PIAB KCS Series User manual

KCS SERIES
ASSEMBLY MANUAL
Rev: 02
www.piab.com

INDEX
1. GENERAL SAFETY INSTRUCTIONS....................................................................................................................................3
2. DANGEROUS AREAS .............................................................................................................................................................5
3. PICTOGRAMS........................................................................................................................................................................... 6
4. R.E.S.S. APPLIED AND RESPECTED.................................................................................................................................... 7
5. INSTALLATION ........................................................................................................................................................................ 9
6. WORKING CYCLE DETAILS.................................................................................................................................................17
7. PARTS LIST.............................................................................................................................................................................. 18
8. MAINTENANCE ..................................................................................................................................................................... 21
9. PROBLEMS/SOLUTIONS.....................................................................................................................................................22
10. ACCESSORIES ........................................................................................................................................................................23
11. TECHNICAL DATA ................................................................................................................................................................25
12. PNEUMATIC DIAGRAM.......................................................................................................................................................26
13. SPARE PARTS.........................................................................................................................................................................28
14. WARRANTIES .........................................................................................................................................................................29

Page 3 of 30
1. 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 prevent 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.
Pneumatic supply and connection
The supply pressure should not
exceed the recommended one of 7
Bar. (102 psi)
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, paying close attention
to avoiding the short-circuiting of
loads.
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
personnel. 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.
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 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.

Page 4 of 30
Intended use
The gripper is intended exclusively for handling, lifting and storing products of appropriate size, as reported in the
agreement.
The products handled by this equipment must have the following characteristics:
-They must not be deformed;
-Have a uniform height over the entire gripping surface. Any height differences must be reported in the agreement. If
they are not reported, Piab AB and / or Kenos will not be responsible for malfunction.
Not intended use
The gripper must not be used:
-For uses other than those established by the manufacturer or reported in this manual;
-In direct contact with corrosive gases, chemical products, water, vapor or in environments with droplets or splashes of
water, oil, etc.;
-In explosive atmospheres;
-In environments subject to strong vibrations and/or impacts;
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 parts of the system are concerned, it is sufficient to subdivide the different materials
for a correct recycling by casting.
Identification data and product number
Example of label:
Each product is identified by a label on which the reference data of the same are indelibly marked.
For any communication with PIAB or service centers always quote these references.
Kenos Code: K-06-00083-00
Type model product: KCS.Q110.N301.110.FR6.SX422.X.X.50
Item no: 9936329
Foam spare part no: 9936294
Foam spare part MP no: -
Country of origin: ITALY
-- 29/01/2019 --

Page 5 of 30
2. DANGEROUS AREAS
Areas with danger of crushing
Areas with danger of air ejection
Notes for the final manufacturer of machinery
It is prohibited stopping or passing through the work area of the gripper module. In case of electrical or pneumatic supply
failure, the load handled by the module is released.
Never look and / or insert the hands in cavities, holes or openings (for example: air discharge, openings / holes under the
foam etc.).
The gripping module described in this manual is designed for implementation in industrial systems; therefore, it must not be
used with the conditions other than those specified.
The final evaluation of the safety systems to be applied for starting up the system, after the assembly of the gripping module,
is the task of the final manufacturer of machinery. It is up to the final manufacturer of machinery to report the PPE needed
by the operators who are stationed in the surroundings or the operators who have access to the work area. In addition, the
same manufacturer will certify the final commissioning according to the regulations in force for each individual country.

Page 6 of 30
3. PICTOGRAMS
PIC.
DESCRIPTION
Generic danger. Warning!
Danger of crushing or entrapment of upper limbs!
Danger of air ejection or expulsion of particles!
Pictograms related to the operator's qualification highlighted in this manual
PIC.
DESCRIPTION PICTOGRAMS
Generic manual: operator without specific skills, able to perform only simple tasks on the orders of qualified
technicians.
Mechanical maintenance technician: qualified technician able to intervene on the mechanical parts to make
the necessary adjustments, maintenance and repairs.
Electric maintenance technician: qualified technician is proposed to all the electrical interventions of
regulation, maintenance and repairs.

Page 7 of 30
4. R.E.S.S. APPLIED AND RESPECTED
Essential Health and Safety Requirement
Compliance
1 ESSENTIAL SAFETY AND PROTECTION OF HEALTH
1.1 General considerations
1.1.1 definitions
√
1.1.2 Principles of safety integration
√
1.1.3 Materials and products
√
1.1.4 Lighting
1.1.5 Design of machinery to facilitate its handling
√
1.1.6 Ergonomics
1.1.7 Jobs
1.1.8 Seats
1.2.1 Safety and reliability of control systems
1.2.2 Control devices
1.2.3 Startup
1.2.4 Shutdown
1.2.4.1 Normal Shutdown
1.2.4.2 Operational stop
1.2.4.3 Emergency Stop
1.2.4.4 Assembling machines
√
1.2.5 Selection of control or operating
1.2.6 Failure of the power supply
1.3 Measures of protection against mechanical hazards
1.3.1 Risk of loss of stability
1.3.2 Risk of break-up during operation
√
1.3.3 Risks due to falling or ejected objects
√
1.3.4 Risks due to surfaces, edges or corners
√
1.3.5 Risks related to combined machinery
1.3.6 Risks related to variations in operating conditions
1.3.7 Risks related to moving parts
√
1.3.8 Choice of protection against risks related to moving parts
1.3.8.1 Moving transmission
1.3.8.2 Moving parts directly involved in the process
1.3.9 Risks of uncontrolled movements
1.4 Required characteristics of guards and protection devices
1.4.1 General Requirement
√
1.4.2 Requirement for special shelters
1.4.2.1 Repair fixed
1.4.2.2 Interlocking movable guards
1.4.2.3 Adjustable guards restricting access
1.4.3 Special requirements for protective devices

Page 8 of 30
Essential Health and Safety Requirement
Compliance
1.5 Risks due to other hazards
1.5.1 Electric Power
1.5.2 Static Energy
1.5.3 Energy supply other than electricity
√
1.5.4 Assembly errors
1.5.5 Extreme temperatures
1.5.6 Fire
1.5.7 Explosion
1.5.8 Noise
√
1.5.9 Vibrations
1.5.10 Radiation
1.5.11 External Radiation
1.5.12 laser radiation
1.5.13 Emission of hazardous materials and substances
1.5.14 Risk of being trapped in the machine
√
1.5.15 Risk of slipping, tripping or falling
1.5.16 Lightning
1.6 Maintenance
1.6.1 Maintaining the Machine
√
1.6.2 Access to jobs and servicing points used for the maintenance
1.6.3 Isolation from sources of energy supply
1.6.4 Operator intervention
√
1.6.5 Cleaning of internal parts
√
1.7 Informations
1.7.1 Information and warnings on the machine
√
1.7.1.1 Information and information devices
1.7.1.2 Warning Devices
1.7.2 Warning of residual risks
√
1.7.4 Instructions
√
1.7.4.1 Basis of preparation
√
1.7.4.2 Contents of the instructions
√
1.7.4.3 Publications illustrative and promotional

Page 9 of 30
5. INSTALLATION
a. Mounting on the adapter system
The pump unit is mounted on the special adapter system.
b. 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
Special adapter system
B
Pump unit
C
Adapter fixing screws
Pos.
Description
A
Quick change system
B
Metal threaded insert for quick change system locking
C
Pump unit
D
Bag cup unit
E
Foam gripper unit

Page 10 of 30
c. Ejector exhaust
The blue arrows show the exhaust air flow, DO NOT COVER the silencer.
d. Pneumatic connection basic version
Pos.
Description
A
Compressed air connection G1/8” for vacuum (1a)
B
Compressed air connection G 1/8” for blow-off (1b) or vacuum monitoring
C
Pump unit
D
Foam gripper unit
E
Bag cup unit

Page 11 of 30
e. Connecting integrated solenoid valve (V1 / V3) with vacuum sensor version
Solenoid valves characteristics
Fluid
Air
Operating pressure range (MPa/psi)
0.15-0.7/22-87
Operating temperature (°C/F)
-10 +50/14-122 without icing
Manual override
Push-locking slotted style
Lubrication
Not required
Impact/Vibration resistance (m/s²)
150/30
Electrical connection
Connector M8 3 pole male
Coil rated voltage (Vcc)
24
Allowable voltage
± 10% rated voltage
Current consumption (mA)
17
Surge voltage suppressor
Diode
Indicator light
LED
Pos.
Description
A
Compressed air connection G 1/8” for solenoid valve
B
Compressed air connection G 1/8” for blow off or vacuum monitoring
C
Solenoid valve, vacuum, N.C. / N.O.
D
Vacuum sensor
E
Connector M8 3 pin male

Page 12 of 30
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 (+)
Round head combination screw
M3x31, Matt nickel plated

Page 13 of 30
f. Connecting integrated solenoid valve (V2) with vacuum sensor version
Pos.
Description
A
Compressed air connection G 1/8” for solenoid valve
B
Compressed air connection G 1/8” for blow off or vacuum monitoring
C
Solenoid valve, vacuum and blow-off N.C. / N.C.
D
Vacuum sensor
E
Connector M8 3 pin male
Solenoid valves characteristics
Fluid
Air
Operating pressure range (MPa/psi)
0.15-0.7/22-87psi
Operating temperature (°C/F)
-10 +50 / 14-122 without icing
Manual override
Non-locking push type
Lubrication
Not required
Impact/Vibration resistance (m/s²)
150/30
Electrical connection
M12 4 pin waterproof connector, Male
Coil rated voltage (Vcc)
24
Allowable voltage
± 10% rated voltage
Current consumption (mA)
27
Surge voltage suppressor
Zener Diode
Indicator light
LED
Solenoid valve A
Vacuum
Solenoid valve B
Blow off
►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.
►Do not use a tool to mount the connector, as this may cause damage. Only tighten by hand. (0.4 to
0.6 Nm, (0.30 to 0.44 lbf))
►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.

Page 14 of 30
M12 Waterproof connector wiring specifications
Note: Solenoid valves have no polarity.
Connection destination (female side) connector cable
Note: This connector is a female connector for (1) relay output model and (2) single unit / sub-plate.
Connector Size
Pin
Manufacturer
Applicable series
M12
4
Correns Corporation
VA-4D
OMRON Corporation
XS2
Azbil Corporation
PA5-41
Hirose Electric OMRON
Corporation Ltd.
HR24
DDK Ltd.
CM01-8DP4S
Coil
Coil
3 (COM)
Solenoid valve side pin
wiring
diagram
Circuit diagram
Solenoid
A:
Solenoid
B:
Solenoid A
Solenoid B
Indicator light
Solenoid B
Solenoid A
Manual override for solenoid B (Green)
Manual override for solenoid A (Orange)
A:Orange
B:Green
Caution
When equipped with indicator light and surge
voltage suppressor, the light window turns
orange when solenoid A is energized, and it
turns green when solenoid B is energized.
4 pin connector M12 plug

Page 15 of 30
Specifications for vacuum sensor “MA” version
Specifications for vacuum sensor pipping
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
Electrical connection
Connector M8 3 pole male
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
(Analog output)
Blue DC (-)
Brown DC (+)
Load
Main circuit
Black out

Page 16 of 30
M8 3 poles male connector:
Connections:
►3
Blue (-)
►4
Black
►1
Brown (+)
MALE
Pressure
Analog output [V]

Page 17 of 30
6. WORKING CYCLE DETAILS
Working 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 if necessary.
Note: In this case the activation of vacuum can be done before or after the contact with the workpiece.
Note: We recommend always running preliminary tests with original samples. We are able to perform these tests
for you.
►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.
►With the Flow reduction technology, the vacuum value in the gripper is the real vacuum
level on the object, so in this case the vacuum switch can be used to check the grip.
►Take in consideration that the vacuum level is influenced by the degree of coverage on
the gripper and the porosity of object.

Page 18 of 30
7. PARTS LIST
a. Pump unit parts list
Pos.
Description
A
Plastic basic body
B
Ejector piCHIP SX42 or SX12
C
Solenoid valve
D
Silencer
E
Vacuum sensor
F
M8 3 pin male connector
G
Metal threaded insert for quick change system lock

Page 19 of 30
b. Pump unit + Bag cup unit parts list
Pos.
Description
A
Pump unit
B
X-Ring
C
Bag cup plastic body
D
Screw for connection to pump unit

Page 20 of 30
c. Pump unit + Foam gripper unit parts list
Pos.
Description
A
Pump unit
B
X-Ring
C
Foam gripper plastic body
D
Screw for connection to pump unit
E
Fixing Screws for technical foam with mounting plate
F
Mounting plate
G
Technical foam