RSP TC5 Instruction Manual

Installation and Maintenance
Manual
Tool changers TC5 and TC20
M0119-1
Tool changers | Swivels | Swivels Tool changers | Grippers | Hose packages | Valve Units | Tool systems

2 M0119-1 version 3.1

M0119-1 version 3.1 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 M0119-1 version 3.1
CONTENTS
1 INTRODUCTION ...................................................................................................... 5
1.1 Installation and Maintenance manual ........................................................................... 5
1.2 Safety ........................................................................................................................... 6
1.2.1 General .............................................................................................................................. 6
1.2.2 Explanation of warnings ..................................................................................................... 6
1.3 Tightening torques ....................................................................................................... 7
1.4 Recommended equipment ........................................................................................... 7
1.5 Required products ........................................................................................................ 7
2 INSTALLATION ........................................................................................................ 8
2.1 Installation of tool changer on robot ............................................................................. 8
2.2 Installation of tool attachment on tool ........................................................................... 9
2.3 Programming .............................................................................................................. 10
3 MAINTENANCE AND SERVICE ............................................................................ 11
3.1 Maintenance scheme ................................................................................................. 11
3.1.1 Every second week .......................................................................................................... 11
3.1.2 Every six-months or 250,000 tool changes ...................................................................... 11
3.1.3 To replace when damaged or worn-out ........................................................................... 11
3.2 Specification of maintenance activities ...................................................................... 12
3.2.1 Visual inspection of tool changer ..................................................................................... 12
3.2.2 Visual inspection and cleaning of tool attachment ........................................................... 13
3.2.3 Cleaning and lubrication of tool changer .......................................................................... 13
3.2.4 Cleaning and lubrication of tool attachment ..................................................................... 14
4 DISMOUNTING AND REPLACEMENT ................................................................. 15
4.1 Replacement of tool changer ..................................................................................... 15
4.2 Replacement of tool attachment ................................................................................ 16
4.3 Replacement of wear parts ........................................................................................ 17
4.3.1 Replacement of air sealings ............................................................................................. 17
4.3.2 Replacement of signal pins (electric versions only) ......................................................... 17
5 DISPOSAL AND RECYCLING ............................................................................... 18

M0119-1 version 3.1 5
1 INTRODUCTION
Robot System Products is a front-rank provider of peripheral products for high performance
robot applications. We provide complete tool systems 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
• Swivel tool changers
• CiRo
• Grippers
• Hose Packages
• Valve units
• Tool systems
• Tool parking systems
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 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 Swivel tool 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 for quick and simple installation.
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 tool changers, TC5 and TC20, including corresponding tool
attachments and options for transfer of signals and air, are installed and replaced. In addition,
the document describes required maintenance activities, including inspection, cleaning,
lubrication, replacement of wear parts, required tools and products and disposal and recycling.
The Technical Descriptions of each respective unit are separate documents containing product
information, drawings, technical data, electrical and pneumatic diagrams and lists of spare parts.

6 M0119-1 version 3.1
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. 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 tools attached to the tool changer if the air pressure is safely
switched off.
WARNING!
Be aware that tool changer and tool attachment 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.
WARNING!
Electric signals must be disconnected/switched off when docking the tool
attachment. This is to prevent sparking between signal pins and tool attachment.
1.2.2 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.

M0119-1 version 3.1 7
1.3 Tightening torques
Tightening torques 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
1.4 Recommended equipment
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 keys
For dismounting and mounting
Pair of pliers
For dismounting the signal pins
Screw driver
For removing the air sealings
1.5 Required products
Product
Specification
Note
Grease, 3HXG1000-413
Magnalube-G, Teflon grease
Air sealings.
Grease I0876
Molykote BR2Plus
For locking balls.
Cleaning agent
Industrial alcohol or similar
For cleaning of tool changer and tool
attachment.
Glue
Loctite 480 (or similar)
For gluing the air sealings.
Cloth
Lint free cloth
For cleaning.
NOTE! Chemical resistance protective gloves are recommended when 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 chemical substances are used.

8 M0119-1 version 3.1
2 INSTALLATION
2.1 Installation of tool changer on robot
Action
Note
1
Safety
Read the safety section 1.2.
2
Service position
Place the robot in service position.
3
Power off
Switch the power off and lock the
circuit breaker.
NOTE! Read the safety chapter for the
robot.
4
Mount guide pin
Press the enclosed guide pin into the
robot flange.
Alternatively, if adaptation plate is
used:
Mount the adaptation plate on the robot
flange (see tightening torques above).
Press the enclosed guide pin into the
adaptation plate.
5
Fit tool changer
Lift the tool changer to the robot flange
(or adaptation plate). The arrow on the
front of the tool changer indicates the
position of the hole for the guide pin.
Make sure that the guide pin is fitted to
the guide hole in the tool changer.
WARNING! The tool changer may
cause personal injury and equipment
damage if dropped.
6
Mount tool changer
Mount the tool changer with the
enclosed screws. Use an Allen key for
tightening (see tightening torques
above).
7
Connect air hoses
Connect the air hoses according to
markings. Pneumatic diagrams are
found in the Technical Description of
respective unit.
8
Connect electrical signals (electrical
versions only)
Connect electrical connectors in
accordance with selected unit. Circuit
diagrams are found in the Technical
Description of respective unit.
9
Power on
Unlock the circuit breaker and switch
the power on.

M0119-1 version 3.1 9
2.2 Installation of tool attachment on tool
Action
Note
1
Safety
Read the safety section
1.2.
2
Mount guide pins
Press guide pins, as
applicable, into the
corresponding holes on
the tool.
3
Fit tool attachment
Fit the tool attachment
and tool to each other
using the guide pins.
WARNING! The tool
attachment may cause
personal injury and
equipment damage if
dropped.
4
Mount tool attachment
Mount the tool attachment
using a torque wrench.
See tightening torques
above.
NOTE! Fastening screws
can be entered either from
the tool attachment side or
the tool side. Screws are
specified in the Technical
Description of respective
tool attachment.

10 M0119-1 version 3.1
5
Connect air hoses
Connect air hoses to
the tool attachment.
Pneumatic diagrams
are found in the
Technical Description
of respective unit.
6
Connect signals (electrical versions only)
Connect electrical
connectors in
accordance with
selected unit.
Circuit diagrams are
found in the Technical
Description of
respective unit.
2.3 Programming
The following will ensure a correct docking position.
Action
1
Attach a spare tool attachment to the tool changer.
2
Position the spare tool attachment above the tool attachment that is mounted at the tool.
3
The correct position is found when the tool attachments are parallel, centered and the
engraved arrows are on the same line.
4
Save the position. The robot can move to this position with high speed.
5
Dismount the spare tool attachment.
6
Go back to the saved position and move the tool changer (in axis 6 direction) the remaining
distance to the tool attachment (mounted at the tool).
7
Save the position. The robot should move the final distance to this position with low speed.

M0119-1 version 3.1 11
3 MAINTENANCE AND SERVICE
The tool changers and the tool attachments 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 tool
changes per month. Under extreme conditions, such as dirty environments or extreme robot
movements, the intervals should be shortened. Consider the table as a guide and update as
your production experience of each system increases.
NOTE
Read the safety section 1.2 before any maintenance activities are carried out.
NOTE!
Tool changers must only be dismantled and repaired by Robot System Products
during the warranty period. Otherwise the warranty will not be valid.
3.1 Maintenance scheme
3.1.1 Every second week
The following maintenance activities should be carried out every second week.
Activity
Equipment
Description
Inspection
Tool changer
General
Visual inspection (section 3.2.1).
Locking balls
Check locking balls (section 3.2.1).
Air sealings
Check air sealings (section 3.2.1).
Spring-loaded pins
Check spring-loaded signal (section
3.2.1).
Tool attachment
General
Visual inspection of tool attachment and
cables (section 3.2.2).
Cleaning
Tool attachment
Signal contacts
Clean contact surfaces (section 3.2.2).
3.1.2 Every six-months or 250,000 tool changes
The following maintenance activities should be carried out every six-months or 250,000 tool changes,
whichever comes first.
Activity
Equipment
Description
Cleaning
and
lubrication
Tool changer
Locking balls
Clean locking balls and add new
lubrication (section 3.2.3).
Air sealings
Clean air sealings (section 3.2.3).
Spring-loaded pins
Clean spring-loaded signal pins (section
3.2.3).
Tool attachment
Locking cavities
Clean the cavities of the locking balls
(section 3.2.4).
Contact surfaces
Clean the contact surfaces of air
sealings (section 3.2.4).
3.1.3 To replace when damaged or worn-out
Equipment
Description
Tool changer
Air sealings
See section 4.3.1.
Spring-loaded signal pins
See section 4.3.2.

12 M0119-1 version 3.1
3.2 Specification of maintenance activities
3.2.1 Visual inspection of tool changer
The following maintenance activities should be carried out on the TC every 2nd week.
Action
Note
Check locking balls
Check each ball to make sure it
moves freely. For cleaning and
lubrication of balls see section
3.2.3.
NOTE! If balls get stuck there is a
risk that the tool attachment jams.
WARNING! Risk of getting
squeezed between piston and ball
holder when the piston is taking
closed position
Check air sealings
Check that the air sealings are
clean. For cleaning see section
3.2.3.
Check that the air sealings are not
damaged. For making
replacements see section 4.3.1.
Check spring-loaded signal pins (electrical
versions only)
Check that the spring-loaded
signal pins are clean. For cleaning
see section 3.2.3.
Check that the spring-loaded
signal pins are not worn-out or
damaged. For making
replacements see section 4.3.2.
Check cables and hoses
Check for damages and
squeezing, replace if damaged.
Check rotation stops
Check that rotation stops are not
worn-out or damaged, replace if
damaged.
Check tool changer in general
Check tool changer for damages.
For replacement see section 4.1.

M0119-1 version 3.1 13
3.2.2 Visual inspection and cleaning of tool attachment
The following maintenance activities should be carried out on the TA every 2nd week.
Action
Note
Clean contact surface (electrical versions
only)
Wipe the contact surface with a lint
free cloth.
Check cables and hoses
Check cables and hoses for
damages and squeezing, replace if
damaged.
Check tool attachment in general
Check the tool attachment for
damages. For replacement see
section 4.2.
3.2.3 Cleaning and lubrication of tool changer
The following maintenance activities should be carried out on the TC every 6th month or
after 250,000 tool changes, whichever comes first.
Action
Note
Clean locking balls
Check the locking balls and wipe them
clean with a lint free cloth.
WARNING! Risk of getting squeezed
between piston and ball holder when
the piston is taking closed position
Lubricate locking balls
Apply a small amount of grease
(Molykote BR2Plus) on the locking
balls.
NOTE! It is important that this is done
or else there is a risk that the tool
attachment jams.

14 M0119-1 version 3.1
Clean air sealings
Wipe air sealings clean with a lint free
cloth.
Clean spring-loaded signal pins
Clean the contact surfaces of the
spring-loaded signal pins with a nylon
brush.
NOTE!
Signal pins shall be cleaned whenever
blackened.
3.2.4 Cleaning and lubrication of tool attachment
The following maintenance activities should be carried out on the TA every 6th month or
after 250,000 tool changes, whichever comes first.
Action
Note
Clean locking cavities
Clean the cavities of the locking balls
with a lint free cloth.
NOTE!
It is important that this is done or else
there is a risk that the tool attachment
jams.
Clean contact surfaces of air sealings
Wipe the contact surfaces of the air
sealings clean with a lint free cloth.

M0119-1 version 3.1 15
4 DISMOUNTING AND REPLACEMENT
4.1 Replacement of tool changer
Action
Note
1
Safety
Read the safety section 1.2.
2
Dismount tool
Leave tool, with tool attachment
mounted, in tool stand.
3
Service position
Place the robot in service position.
NOTE! The tool change function shall
be in locked position.
4
Power off
Switch the power off and lock the circuit
breaker.
NOTE! Read the safety chapter for the
robot.
5
Pneumatic air off
NOTE! The pressure in the pneumatic
system must be released before
dismounting begins.
6
Dismount hoses
Dismount the air hoses from the tool
changer.
NOTE! Make sure that no dirt enters
the air hoses.
7
Release electrical connectors
NOTE! Handle the contact with care, as
it is sensitive to mechanical damage.
Make sure that no dirt enters the
contacts.
8
Remove screws
Remove the screws holding the tool
changer to the robot flange.
WARNING! The tool changer may
cause personal injury and equipment
damage if dropped.
NOTE! Be careful not to damage the
signal pins.
9
Dismount tool changer
NOTE! A guide pin is mounted between
the tool changer and the robot flange.
10
Clean robot flange
Clean the robot flange/adaptation plate
using a lint free cloth.
11
Mount replacement tool changer
Follow instructions in section 2.1.

16 M0119-1 version 3.1
4.2 Replacement of tool attachment
Action
Note
1
Safety
Read the safety section 1.2.
2
Undock tool
Undock tool attachment, with tool
mounted, in a safe and fully
supported position for dismounting.
3
Release electrical connections
Disconnect electric power and
signals.
NOTE! Handle contacts with care,
as they are sensitive to mechanical
damage. Make sure that no dirt
enters the contacts.
4
Dismount hoses
Dismount the air hoses from the
tool attachment.
NOTE! Make sure that no dirt
enters the air hoses.
5
Remove screws
Remove the screws holding the
tool attachment to the tool.
WARNING! The tool attachment is
heavy and may cause personal
injury and equipment damage if
dropped.
6
Dismount tool attachment
NOTE! A guide pin is mounted
between the tool attachment and
the tool.
7
Clean the flange at the tool
Clean flange at the tool using a lint
free cloth.
8
Mount tool attachment
Follow instructions in section 2.2.

M0119-1 version 3.1 17
4.3 Replacement of wear parts
4.3.1 Replacement of air sealings
4.3.2 Replacement of signal pins (electric versions only)
Replace a signal pin when worn or damaged.
Action
Note
1
Remove air sealings
Remove the air sealings with a screw
driver.
NOTE! There are totally 6 air sealings.
2
Clean sealing holes
Wipe clean the sealing holes. Remove all
remaining parts of sealing and glue.
3
Replace air sealing
Glue the new air sealing in the sealing
groove. Use a small amount of Loctite 480
(or similar). Press the sealing 60-120
seconds until the glue hardens.
Action
Note
1
Power off
Switch the power off and lock the circuit
breaker.
2
Remove signal pins
Pull out the signal pins with a pair of pliers.
NOTE! There are totally 8 signal pins.
3
Replace signal pins
Fit the new signal pins by pushing them
into the sleeves.
NOTE! The signal pins should be fully
pressed into the sleeve using a small
screwdriver.
4
Power on
Unlock the circuit breaker and switch the
power on.

18 M0119-1 version 3.1
5 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. Non-recyclable components shall be handed over to an authorized environmental waste
treatment facility for destruction or disposal.
Electronics
Electronic equipment shall be sent to an authorized recycling company or sorted into different
component materials and treated as such.
Metals
Metals can, in general, be melted down, recycled and used in new products. They shall be
sorted according to type and surface coating and handed over to an authorized recycling facility.
Metal components of steel and aluminium are substantial in size and easy to identify. Copper is
primarily used in transmission of power for spot welding. Silver or gold plating of contact
surfaces may occur.
Plastics
Thermoplastics can, in general, be re-heated and recycled without any major loss of quality.
They shall be handed over to an authorized recycling facility. POM occurs in swivel housings,
etc. PTFE in some sealings.
Rubber
Rubber shall be handed over to an authorized environmental waste treatment facility either for
recycling, disposal or destruction. Rubber occurs in O-rings.
Other material
All other material shall be sorted and handed to an authorized environmental waste treatment
facility in accordance with national legislation.

M0119-1 version 3.1 19

20 M0119-1 version 3.1