RSP TC250-8 User manual

m0403
Product Manual
Tool changer TC250-8, TC250-8E
M0619-1
Tool changers | Swivels | Swivel tool changers | Grippers | Hose packages | Valve units | Tool systems

2 M0619-1 ver. 2.6

M0619-1 ver 2.6 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.
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. Infringement hereof will be subject to action in accordance with the
applicable laws.
Further copies of this document can be obtained from Robot System Products AB at
current prices.
© Robot System Products AB
Robot Systems Products AB
Isolatorvägen 4
SE-721 37 Västerås
Sweden

4 M0619-1 ver. 2.6
CONTENTS
1 INTRODUCTION......................................................................................................6
1.1 Safety.........................................................................................................................7
1.1.1 General...............................................................................................................................7
1.1.2 Explanation of warnings .....................................................................................................7
1.2 Description of RSP tool changers...............................................................................8
1.3 Complementary Equipment........................................................................................8
2 TECHNICAL SPECIFICATIONS..............................................................................9
2.1 Description of tool changers and tool attachments .....................................................9
2.1.1 Coordinate System Definition...........................................................................................10
2.1.2 Tool Changer with air, TC250-8. Article no: P6411..........................................................11
2.1.3 Tool Attachment, TA250-8. Article no: P6417..................................................................12
2.1.4 Square Tool Attachment TA250-8. Article no: P6474......................................................13
2.1.5 Tool Changer with air and electric signals TC250-8E. Article: P6412 .............................14
2.1.6 Tool Attachment, TA250-8E. Article no: P6418 ...............................................................16
2.1.7 Tool Attachment, TA250-8E. Article no: P6431 ...............................................................17
2.1.8 Square Tool Attachment, TA250-8E. Article no: P6473...................................................18
2.1.9 Pneumatic diagram for tool changers P6411 and P6412 ................................................19
2.1.10 Circuit diagram E0196-001 for P6412............................................................................20
2.1.11 Circuit diagram E0196-002 for P6418............................................................................21
2.1.12 Circuit diagram E0196-009 for P6431 and P6473 .........................................................22
2.2 Options to TC...........................................................................................................23
2.2.1 Robot adaptation kit .........................................................................................................23
2.2.2 Tool stand kit. Article no: P6472.......................................................................................24
2.2.3 Limitation of Robot movements........................................................................................24
2.2.4 Connection kits and cables ..............................................................................................24
3 INSTALLATION.....................................................................................................25
3.1 Tightening torques....................................................................................................25
3.2 Recommended tools for installation..........................................................................25
3.3 Installation of tool changer on robot..........................................................................26
3.4 Installation of tool attachment P6623A/ P6624A on tool ..........................................27
3.5 Hints.........................................................................................................................28
3.5.1 Programming....................................................................................................................28
3.5.2 Sparking ...........................................................................................................................28
3.5.3 Electrical installation.........................................................................................................28
3.5.4 Tool stand.........................................................................................................................28
3.5.5 Tool Identification .............................................................................................................28

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4 MAINTENANCE AND SERVICE...........................................................................29
4.1 Maintenance chart.................................................................................................... 29
4.1.1 Required products............................................................................................................29
4.1.2 Recommended tools for maintenance .............................................................................30
4.1.3 Wear parts........................................................................................................................30
4.1.4 Activities and intervals on tool changer............................................................................30
4.1.5 Activities and intervals on tool attachment.......................................................................31
4.2 Visual inspection...................................................................................................... 31
4.2.1 Inspection of the tool changer..........................................................................................31
4.2.2 Inspection of the tool attachment .....................................................................................31
4.3 Cleaning................................................................................................................... 32
4.3.1 Cleaning and lubrication of tool changer..........................................................................32
4.3.2 Cleaning of tool attachment..............................................................................................33
4.4 Replacement of tool changer.................................................................................... 34
4.5 Replacement of wear parts....................................................................................... 35
4.5.1 Replacement of air sealings.............................................................................................35
4.5.2 Replacement of signal pins (TC250-8E only)...................................................................35
4.5.3 Replacement of O-ring.....................................................................................................36
4.6 Complete service of tool changer............................................................................. 36
5 SPARE PARTS .....................................................................................................37
5.1 Part list for tool changer P6411 and P6412.............................................................. 37
5.2 Part list for tool attachment P6417 and P6418.......................................................... 38
5.3 Part list for tool attachment P6431............................................................................ 38
5.4 Part list for square tool attachment P6474 and P6473.............................................. 39
6 DISPOSAL AND RECYCLING.............................................................................. 40

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1 INTRODUCTION
Robot System Products is a front-rank provider of peripheral products for high performance
robot applications. We provide complete system solutions for your robot installations, aiming to
improve your productivity with the most reliable and cost-effective tooling on the market.
Continuously we explore emerging technologies, working with leading edge design.
Robot System Products has a wide range of standard robot peripheral products:
•Tool changers
•Swivels
•Swivels with integrated tool changers
•Grippers
•Hose Packages
•Valve units
•Tool systems
•Tool stands
Robot System Products’ tool changers are constructed to maximize the flexibility and reliability
of your robot fleet. Through our patented locking device TrueConnect™ robustness and high
safety are combined with low weight and compactness. With our swivels you can provide
compressed air, water, electrical and data signals as well as weld and servo power to your tools
with robot motion capabilities fully maintained. Our swivels with tool changers unites the
TrueConnect™ tool changing mechanism with our swivel technology, combining the best out of
two technologies.
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.

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1.1 Safety
1.1.1 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. The user is also
responsible to guarantee that all safety devices are installed correctly.
WARNING!
Never carry out service work on a robot that has not been taken out of operation.
See safety information for the 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 attachment are 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.
1.1.2 Explanation of warnings
The warnings in this document are specific to the products in this manual. It is expected that the
user also pay attention to certain notifications from the robot manufacturer and/or the
manufacturers of other components used in the installation.
WARNING!
The warning sign will make you 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.

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1.2 Description of RSP tool changers
Our tool changers enable robots to handle and switch between multiple tools. They are built to
ensure reliable and smooth operation, being compact with low weight and robust design and
incorporating many safety features. Depending on model and options, electrical signals, weld
and servo power, data, water and compressed air are transferred from the robot side to the tool.
The patented locking device TrueConnect™ has a minimum of play and gives a practically,
through the lifespan, absolute positioning repeatability. The principle behind the locking
mechanism is the uniform distribution of load obtained by pressing looking balls into spherical
grooves. In consequence, substantially larger positional tolerances are accepted during docking.
1.3 Complementary Equipment
Complementary equipment is described in separate documents.
Article
Note
Cable and Hose Package
Complete packages for most robots on the market ready to be
mounted without any modifications.
Tool Stands
Tool stands will, combined with tool attachments and
adaptation kits, give a rigid installation for easy tool changing.
Connection kits
In order to make electrical installation easier, connection kits
are available for tool changers and tool attachments.
3D-models
Available in Solid Works® and STEP-format.

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2 TECHNICAL SPECIFICATIONS
2.1 Description of tool changers and tool attachments
This document presents the Robot System Products TC250-8 and TC250-8E tool changers
including tool attachments dedicated for material handling. Likewise presented are adaptation
kits, connection kits to facilitate electrical installation and a tool stand kit.
The tool changer TC250-8 transfers compressed air to the tool. It can be equipped with transfer
of electrical signals, via spring loaded signal pins, to the tool attachment. The electrical version is
designated ’E’. The tool changers TC250-8 and TC250-8E cannot transport fluids.
The spring loaded signal pins of TC250-8E are placed and protected at the centre of the tool
changer. The contact surface of the tool attachment and the signal pins are not in connection
until at the very end of the docking cycle when the tool attachment is already properly aligned.
This guarantees a minimum of wear of the contact surfaces.
The electrical unit is primarily intended for transfer of sensor signals from grippers. In addition it
can be used for checking the presence and identifying tools by using signal jumpers and binary
coding of signals on the tool attachment.
For other bolt circles adaptation plates between the tool changer and the turning disc on the
robot may be needed. Such adaptation plates are available from RSP.
TC250-8E

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2.1.1 Coordinate System Definition
A tool changer adds load to the robot. If the arm and tool loads are not stated correctly during
programming the behaviour of the robot and the wear of the equipment will be affected.
Information about weight and centre of gravity can, in accordance with the co-ordinate system
stated below, be found in the technical specification tables of the tool changer.
NOTE!
For the tool changer and tool changer with tool attachment, the origo is situated in
the centre of the robot mounting flange.

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2.1.2 Tool Changer with air, TC250-8. Article no: P6411
Tool changer P6411 transfers 8 pneumatic channels to the tool attachment. To be used together
with tool attachment P6417 or P6474.
Technical data
Working temperature
+10°C−+60°C
Bolt pattern
ISO9409-1-125-6-M10
Weight
P6411
P6411 and P6417
P6411 and P6474
6.0 kg
8.6 kg
9.5 kg
Maximum tool load
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±1 250 Nm
Air ducts
Pneumatic diagram
Total number of ducts
Dedicated air ducts
Max air pressure
Air flow
Air quality
Connection, robot side
See section 2.1.9
10
“Open TC”marked Open (6−10 bar)
“Close TC”marked Close (6−10 bar)
10 bar
1 600 l/min
Oil-clean and waterless filtered air, with max
25µm particle content
G 1/4"

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2.1.3 Tool Attachment, TA250-8. Article no: P6417
Tool attachment P6417 transfers 8 pneumatic channels to the tool. To be used together with tool
changer P6411.
Technical data
Working temperature
+10°C−+60°C
Bolt pattern
ISO9409-1-125-6-M10
Weight
2.7 kg
Maximum tool load
(M10-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±1 250 Nm
Maximum tool load
(M8-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±750 Nm
Air ducts
Number of air ducts
Connection, tool side
8
G 1/4”
Note! Tools can be mounted to the tool attachment using six M10-screws,
alternatively the tool attachment can be mounted to the tool using six M8-screws.

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2.1.4 Square Tool Attachment TA250-8. Article no: P6474
Tool attachment P6474 transfers 8 pneumatic channels to the tool. When combined with option
P6472 it can be used as a tool stand for easy parking and exchange of tools. To be used
together with tool changer P6411.
Technical data
Working temperature
+10°C−+60°C
Bolt pattern
ISO9409-1-125-6-M10
Weight
3.6 kg
Maximum tool load
(M10-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±1 250 Nm
Maximum tool load
(M8-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±750 Nm
Air ducts
Number of air ducts
Connection, tool side
8
G 1/4”
Note! Tools can be mounted to the tool attachment using six M10-screws,
alternatively the tool attachment can be mounted to the tool using six M8-screws.

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2.1.5 Tool Changer with air and electric signals TC250-8E. Article: P6412
Tool changer P6412 transfers 8 pneumatic channels and 19 electrical signals to the tool
attachment. To be used together with tool attachment P6418, P6473 or P6431.

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Technical data
Working temperature
+10°C−+60°C
Bolt pattern
ISO9409-1-125-6-M10
Weight
P6412
P6412 med P6418
P6412 med P6431
P6414 med P6473
6.1 kg
8.8 kg
8.8 kg
9.7 kg
Maximum tool load
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±1 250 Nm
Air ducts
Pneumatic diagram
Total number of ducts
Dedicated air ducts
Max air pressure
Air flow
Connection, robot side
Air quality
See section 2.1.9
10
“Open TC”marked Open (6−10 bar)
“Close TC”marked Close (6−10 bar)
10 bar
1 600 l/min
G 1/4"
Oil-clean and waterless filtered air, with max
25µm particle content
Electric channels
Circuit diagram
Total number of signals
Dedicated signals
Max currency
Max voltage
Connections
E0196-001 (see section 2.1.10)
21
+24 V
+0 V
TC Opened
TC Closed
2 A
60 V
Souriau UTO01823PH

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2.1.6 Tool Attachment, TA250-8E. Article no: P6418
Tool attachment P6418 transfers 8 pneumatic channels and 19 electrical signals to the tool. To
be used together with tool changer P6412.
Technical data
Working temperature
+10°C−+60°C
Bolt pattern
ISO9409-1-125-6-M10
Weight
2.7 kg
Maximum tool load
(M10-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±1 250 Nm
Maximum tool load
(M8-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±750 Nm
Air ducts
Number of air ducts
Connection, tool side
8
G 1/4”
Electrical signals
Circuit diagram
Total number of signals
Dedicated signals
Connection, tool side
E0196-002 (see section 2.1.11)
19
+24V DC
0V DC
Souriau UTOW01419SH
Note! Tools can be mounted to the tool attachment using six M10-screws,
alternatively the tool attachment can be mounted to the tool using six M8-screws.

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2.1.7 Tool Attachment, TA250-8E. Article no: P6431
Tool attachment P6431 transfers 8 pneumatic channels and 19 electrical signals to the tool. To
be used together with tool changer P6412.
Technical data
Working temperature
+10°C−+60°C
Bolt pattern
ISO9409-1-125-6-M10
Weight
2.8 kg
Maximum tool load
(M10-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±1 250 Nm
Maximum tool load
(M8-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±750 Nm
Air ducts
Number of air ducts
Connection, tool side
8
G 1/4”
Electrical signals
Circuit diagram
Total number of signals
Dedicated signals
Connection, tool side
E0196-009 (see section 2.1.12)
19
+24 V DC
0 V DC
1.0 m cable (20x0.5mm²) with free end
Note! Tools can be mounted to the tool attachment using six M10-screws,
alternatively the tool attachment can be mounted to the tool using six M8-screws.

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2.1.8 Square Tool Attachment, TA250-8E. Article no: P6473
Square Tool Attachment P6473 transfers 8 pneumatic channels and 19 electrical signals to the
tool and gives together with option P6472 a stable tool stand for easy tool changing. To be used
together with tool changer P6412.
Technical data
Working temperature
+10°C−+60°C
Bolt pattern
ISO9409-1-125-6-M10
Weight
3.7 kg
Maximum tool load
(M10-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±1 250 Nm
Maximum tool load
(M8-screws)
Fz (static)
Mx/My (dynamic)
Mz (dynamic)
±2 000 N
±2 000 Nm
±750 Nm
Air ducts
Number of air ducts
Connection, tool side
8
G 1/4”
Electrical signals
Circuit diagram
Total number of signals
Dedicated signals
Connection, tool side
E0196-009 (see section 2.1.12)
19
+24 V DC
0 V DC
1.0 m cable (20x0.5mm²) with free end
Note! Tools can be mounted to the tool attachment using six M10-screws, alternatively
the tool attachment can be mounted to the tool using six M8-screws.

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2.1.9 Pneumatic diagram for tool changers P6411 and P6412

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2.1.10 Circuit diagram E0196-001 for P6412