RSP Moduflex Series Instruction Manual

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

2 M0720-1ver 3.4

M0720-1 ver 3.4 3
The information in this document is subject to change without prior notice and should not be
regarded as an undertaking from RobotSystem Products AB. Robot System Products AB
assumes no responsibility for errors that may occurin this document.
Robot System Products AB bears no responsibility fordamage that is incurred by the use of this
document, or the software or hardware described in this document.
The document, or parts of it, may not be reproduced or copied without prior permission from
Robot System Products AB. It may neither be imparted to a third party,nor otherwise be used
without authorization. Infringementhereof will be subject to action in accordancewith the
applicable laws.
Further copies of this document canbe obtained from Robot System Products ABat
current prices.
© Robot System Products AB
Robot Systems Products AB
Isolatorvägen 4
SE–721 37 Västerås
Sweden

4 M0720-1ver 3.4
CONTENTS
1 INTRODUCTION..................................................................................................................6
1.1 Installation and Maintenance manual.............................................................................6
1.2 Safety..............................................................................................................................7
1.2.1 General .....................................................................................................................7
1.2.2 Explanation of warnings..............................................................................................7
1.3 Tightening torques ..........................................................................................................8
1.4 Recommended equipment..............................................................................................8
1.5 Required products...........................................................................................................9
2 INSTALLATION.................................................................................................................10
2.1 Installation of tool changer on robot .............................................................................10
2.2 Installation of tool attachment to tool............................................................................11
2.3 Mounting of cable/cables in weld power connectors, P6716/P6784 and P6726.........14
2.4 Mounting of electric modules on tool changer or tool attachment ...............................16
2.5 Mounting of water/air modules on tool changer or tool attachment.............................17
2.6 Mounting of integrated valve, P7710............................................................................18
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
3.5 Tool Stand.....................................................................................................................25
3.6 Tool Identification..........................................................................................................25
4 MAINTENANCE AND SERVICE....................................................................................26
4.1 Maintenance scheme....................................................................................................26
4.1.1 Every second week ..................................................................................................26
4.1.2 Every three-months or every 125,000 tool changes ....................................................26
4.1.3 Every six-months or after every 250,000 tool changes ................................................27
4.1.4 To replace when damaged or worn-out......................................................................27
4.2 Specification of maintenance activities.........................................................................28
4.2.1 Visual inspection of tool changer (every 2nd week).....................................................28
4.2.2 Visual inspection and cleaning of tool attachment (every 2nd week) ............................30
4.2.3 Cleaning and lubrication of TC (every 3rd month or 125,000 tool changes) ..................32
4.2.4 Cleaning and lubrication of tool attachment (every 3rd month or 125,000 tool changes) 33
4.2.5 Cleaning and lubrication of TC (every 6th month or 250,000 tool changes) ...................34
4.2.6 Cleaning and lubrication of tool attachment (every 6th month or 250,000 tool changes) 36
5 MANUAL UNLOCKING OF TOOL CHANGER ...........................................................38
5.1 Manual unlocking..........................................................................................................38
5.2 Forced manual unlocking, P6910.................................................................................39

M0720-1 ver 3.4 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 guidebushings on tool attachments...................................................48
6.3.4 Replacement of spring-loaded signal pins ..................................................................49
6.3.5 Replacement of water/air couplings ...........................................................................50
6.3.6 Replacement of weld power sockets..........................................................................52
6.3.7 Replacement of weld power pins ...............................................................................55
6.3.8 Replacement of air sealings ......................................................................................58
6.3.9 Replacement of O-rings on signal modules.................................................................59
6.3.10 Replacement of electric modules on tool changer or tool attachment..........................60
6.3.11 Replacement of water/air modules on tool changer or tool attachment .......................61
7 DISPOSAL AND RECYCLING........................................................................................62

6 M0720-1ver 3.4
1 INTRODUCTION
Robot System Products is a front-rank provider of peripheral products forhigh performance
robot applications. We provide complete tool systems solutions foryour robot installations,
aiming to improveyour productivity with the most reliable and cost-effectivetooling on the
market.Continuously we explore emerging technologies, workingwith leading edge design.
Robot System Productshas a wide range of standard robot peripheral products:
•Tool changers
•Swivels
•Swiveltool changers
•CiRo
•Grippers
•Hose Packages
•Valve units
•Tool systems
•Tool parking systems
Robot System Products’ tool changers are constructed to maximizethe flexibility and reliability
of your robot fleet. Through our patented locking device TrueConnect™ robustness and high
safety are combinedwith low weight and compactness.With our swivels compressed air, water,
electrical and data signals as well as weld and servo power are transferred to your tools with
robot motion capabilities fully maintained. Our Swiveltool changers unite the TrueConnect™
mechanism with our swivel technology, combining the best out of the two technologies. With
RSPs unique Circular Rotators cables and hoses can be freely selected with high robot flexibility
maintained, and the space requirements reduced. Our integrated tool systems are delivered as
complete plug-and-play solutions designed forquick and simple installation.
Robot System Products’product lines are available forall major robot brands and comewith
complete documentation. 3D-models forsimulation are available fordownload at:
www.rsp.eu.com
1.1 Installationand Maintenance manual
This documentdescribes how the Moduflex group of tools changers, TC240, TC480, TC720 and
TC960, including corresponding tool attachments and options fortransfer of power, signals,
water and air are installed and replaced. In addition, the document describes required
maintenance activities, including inspection, cleaning, lubrication, replacementof wear parts,
required tools and products and disposal and recycling.
The document, Product Description(M0723-1) contains general product information,drawings,
technical data, electrical and pneumatic diagrams, safety softwarefunction and lists of spare
parts.

M0720-1 ver 3.4 7
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 forCE-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. The user is also
responsible to guarantee that all safetydevices are installed correctly.
WARNING!
Nevercarry out service work on a robot that has not been taken out of operation.
See safety information forthe robot.
WARNING!
Only perform work on grippers or tools attached to the tool changer if the air
pressure is safely switched off.
WARNING!
Be aware that tool changer and tool attachmentare heavy and may cause personal
injury and equipment damage if dropped.
NOTE!
The tool changer shall always be in locked position, also when empty,to avoid
unexpected locking if air pressure is lost.
NOTE!
For the tool changer to comply withinternational safety standards like ISO 13849
and ISO10218, double channel technology is required forcontrol and supervision,
using valves like P6718 or P7710.
1.2.2 Explanation of warnings
The warnings in this documentare specific to the products in this manual. It is expected that the
user also pay attention to certain notifications from the robot manufacturerand/or the
manufacturersof other components used in the installation.
WARNING!
The warning sign will makeyou aware that a situation could result in potential
serious injury or damage to equipment.
NOTE!
The note sign will alert you about something important to consider.

8 M0720-1ver 3.4
1.3 Tighteningtorques
Tighteningtorques for mounting (screw class 8.8)
Dimension
Torque
M4
3 Nm
M5
6 Nm
M6
10 Nm
M8
24 Nm
M10
47 Nm
M12
82 Nm
M16
200 Nm
Tighteningtorques for mounting(screw class 12.9)
Dimension
Torque
M8
41 Nm
M10
79 Nm
M12
138 Nm
M14
221 Nm
M16
338 Nm
1.4 Recommendedequipment
Equipment recommended for installation and maintenance work
Tools
Applications
Complete set of Allen keys
For all socket head cap screws
Torque wrench
For dismounting and mounting
Torx key
For dismounting and mounting
Pair of pliers
For dismounting the signal pins.
27mm socket wrench
For dismounting water/air couplings
Guide pin puller (VA0178.004)
For dismounting the guide pins
2 x 16 mm spanners
For dismounting the guide pins
Screw driver
For removing the air sealings.

M0720-1 ver 3.4 9
1.5 Requiredproducts
Products required for installation and maintenance work
Product
Specification
Note
Grease, 3HXG1000-413
Magnalube-G, Teflon grease
For air sealings and water/air
couplings.
Grease
3HXG1000-262
Electrolube SGB Contact
Treatment Grease
For weld and servo power sockets.
Grease I0876
Molykote BR2Plus
For guide pins, guide bushings and
locking balls.
Cleaning agent
Industrial alcohol orsimilar
For cleaning of tool changerand tool
attachment.
Glue
Loctite 638 (or similar)
For gluing the guide pins and guide
bushings.
Cloth
Lint free cloth
For cleaning.
NOTE! Chemicalresistance protective gloves are recommendedwhen using grease
or cleaning agents such as industrial alcohol. Safety goggles are recommended
when working with cleaning agents such as industrial alcohol. Adequate ventilation
should be provided when chemicalsubstances are used.

10 M0720-1ver 3.4
2 INSTALLATION
2.1 Installationof tool changeronrobot
Action
Note
1
Safety
Read the safety section
(1.2)
2
Service position
Place the robot inservice
position
3
Power off
Switch the poweroff and
lock the circuit breaker.
NOTE! Read the safety
chapter for the robot.
4
Mount guide pin
Press the enclosed guide
pin into its position onthe
robot flange.
Alternatively, if adaptation
plate is used:
Mount the adaptation
plateon the robot flange
(see tightening torques
above). Press the
enclosed guide pin into
the adaptation plate.
5
Fit tool changer
Lift thetool changer to the
robot flange (or adaptation
plate). Make sure the
guide pin is fitted to the
guide hole in the tool
changer.
WARNING! The tool
changer is heavy and may
cause personal injury and
equipment damage if
dropped.
6
Mount tool changer
Mount the tool changer
with the enclosed screws
using a torquewrench
(see tightening torques
above).

M0720-1 ver 3.4 11
7
Connect air and water
Connect air and water
hoses to the hose fittings.
Ensure they are tightly
attached with securing
straps.
Pneumatic diagrams are
found in the product
description of respective
unit.
8
Connect signals
Connect electrical
connectors and field bus
in accordance with
selected options.
Circuit diagrams are found
in the product description
of respective unit.
9
Connect weld power (SW-versions only)
Mount cable/cables orMC
connector in the weld
power connector.
NOTE! The module can
be mounted in two ways,
with cable/connector to
the right or left.
10
Power on
Unlock circuit breaker and
switch power on.

12 M0720-1ver 3.4
2.2 Installation of tool attachmentto tool
Action
Note
1
Safety
Read the safety section (1.2).
2
Mount guide pin
Press a guide pin into its
position on the tool.
3
Fit the tool attachment
Lift and fit thetool attachment
with the tool. Makesure the
guide pin is fitted to the guide
hole in the tool.
4
Mount the attachment on the tool
Mount the tool attachment
using a torque wrench.
NOTE! Mounting can be
made either from the tool
attachment side or the
gripper/tool side. Screws are
specified in the product
description of respective unit.
See tightening torques
above.

M0720-1 ver 3.4 13
5
Connect air and water hoses
Connect air and water hoses
to the hose fittings.
NOTE! Water forward and
return must be connected in
accordance with
corresponding connections
on the robot side.
Pneumatic diagrams are
found in the product
description of respective unit.
6
Connect signals
Connect electrical connectors
and field bus in accordance
with selected options.
Circuit diagrams are found in
the product description of
respective unit.
7
Connect weld power (SW-versions only)
Mount the modulewith the
provided screws. Tighten with
a torque of 24 Nm.
NOTE! The module can be
mounted in two ways, with
cableto the right orleft.

14 M0720-1ver 3.4
2.3 Mountingof cable/cablesin weld powerconnectors,
P6716/P6784 andP6726
Action
Note
1
Remove screws
Remove the fourM4x25
screws or M5x30 screws
(depending on unit), on the
rear side of the weld power
connector holding the cover.
2
Remove cover
Insert two M5 screws
respective M6 screws
(depending onunit), in the
screw holes to facilitate
removal of the cover.
3
Remove nuts
Unscrew and remove the
three M8 nuts and the
washers.

M0720-1 ver 3.4 15
4
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 free to place. Place
marking labels accordingly.
NOTE!
Maximum torque for the M8
nuts are 6 Nm.
5
Mount rear cover
Mount the rear cover using
the fourM4x25 screws or
M5x30 screws (depending
on unit), Apply a small
amount of grease
(Electrolube SGB) inside the
weld power sockets.
NOTE!
Be careful not to damagethe
O-ring seal.

16 M0720-1ver 3.4
2.4 Mountingof electric modulesontoolchangerortoolattachment
Action
Note
1
Fit module
Fit the signal, field bus, servo
power and/orweld power
modulethe tool changer/tool
attachment.
NOTE! When guide pins are
used make sure they are
fitted to the corresponding
guide holes in the tool
changer/tool attachment.
2
Mount module
Mount the module with the
fourenclosed M6-screws
using a torque wrench (see
tightening torques above).
3
Connect signals
Connect electrical connectors
and field bus in accordance
with selected option.
NOTE! Circuit diagrams are
found in the product
description of respective unit.

M0720-1 ver 3.4 17
2.5 Mountingofwater/airmodulesontool changerortool attachment
Action
Note
1
Fit module
Fit the water/air module to
the tool changer/tool
attachment.
NOTE! When guide pins are
used make sure they are
fitted to the corresponding
guide holes in the tool
changer/tool attachment.
2
Mount module
Mount the module with the
two enclosed M10-screws
using a torque wrench (see
tightening torques above).
3
Connect air/water
Connect air and water hoses
to the hose fittings in
accordance with selected
option.
NOTE! Pneumatic diagrams
are found in the product
description of respective unit.

18 M0720-1ver 3.4
2.6 Mountingofintegratedvalve,P7710
Action
Note
1
Mount circuit board
Mount the circuit board with
the enclosed M3x6 screw.
2
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 before
the cable is mounted.
NOTE! Ensure that the
cable is not squeezed by
the cover.
3
Mount valve connector cover
Mount the valve connector
cover with three M3x8
screws.
4
Mount blind plugs
Insert and mount two blind
plugs.

M0720-1 ver 3.4 19
5
Mount silencers
Insert and mount the two
silencers.
6
Mount valve
Insert and mount the valve
with two M3x45 screws.
5
Mount valve cover
Insert and mount the valve
cover with two M4x8
screws.
6
Mount rear valve cover
Insert and mount the rear
valve coverwith two M4x6
and two M4x8 screws.

20 M0720-1ver 3.4
2.7 MountingofTC groundsocket,P7239
Action
Note
1
Mount TC ground socket
Mount the ground socket in the
tool changer with enclosed screw
and washers.
NOTE! Apply a small amount
contact grease before mounting.
2
Mount PE label
Mount the enclosed PE label in
the dedicated area closeto the
RSP label.
3
Mount PE cabling
Mount the robots earth cable with
either an M8 or an M5 screw.
NOTE! The dedicated screwholes
are situated close to the PE
marking.