RSP Moduflex Series Installation And Maintenance Manual
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RSP Moduflex Series Installation And Maintenance Manual

Manual tool changers
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Installation and Maintenance
Manual
Tool changers Moduflex-series
M0720-1
Tool changers | Swivels | Swivels with Tool changers | Grippers | Hose packages | Valve Units | Tool systems

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Summary of Contents for RSP Moduflex Series

  • Page 1 Installation and Maintenance Manual Tool changers Moduflex-series M0720-1 Tool changers | Swivels | Swivels with Tool changers | Grippers | Hose packages | Valve Units | Tool systems...
  • Page 2 M0720-1 ver 3.4...
  • Page 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.

  • Page 4: Table Of Contents

    2.7 Mounting of TC ground socket, P7239 .................20 2.8 Mounting of TA ground socket, P7147 .................21 3 TC OPERATION AND INTERFACE ................22 3.1 Software function with RSP integrated safety module ..........22 3.2 Software function without RSP integrated safety module ..........22 3.3 Sparking ........................25 3.4 Programming.........................25...
  • Page 5 6 DISMOUNTING AND REPLACEMENT .................41 6.1 Replacement of tool changer ..................41 6.2 Replacement of tool attachment .................. 43 6.3 Replacement of wear parts ..................45 6.3.1 Replacement of dampers on tool changers..............45 6.3.2 Replacement of guide pins on tool changers ..............46 6.3.3 Replacement of guide bushings on tool attachments ...........48 6.3.4 Replacement of spring-loaded signal pins ..............49 6.3.5 Replacement of water/air couplings ................50...

  • Page 6: Introduction

    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 1.1 Installation and Maintenance manual This document describes how the Moduflex group of tools changers, TC240, TC480, TC720 and TC960, including corresponding tool attachments and options f or transfer of power, signals, water and air are installed and replaced.

  • Page 7: Safety

    1.2 Safety 1.2.1 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 to be 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 followed.

  • Page 8: Tightening Torques

    1.3 Tightening torques Tightening torques for mounting (screw class 8.8) Dimension Torque 3 Nm 6 Nm 10 Nm 24 Nm 47 Nm 82 Nm 200 Nm Tightening torques for mounting (screw class 12.9) Dimension Torque 41 Nm 79 Nm 138 Nm 221 Nm 338 Nm 1.4 Recommended equipment...

  • Page 9: Required Products

    1.5 Required products Products required for installation and maintenance work Product Specification Note Grease, 3HXG1000-413 Magnalube-G, Tef lon grease For air sealings and water/air couplings. Grease Electrolube SGB Contact For weld and servo power sockets. Treatment Grease 3HXG1000-262 Grease I0876 Molykote BR2Plus For guide pins, guide bushings and locking balls.

  • Page 10: Installation

    2 INSTALLATION 2.1 Installation of tool changer on robot Action Note Safety Read the saf ety section (1.2) Service position Place the robot in service position Power off Switch the power of f and lock the circuit breaker. NOTE! Read the saf ety chapter f or the robot.
  • Page 11 Connect air and water Connect air and water hoses to the hose f ittings. Ensure they are tightly attached with securing straps. Pneumatic diagrams are f ound in the product description of respective unit. Connect signals Connect electrical connectors and f ield bus in accordance with selected options.

  • Page 12: Installation Of Tool Attachment To Tool

    2.2 Installation of tool attachment to tool Action Note Safety Read the saf ety section (1.2). Mount guide pin Press a guide pin into its position on the tool. Fit the tool attachment Lif t and f it the tool attachment with the tool.
  • Page 13 Connect air and water hoses Connect air and water hoses to the hose f ittings. NOTE! Water f orward and return must be connected in accordance with corresponding connections on the robot side. Pneumatic diagrams are f ound in the product description of respective unit.

  • Page 14: Mounting Of Cable/Cables In Weld Power Connectors, P6716/P6784 And P6726

    2.3 Mounting of cable/cables in weld power connectors, P6716/P6784 and P6726 Action Note Remove screws Remove the f our M4x25 screws or M5x30 screws (depending on unit), on the rear side of the weld power connector holding the cover. Remove cover Insert two M5 screws respective M6 screws (depending on unit), in the...
  • Page 15 Mount cable Insert weld cable/cables and mount the cable lugs with washers and M8 nuts. NOTE! PE shall be in the centre. The other two, U and V, are f ree to place. Place marking labels accordingly. NOTE! Maximum torque f or the M8 nuts are 6 Nm.

  • Page 16: Mounting Of Electric Modules On Tool Changer Or Tool Attachment

    2.4 Mounting of electric modules on tool changer or tool attachment Action Note Fit module Fit the signal, f ield bus, servo power and/or weld power module the tool changer/tool attachment. NOTE! When guide pins are used make sure they are f itted to the corresponding guide holes in the tool changer/tool attachment.

  • Page 17: Mounting Of Water/Air Modules On Tool Changer Or Tool Attachment

    2.5 Mounting of water/air modules on tool changer or tool attachment Action Note Fit module Fit the water/air module to the tool changer/tool attachment. NOTE! When guide pins are used make sure they are f itted to the corresponding guide holes in the tool changer/tool attachment.

  • Page 18: Mounting Of Integrated Valve, P7710

    2.6 Mounting of integrated valve, P7710 Action Note Mount circuit board Mount the circuit board with the enclosed M3x6 screw. Mount cable Mount the cable with the cable tray cover mounted on the tool changer. Fasten with the two M3x6 screws. NOTE! The two M3 screws must be loosened bef ore the cable is mounted.
  • Page 19 Mount silencers Insert and mount the two silencers. Mount valve Insert and mount the valve with two M3x45 screws. Mount valve cover Insert and mount the valve cover with two M4x8 screws. Mount rear valve cover Insert and mount the rear valve cover with two M4x6 and two M4x8 screws.

  • Page 20: Mounting Of Tc Ground Socket, P7239

    Mount PE label Mount the enclosed PE label in the dedicated area close to the RSP label. Mount PE cabling Mount the robots earth cable with either an M8 or an M5 screw. NOTE! The dedicated screw holes are situated close to the PE marking.

  • Page 21: Mounting Of Ta Ground Socket, P7147

    NOTE! Apply a small amount contact grease bef ore mounting. NOTE! The dedicated hole can be f ound close to the RSP label. Mount PE label Mount the enclosed PE label in the dedicated area close to the RSP label.

  • Page 22: Tc Operation And Interface

    3 TC OPERATION AND INTERFACE 3.1 Software function with RSP integrated safety module When the RSP integrated safety module is used the procedures and software logic described in the product manual M8353-1 Integrated safety module shall be adhered to by the system integrator installing the tool changer.
  • Page 23 Piston status monitoring sensors Signal “TC Closed” Signal “TC Opened” There are two sensors built in into the main body supervising the location of the piston. Signal “TC Opened” is high when the piston is in open position. Signal “TC Closed” is high when the piston is in locked position. Signal logic for picking up a tool Open the tool changer by setting signals “doOpen TC 1”...
  • Page 24 Signal logic for leaving a tool in the tool stand Opening of tool changer should only be possible when tool is positioned in tool stand. A switch or sensor mounted at the tool stand should give a signal that allows the tool changer to open.

  • Page 25: Sparking

    3.3 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. 3.4 Programming The following will ensure a correct docking position. Action Attach a spare tool attachment to the tool changer.

  • Page 26: Maintenance And Service

    4 MAINTENANCE AND SERVICE The tool changer and tool attachment must be maintained regularly to ensure proper function. The specified intervals are approximate and valid under normal conditions, corresponding to 2 tool changes per minute during 2 work shifts per working day, i.e. 42.000 changes per month. Under extreme conditions, such as dirty environments or extreme robot movements, the intervals should be shortened.

  • Page 27: Every Six-Months Or After Every 250,000 Tool Changes

    4.1.3 Every six-months or after every 250,000 tool changes The f ollowing maintenance activities should be carried out every six-months or af ter every 250,000 tool changes, whichever comes f irst. Activity Equipment Description Cleaning Tool changer Locking balls Clean locking balls and add new lubrication, (see section 4.2.5).

  • Page 28: Specification Of Maintenance Activities

    4.2 Specification of maintenance activities 4.2.1 Visual inspection of tool changer (every 2nd week) The f ollowing maintenance activities should be carried out on the TC every 2 week. Action Note Check locking balls Check each ball to make sure it moves f reely.
  • Page 29 Check servo power socket Check that the area around the servo power sockets is clean. For cleaning and lubrication see section 4.2.5. Check that the servo power sockets are not worn-out or damaged. If worn-out or damaged replace module, see section 6.3.10.

  • Page 30: Visual Inspection And Cleaning Of Tool Attachment (Every 2Nd Week)

    4.2.2 Visual inspection and cleaning of tool attachment (every 2nd week) The f ollowing maintenance activities should be carried out on the TA every 2 week. Action Note Check guide bushings Check that the guide bushings are greased. For cleaning and lubrication see section 4.2.6.
  • Page 31 Check air sealings Check that the air sealings are clean. For cleaning see section 4.2.4. Check that the air sealings, or the module, are not damaged. For replacing air sealings see section 6.3.8. For replacing the module see section 6.3.11. Check O-rings Check that O-rings on signal and power modules are not worn-out...

  • Page 32: Cleaning And Lubrication Of Tc (Every 3Rd Month Or 125,000 Tool Changes)

    4.2.3 Cleaning and lubrication of TC (every 3rd month or 125,000 tool changes) The f ollowing maintenance activities should be carried out on the tool changer every 3 month or af ter 125,000 tool changes, whichever comes f irst. Action Note Clean around weld power sockets Wipe the outer parts of the weld...

  • Page 33: Cleaning And Lubrication Of Tool Attachment (Every 3Rd Month Or 125,000 Tool Changes)

    4.2.4 Cleaning and lubrication of tool attachment (every 3rd month or 125,000 tool changes) The f ollowing maintenance activities should be carried out on the tool attachment every 3 month or af ter 125,000 tool changes, whichever comes f irst. Action Note Clean water/air couplings...

  • Page 34: Cleaning And Lubrication Of Tc

    4.2.5 Cleaning and lubrication of TC (every 6 month or 250,000 tool changes) The f ollowing maintenance activities should be carried out on the tool changer every 6 month or af ter 250,000 tool changes, whichever comes f irst. Action Note Clean locking balls Check the locking balls and wipe...
  • Page 35 Clean signal pins Clean the contact surf aces of the spring-loaded signal pins with a nylon brush. NOTE! Signal pins shall be cleaned whenever blackened. Lubricate servo power socket Wipe the area around the servo power sockets clean and apply a small amount of grease (Electrolube SGB) in the sockets.

  • Page 36: Cleaning And Lubrication Of Tool Attachment (Every 6Th Month Or 250,000 Tool Changes)

    4.2.6 Cleaning and lubrication of tool attachment (every 6th month or 250,000 tool changes) The f ollowing maintenance activities should be carried out on the tool attachment every 6th month or af ter 250,000 tool changes, whichever comes f irst. Action Note Clean locking cavities...
  • Page 37 Lubricate servo power pins Apply a small amount of grease (Electrolube SGB) on the servo power pins. Clean weld power pins Wipe clean the weld power pins with a lint f ree cloth! M0720-1 ver 3.4...

  • Page 38: Manual Unlocking Of Tool Changer

    5 MANUAL UNLOCKING OF TOOL CHANGER 5.1 Manual unlocking In case of failure of the control system controlling the integrated valve, the tool attachment can be released through manual operation of the twin switches on the integrated valve. Action Note Safety Read the saf ety section (1.2).

  • Page 39: Forced Manual Unlocking, P6910

    5.2 Forced manual unlocking, P6910 In case the tool attachment is jammed and mechanically stuck to the tool changer, the tool attachment can be released using a forced opening kit and a grease gun. Such forced opening kit, with product number P6910, can be obtained from Robot System Products. NOTE! Forced manual unlocking shall only be carried out when tool attachment is stuck to the tool changer and cannot be released through other means.
  • Page 40 Analysis and overhaul NOTE! Af ter f orced unlocking, a f ailure analysis and a complete overhaul of the tool changer should be perf ormed. It is recommended that these are carried out by qualif ied RSP personnel. M0720-1 ver 3.4...

  • Page 41: Dismounting And Replacement

    6 DISMOUNTING AND REPLACEMENT 6.1 Replacement of tool changer Action Note Safety Read the saf ety section (1.2). Dismount tool Leave tool, with tool attachment mounted, in tool stand. Service position Place the robot in service position. NOTE! The tool change f unction shall be in locked position.
  • Page 42 Remove screws Remove the screws holding the tool changer to the robot f lange. WARNING! The tool changer is heavy and may cause personal injury and equipment damage if dropped. Dismount tool changer NOTE! Be caref ul not to damage the signal pins at the tool side of the tool changer.

  • Page 43: Replacement Of Tool Attachment

    6.2 Replacement of tool attachment Action Note Safety Read the saf ety section (1.2). Undock tool Place and undock tool attachment, with tool mounted, in a saf e and f ully supported position f or dismounting. Dismount hoses Dismount the water/air hoses f rom the tool attachment.
  • Page 44 Dismount tool attachment NOTE! A guide pin is mounted between the tool attachment and the tool. Clean the flange at the tool Mount tool attachment Follow instructions in section 2.2. M0720-1 ver 3.4...

  • Page 45: Replacement Of Wear Parts

    6.3 Replacement of wear parts 6.3.1 Replacement of dampers on tool changers Replace dampers when damaged. Action Note Remove dampers Remove dampers with a screw driver. NOTE! There are totally 4 dampers on TC240 and totally 3 on TC480, TC720 and TC960 respectively.

  • Page 46: Replacement Of Guide Pins On Tool Changers

    6.3.2 Replacement of guide pins on tool changers Replace guide pins when worn-out or damaged. Action Note Loosen stop screws Loosen the two M6 socket head cap screws securing the guide pins. Mount puller housing Enter the puller housing of the Guide pin puller (VA0178.004) over the guide pin.
  • Page 47 Dismount guide pins Pull out the guide pin by screwing the M10 nut clockwise with a 16 mm spanner. NOTE! The puller screw shall be kept in position with a 16 mm spanner! Mount new guide pins Apply Loctite 638 on the guide pins and in the guide pin holes.

  • Page 48: Replacement Of Guide Bushings On Tool Attachments

    Use a sliding hammer with bearing puller. NOTE! A special demounting tool, P0230- 141, can be ordered f rom RSP. Clean bushing holes Remove all remaining parts of glue and clean with industrial alcohol or similar. Mount new guide bushings...

  • Page 49: Replacement Of Spring-Loaded Signal Pins

    6.3.4 Replacement of spring-loaded signal pins Replace spring-loaded signal pins when worn-out or damaged. Action Note Switch power off Switch the power of f and lock the circuit breaker. Remove signal pins Pull out the signal pins with a pair of pliers. Replace signal pins Fit the new signal pins by pushing them into the...

  • Page 50: Replacement Of Water/Air Couplings

    6.3.5 Replacement of water/air couplings Replace water/air couplings when worn-out, leaking or damaged. Action Note Water and air off Switch of f and evacuate water and pneumatic air. Clean water/air couplings Clean the area around the water/air couplings. Remove water/air couplings Remove the water/air couplings with a 27mm socket wrench.
  • Page 51 Lubricate new water/air couplings Apply a small amount of grease (Magnalube-G) on the O-ring and threads. Mount new water/air couplings Mount the new water/air coupling and apply a small amount of grease (Magnalube-G) on the contact surf ace. NOTE! Tightening torque 20Nm. Water and air on Switch on water and pneumatic air.

  • Page 52: Replacement Of Weld Power Sockets

    6.3.6 Replacement of weld power sockets Replace weld power sockets when worn-out or damaged. Action Note Switch power off Switch the power of f and lock circuit breaker. NOTE! Both weld and robot power must be switched of f . Remove screws Remove the f our M4 screws which are holding the cover on...
  • Page 53 Remove cover Remove the two M4 screws and the cover on the f ront side. Pull out weld power sockets Pull out the three weld power sockets. NOTE! Be caref ul not to drop or damage the O-rings around the sockets.
  • Page 54 Mount cover Mount the cover on the f ront side with two M4 screws. Mount cable lugs and nuts Mount the cable lugs at the weld cable with washers and M8 nuts, on the rear side of the weld power connector. NOTE! Maximum torque f or the M8 nuts are 6 Nm.

  • Page 55: Replacement Of Weld Power Pins

    6.3.7 Replacement of weld power pins Replace weld power pins when worn-out or damaged. Action Note Remove screws Unscrew and remove the f our M5 screws holding the cover on the rear side of the weld power connector. Remove cover Insert two M6 screws to remove the cover.
  • Page 56 Remove nuts and weld cable Remove the cable lugs f rom the backside of the weld power pins. Release weld power pins Unscrew and remove the three M8 nuts holding the weld power pins Pull out weld power pins Pull out the three weld power pins f rom the opposite side of the interf ace.
  • Page 57 Fasten weld power pins Fasten the replaced weld power pins with three M8 nuts f rom the rear side of the weld contact. NOTE! Maximum torque is 6 Nm. Mount weld cable Mount the cable lugs of the weld cable with washers and three M8 nuts NOTE! Maximum torque...

  • Page 58: Replacement Of Air Sealings

    6.3.8 Replacement of air sealings Replace air sealings when damaged. Action Note Air off Switch of f pneumatic air. Remove air sealings Remove the air sealings with a screw driver. NOTE! There are totally 4 air sealings on each unit. Clean sealing holes Remove all remaining parts of the sealing.

  • Page 59: Replacement Of O-Rings On Signal Modules

    6.3.9 Replacement of O-rings on signal modules Replace O-rings when worn-out or damaged. Action Note Remove O-rings Remove the O-ring/O- rings on the tool attachments signal contact. Replace O-rings Put small amount of grease (Magnalube-G) on the new O-rings bef ore they are mounted.

  • Page 60: Replacement Of Electric Modules On Tool Changer Or Tool Attachment

    6.3.10 Replacement of electric modules on tool changer or tool attachment Action Note Disconnect electric connections Disconnect electrical and f ield bus connectors f rom the module. NOTE! Handle contacts with care, as they are sensitive to mechanical damage. Make sure that no dirt enters the contacts.

  • Page 61: Replacement Of Water/Air Modules On Tool Changer Or Tool Attachment

    6.3.11 Replacement of water/air modules on tool changer or tool attachment Action Note Disconnect air/water Disconnect air and water hoses f rom the air/water- module. Release module Unscrew and remove the two M10-screws holding the module. WARNING! The module may be heavy and may cause personal injury and equipment damage if...

  • Page 62: Disposal And Recycling

    7 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.
  • Page 63 M0720-1 ver 3.4...
  • Page 64 M0720-1 ver 3.4...

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M0720-1

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