacement can be done by yourself. 9.2 Maintenance and care intervals NOTICE At ambient temperature above 60 C the lubricants can harden faster. Interval decrease accordingly. Size KHM 40 Interval [Mio. cycles] Lubricants/Lubrication points (basic lubrication) We recommend the lubricants listed. During maintenance, treat all greased areas with lubricant. Thinly apply lubricant with a lint-free cloth. Lubrication point Lubricant Sliding metal Molykote BR 2 plus Metallic sliding surfaces Renolit HLT 2 All seals Renolit HLT 2 Sliding surfaces outside the cylinder Metaflux KHM 40 en

23 Maintenance and Care 9.4 Disassembling the linear unit Position of the position numbers ( 10, Page 25) NOTICE When sticking in the sealing rings, ensure that the linear bearings remain clear of adhesive. Move the linear unit to the»down«position and let the air pressure of 6 bar act on the piston. 1 Remove the nut (24). 2 Pull out the lifting plate (4) with the guide rods (8) (rods (8) remain screwed on). 3 Remove pressure lines. 4 Take out the safety ring (32) and push the base (3) and piston (2) out of the housing. The pipe (10) and the bearings (13) remain in the housing. Ensure that no dirt can enter the linear bearings. 5 Remove all seals according to the sealing kit list ( 11, Page 26). 6 Thoroughly clean all parts and check for defects and wear. 7 Replace all seals. NOTE The sealing rings (22 and 38) must be stuck in with Loctite No KHM 40 en 23

24 Maintenance and Care 9.5 Maintenance Servicing and assembling the module Clean all parts thoroughly and check for damage and wear. Treat all greased areas with lubricant. ( 9.3, Page 22) Oil or grease bare external steel parts. Compressed air is oiled. Replace all wear parts / seals. Position of the wearing parts ( 10, Page 25) Sealing kit ( 11, Page 26) Assembly Assembly takes place in the opposite order to disassembly. Observe the following: Unless otherwise specified, secure all screws and nuts with Loctite no. 243 and tighten with the appropriate tightening torque KHM 40 en

25 Assembly drawings 10 Assembly drawings Fig. 10 * Wearing part, replace during maintenance. Included in the seal kit. Seal kit can only be ordered completely. ** Contained in accessory pack KHM 40 en 25

26 Accessories kit 11 Seal kit ID.-No. of the seal kit Sealing kit for ID number KHM Contents of the seal kit ( 10, Page 25). 12 Accessories kit ID.-No. of the accessory pack Accessory pack for ID number KHM Contents of the accessories pack ( 10, Page 25) KHM 40 en

27 Translation of original declaration of incorporation 13 Translation of original declaration of incorporation In terms of the EC Machinery Directive 2006/42/EG, Annex II, Part B Manufacturer/ Distributor SCHUNK GmbH & Co. KG Spann- und Greiftechnik Bahnhofstr D Lauffen/Neckar We hereby declare that the following product: Product designation: ID number Linear unit, pneumatic / KHM 40 / pneumatic meets the applicable basic requirements of the Machinery Directive (2006/42/EC). The incomplete machine may not be put into operation until conformity of the machine into which the incomplete machine is to be installed with the provisions of the Machinery Directive (2006/42/EC) is confirmed. Applied harmonized standards, especially: EN ISO 12100: EN 62079:2001 Safety of machinery - General principles for design - Risk assessment and risk reduction Preparation of instructions - Structuring, content and presentation The manufacturer agrees to forward on demand the special technical documents for the incomplete machine to state offices. The special technical documents according to Annex VII, Part B, belonging to the incomplete machine have been created. Person responsible for documentation: Mr. Robert Leuthner, Address: see address of the manufacturer Lauffen/Neckar, September 2013 Ralf Winkler; Business Unit Manager R & D Mechanical Gripping Systems KHM 40 en 27

28 KHM 40 en

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