PIAB KCS Series User manual

Art. No. 0209961 Rev.00
Piab AB, 2017-07
MANUAL
KCS

KCS Series
Specifications subject to change without notice
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CONTENTS
Safety instructions..........................................................................................3
Overview ........................................................................................................6
Work cycle details for Flow reduction and Bag cup version...........................8
Installation ......................................................................................................9
Parts diagram...............................................................................................15
Maintenance.................................................................................................18
Problems/solutions.......................................................................................20
Technical data..............................................................................................21
Pneumatic diagram ......................................................................................22
Copyright protection
- This manual has the Use and Maintenance instructions for the vacuum gripping system and
as such it must be treated with the utmost confidentiality.
- It is intended exclusively for use by persons authorized in your company.
- The transfer to third parties can only take place with the prior written consent of Piab AB.
- All documentation is protected under the copyright law.
- Transmission to third parties and reproduction of this documentation is prohibited.
English

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Specifications subject to change without notice
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Safety instructions
General safety instructions
The correct use of pneumatic equipment within a system is the responsibility of the system
designer or the person who determines its technical specifications.
The use of safety guards is recommended to minimize the risk of injury to persons; pay close
attention to the fact that compressed air may lead to the explosion of closed containers, and
vacuum may lead to the implosion of closed containers. The vacuum generator, even if silenced,
makes noise: if necessary, wear suitable protection.
In the event that, contrary to indications, dusts, oil mists, fumes, etc. are suctioned, these will be
mixed with the discharge air of the vacuum generator and expelled via the discharge conduit; use
suitable, approved air filters to avoid possible intoxications.
The discharge air has a high output speed. Do not obstruct the discharge of the gripper module.
Ensure that the components are properly secured; regularly check that connections are in good
working order, as high cycles or vibrations may cause them to loosen.
Consider the possibility of pressure drops in the pneumatic supply line: then provide for a safety
system that, in order to prevent injury to the operator or damage to the machine, prevents the
risk of the piece being released.
Consider the possibility the electrical or pneumatic supply is interrupted, to protect persons and
systems.
Consider the emergency stop when designing the system.
Consider restarting the machine after an emergency stop and machine downtime in order to
avoid the risk of injury to persons and/or damage to the system.
The products in this manual are designed for implementation in industrial systems; therefore,
they should not be used under application conditions different from those specified.
Never look and / or insert the hands in any cavities, holes or openings (for example: the air
discharge, the openings/holes under the foam, etc.)
Pneumatic supply and connection
The supply pressure should not exceed the recommended one of 7 bar.
If the compressed air contains impurities, the components may malfunction. Install a filter
upstream of the component; the filter grade should be at least 5 µm.
Air containing excessive quantities of condensate may cause the components to malfunction.
Installing condensate drains or dryers prevents these malfunctions.
For more information, see the Installation and Commissioning section.
Electric connection
Connect the cables separately from power or high voltage lines, avoiding parallel wiring or
wiring in the same conduit of the same lines. Control circuits that include sensors and coils may
malfunction due to the noise from these other lines.
Carefully follow the electrical wiring instructions contained in the Installation and Commissioning
section, paying close attention to avoiding the short-circuiting of loads.

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Assembly
Compressed air may be dangerous if used by unskilled personnel. Assembling, using and
maintaining systems should solely be carried out by experienced and specially trained per-
sonnel. Both for fastening and supplying, solely use the bores and methods provided by the
manufacturer. Prior to assembly/disassembly of the components, cut off voltage and pressure.
Install and maintain the components only after thoroughly reading and understanding this
manual.
Environment
Do not use the component in direct contact with corrosive gases, chemical products, water or
vapor. For use in environments with droplets or splashes of water, oil, etc., provide suitable
protective covers. Do not use the component in explosive atmospheres.
Do not use in environments subject to strong vibrations and/or impact.
Provide suitable protection in case the component is exposed to direct sunlight. Do not ex- pose
to sources of heat.
Maintenance
Maintenance must be carried out in accordance with the instructions in this manual.
Prior to any maintenance work, check the conditions to prevent the sudden release of pieces,
then suspend pneumatic/electrical supply, and discharge residual pressure.
Safety instructions
►Handle the components with care
►During installation and maintenance, cut off voltage and pressure
►Modifying the components is prohibited
►Cleaning the environment and place of use is recommended
►Follow the installation and commissioning instructions
►The electrical and pneumatic connections should be permanently connected to the
component
Storage
For a correct storage of the incoming system or its spare parts, we recommend:
- Exclude outdoor areas, areas exposed to the elements or with excessive humidity or
exposed to direct sunlight.
- The environment must be sufficiently clean, arrange the system almost in such a way that it
has a stable base of support and make sure that there is no risk of unexpected movements.
- Position the equipment with the gripping elements upwards or on one side and well
protected.
Waste disposal
In case of disposal of the system or non-working parts, follow these procedures:
Provide for disposal to Authorized Bodies, in full compliance with current regulations regarding
waste.
Where non-reusable and / or deemed RAEE "waste" such as electrical and electronic
equipment are not to be given in urban waste collection bins. As far as the metal mass of the

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machine is concerned, the division between the steel parts and those in other metals or alloys is
sufficient for a correct sending to recycling by casting.
Failure to comply with the above rules may cause malfunctions, damage, injury, including with
serious consequences.

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Overview
Part list with flow reduction version
Pos.
Description
A
Pneumatic supply G 1/8” connection
B
Blow-off G 1/8” connection
C
Pump unit
D
Flow reduction module with technical foam
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Part list with bag cup version
Pos.
Description
A
Pneumatic supply G 1/8” connection
B
Blow-off G 1/8” connection
C
Pump unit
D
Bag cup module

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Work cycle details for Flow reduction and Bag cup version
The working cycle for a KCS gripping module follows the steps showed in the bellow:
1. Positioning the module at the object to handle with the grip pad parallel to the grip surface.
2. Lowering of module until contact with the grip surface. For fast cycle we suggest to
activate vacuum before be in contact with the object.
3. Pick-up of object to handle
4. Drop-off of object with removal of vacuum and blow-off ifnecessary
N.B. In this case, the activation for vacuum can be done
before or after the contact with the workpiece.
►Stopping or passing through the work area of the gripper module
is prohibited, as in case of electrical or pneumatic supply failure,
the load handled by the module is released.
►The vacuum value in the gripper is influenced by the degree of
coverage of the gripper. Higher is the degree of coverage, higher
is the vacuum level measured. So in this case the vacuum switch
can be used to check the grip.
Note: We recommend always running preliminary tests with original samples. We are able
to perform these tests for you.
English

KCS Series
Specifications subject to change without notice
9
Installation
Mounting on the adapter system
The pump unit is mounted on the special adapter system.
Pos.
Description
A
Special adapter system
B
Pump unit
C
Hole for ISO 4762 M5x12mm screw
Adapter ISO9409-1-50-4-M6 Adapter ISO9409-1-40-4-M6

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Quick change system
The pump unit and the gripper modules are connected by a quick change system.
Attention: the point 1 need to be aligned with the indication B.
Pos.
Description
A
Quick change system
B
Metal threaded insert for quick change system locking
C
Pump unit
D
Bag cup module
E
Flow reduction module

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Connecting integrated solenoid valve (EV)
Pos.
Description
A
Connection G 1/8” compressed air for pneumatic supply
B
Connection G 1/8” compressed air for blow off
C
Solenoid valve, vacuum, N.C.
D
Vacuum sensor
E
Connector M8 3 pole male
Specifications for solenoid valves
Fluid
Air
Operating pressure range (MPa/psi)
0.15-0.7/22-87psi
Operating temperature (°C/F)
-10 +50/14-122
Manual override
Push-locking slotted style
Lubrication
Not required
Impact/Vibration resistance (m/s²)
150/30
Electrical connection
Connector M8 3 pole
Coil rated voltage (Vcc)
24
Allowable voltage
±10% rated voltage
Current consumption (mA)
17
Surge voltage suppressor
Diode
Indicator light
LED

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Round head combination screw
M3x31, Matt nickel plated
Gasket
SYJ700-5-4
Push-turn slotted locking type (Type D)
While pressing, turn in the direction of the
arrow. If it is not turned, it can be opened in
the same way as the non-locking type.
Locked position:
Caution, when operating the
locking type D with a screw
driver, turn it gently using a
watchmakers screw driver.
[Torque: Less than 0.1 Nm/ 0.07
lbf]
With light/surge voltage suppressor (□ U)
Solenoid valve side pin wiring
diagram (for WA type)
Specifications for solenoid valve connector
Number and section of conductors (mm²)
3x0.25
Safety classification
IP 67
External diameter mm/in
4.1 /0.16
Max. curvature ray for flexing use
10 x external diameter
Case
PUR (UL/CSA)
Connections:
►3
Blue (-)
►4
Black
►1
Brown (+)

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►1. M8 connector has an indication of IP65 (enclosure) that give protection
to dust and water. Take note, however, that the product is not designed
to be used in contact with water.
►2. Do not use a tool to mount the connector, as this may cause damage.
Only tighten by hand. (0.4 to 0.6 Nm, (.30 to .44 lbf))
►3. The excessive stress on the cable connector will not be able to satisfy
the IP65 rating. Please use caution and do not apply a stress of 30 N
(6.74 lbf ) or greater.
►Torque couple of mounting screw M3: 0.8 Nm (0.59 lbf). Put attention at the
direction of mounting for electro valve and seal.
Specifications for vacuum sensor
Fluid
Air/Non-corrosive gas/Non-flammable gas
Rated pressure range
0 to –101 kPa
Extension analogue output range
10.1 to 0 kPa
Proof pressure
500 kPa
Power supply voltage
12 to 24 V DC 10 %, Ripple (p-p) 10 % or less (with
reverse connection protection)
Current consumption
15 mA or less
Output specifications
Analogue output 1 to 5 V (within rated pressure range), 0.6
to 1 V (within extension analogue output range), Output
impedance: Approx. 1 kΩ
Accuracy (Ambient temperature
at 25 °C)
±2 % F.S. (within rated pressure range), ±5 % F.S. (within
extension analogue output range)
Linearity
±0.4 % F.S.
Repeatability
±0.2 % F.S.
Power supply voltage effect
±0.8 % F.S.
Enclosure
IP40
Operating temperature range
Operating: 0 to 50 °C, Stored: –20 to 70 °C (No freezing or
condensation)
Operating humidity range
Operating/Stored: 35 to 85 % RH (No condensation)
Withstand voltage
1000 V AC (in 50 / 60 Hz) for 1 minute between terminals
and housing
Insulation resistance
50 MΩor more (500 V DC measured via megohmmeter)
between terminals and housing
Temperature characteristics
±2 % F.S. (25 °C reference)
Sensor cable
Oilproof heavy-duty vinyl cable (ellipse), 3 cores, 2.7 x 3.2,
Conductor area: 0.15 mm2, Insulator O.D.: 0.9 mm
Standards
CE, UL/CSA (E216656), RoHS

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Specifications for vacuum sensor pipping
Port size
Ø 4 reducer
Case
PBT
Pressure sensing section
Silicon, O-ring: NBR
Max. curvature ray for flexing use
10 x external diameter
Case
PUR (UL/CSA)
A = Ø 4 mm
B = 18 mm

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Parts diagram
Part diagram for pump unit
Pos.
Description
A
Plastic basic body
B
Ejector piCHIP SX422
C
Solenoid valve EV 3/2 N.C
D
Silencer
E
Vacuum sensor, analogue output 1 to 5 V connector Ø4 mm
F
M8 3 pole male connector
G
Metal threaded insert for quick change system lock

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Part diagram for pump unit + Bag cup module
Pos.
Description
A
Pump unit
B
X-RING
C
Bag cup plastic body
D
Screw for connection to pump unit

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Part diagram for pump unit + Flow reduction module
Pos.
Description
A
Pump unit
B
X-RING
C
Flow reduction module plastic body
D
Screw for connection to pump unit
E
Fixing Screws for technical foam with mounting plate
F
Technical foam with mounting plate
G
Technical foam

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Maintenance
-Remove the old foam.
-Clean the metal plate from any
adhesive and dust residues (e.g. with
solvent)
-Attention: Be careful that the holes are
not blocked by any kind of residue, if
they are, clean them.
-Remove the silicon paper from the
foam.
-Align the holes on the metal plate
and on the foam
-Fix the new foam on metal plate
-Attention: Prevent formation of
channels, they must be avoided.

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-Press the new foam
-To store the foam:
Temperature (5 °C to 25 °C)
Not under the light
Be free of tension
No dust
chemical protected
Maintenance plan
Daily
Weekly
Monthly
Every 6
months
Every 12
months
Check Max vacuum level of the
ejector
•
Check the micro holes
•
Check the silencer
•
Check tightenings
•
Check the foam
•
Check supply air pressure
•
Check the electrical connection
•
Check the air connection
•
Check the general condition
•
Clean gripper exterior
•

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Problems/solutions
Problem
Possible reason
Solutions
Insufficient vacuum level
or vacuum achieved too
slowly
Operating pressure too low
Increase the pressure
Internal diameter of pressure
hose too small
Use hoses with larger internal
diameter
Damaged sealing
Check and replace if
necessary
Leak in pressure hose
Check hoses
Dirty ejector
Clean
Object not gripped
Low vacuum level
See above
Insufficient suction capacity
change the ejector
version
Dirty micro holes
Clean
Lift is too fast
Slow down lift, avoid
acceleration peaks
Pieces not suitable for lift with
this system
Replace grip solution
Occluded foam filter (with filter
version)
Clean
Occluded silencer
Replace silencer
Foam wears very quickly
The system is not corrected
placed on the workpiece
The gripping system must
be parallel to the workpiece
surface
Note: We recommend always running preventative tests with original samples. We
are available for running such tests.