Schmalz FXCB User manual

www.schmalz.com
Innovative Vacuum for Automation
EN
Operating Instructions
Vacuum Area Gripping System FXCB/FMCB
30.30.01.01840/01 | 03.2019

www.schmalz.com
Note
These operating instructions were originally written in German and have been translated into English.
Store in a safe place for future reference.
Subject to technical changes without notice. No responsibility is taken for printing or other types of
errors.
Published by
© J. Schmalz GmbH, 03.2019
This document is protected by copyright. J. Schmalz GmbH retains the rights established thereby.
Reproduction of the contents, in full or in part, is only permitted within the limits of the legal provisions
of copyright law. Any modifications to or abridgments of the document are prohibited without explicit
written agreement from J. Schmalz GmbH.
Contact
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.schmalz.com
Contact information for Schmalz companies and trade partners worldwide can be found at
www.schmalz.com/salesnetwork

Contents
Vacuum Area Gripping System FXCB/FMCB
www.schmalz.com
1Safety Instructions...............................................................................................5
Classification of Safety Instructions ..................................................................................51.1 Prohibition Signs................................................................................................................61.2 Warnings ...........................................................................................................................61.3 Mandatory Symbols...........................................................................................................61.4 General Safety Instructions...............................................................................................71.5 Intended Use.....................................................................................................................81.6 Note on the Type Plate......................................................................................................91.7
2Product Description.............................................................................................9
Functional Principle...........................................................................................................92.1 Design of the FXCB with Integrated Vacuum Generation...............................................102.2 Design of the FMCB for External Vacuum Generation ...................................................112.3
3Technical Data..................................................................................................12
4Transport and Assembly ...................................................................................16
Delivery............................................................................................................................164.1
4.1.1 Items Included in Delivery ...............................................................................................16
4.1.2 Checking for Completeness ............................................................................................16
4.1.3 Reporting Damage ..........................................................................................................17
Packaging........................................................................................................................174.2 Storage............................................................................................................................17
4.3
5Start of Operations and Setup...........................................................................18
Mechanical Connection...................................................................................................215.1 Pneumatic Connection ....................................................................................................225.2
22
Vacuum Connection (only FMCB)...................................................................................235.3 Electrical Connection.......................................................................................................245.4
6Operation ..........................................................................................................26
General Notes .................................................................................................................266.1 Handling Solution ............................................................................................................296.2
7Troubleshooting ................................................................................................30
8Maintenance......................................................................................................34
General Maintenance Instructions...................................................................................348.1 Maintenance Schedule....................................................................................................358.2 External Vacuum Generator (only FMCB) ......................................................................368.3 Ejectors (only FXCB).......................................................................................................368.4 Cleaning Agents..............................................................................................................368.5 Sealing Plate ...................................................................................................................368.6 Opening the Gripper to Clean the Ejectors (only FXCB) ................................................378.7 Overview of the Tightening Torque of the Screws ..........................................................388.8

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Mounting the Vacuum Switch in the Housing..................................................................398.9 Checking the System for Leaks.......................................................................................398.10
9Spare and Wearing Parts..................................................................................40
10 Accessories.......................................................................................................42
11 Pneumatic Circuit Diagram................................................................................44
Pneumatic Circuit Diagram FXCB...................................................................................4411.1 Pneumatic Circuit Diagram FMCB –Parallel Circuit.......................................................4511.2
12 Other Applicable Documents.............................................................................46

SAFETY INSTRUCTIONS
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1 Safety Instructions
Classification of Safety Instructions1.1
Danger
This warning informs the user of a risk that will result in death or serious injury if it is not avoided.
DANGER
Type and source of danger
Consequence
►
Remedial action
Warning
This warning informs the user of a risk that could result in death or serious injury if it is not avoided.
WARNING
Type and source of danger
Consequence
►
Remedial action
Caution
This warning informs the user of a risk that could result in injury if it is not avoided.
CAUTION
Type and source of danger
Consequence
►
Remedial action
Attention
This warning informs the user of a risk that could result in damage to property if it is not avoided.
ATTENTION
Type and source of danger
Consequence
►
Remedial action
General notes
This symbol is used when important notes and information regarding the use of the machine/the sys-
tem/the device are provided.
Note/information

SAFETY INSTRUCTIONS
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Prohibition Signs1.2
Explanation of the prohibition signs used in the operating instructions.
Icon
Description
Icon
Description
Do not stand under suspended loads
Warnings1.3
Explanation of the warning symbols used in the operating instructions.
Icon
Description
Icon
Description
Pollution warning
Crushing injury
Suspended load
Hand injury warning
Electrical voltage
General warning symbol
Hearing damage
Warning of overpressure
Electric shock
Mandatory Symbols1.4
Explanation of the mandatory symbols used in the operating instructions.
Icon
Description
Icon
Description
Observe the instructions
Wear eye protection
Use protective footwear
Activate prior to maintenance or repair
Wear protective gloves
Wear a mask
Use ear protectors

SAFETY INSTRUCTIONS
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General Safety Instructions1.5
The system is state-of-the-art and operationally reliable. However, dangers may arise.
WARNING
Failure to comply with the general safety instructions
Personal injuries and damage to the system
►
The operating instructions contain important information on using the system.
Read the operating instructions thoroughly and keep them for later reference.
►
The system must only be used by trained personnel who have read and under-
stood the operating instructions.
►
These operating instructions are specific to the items included in delivery from
Schmalz. These operating instructions do not take into account any modifica-
tions to the system made by the customer.
►
The system may only be connected and operations started once the operating
instructions have been read and understood.
►
Use only the connections, mounting holes and attachment materials that have
been provided.
►
Carry out mounting or removal only when the device is in a voltage-free and
depressurized state.
►
Only qualified specialist personnel, mechanics and electricians may perform
the installation. Qualified specialist personnel are persons who have received
technical training and have the knowledge and experience –including
knowledge of applicable regulations –necessary to enable them to recognize
possible dangers and implement the appropriate safety measures while per-
forming tasks.
►
General safety regulations, European standards and VDE guidelines must be
observed and complied with.
►
The gripper is to be used in combination with an automated handling system
(gantry/robot). For this reason, you must also follow the safety regulations of
the corresponding system.
►
Animals are not permitted to sit or stand in the transport area.
►
Transporting persons or animals is prohibited!
►
Collaborative operation of the gripper is solely permitted with systems designed
for this purpose. The system integrator must ensure that the integrated safety
functions are working properly.
►
It is not permitted to make changes to system components.
►
The system may only be operated with the operating voltages specified for the
corresponding components.
►
Make sure that the workplace and surroundings are kept clean.
►
Protect the components from damage of any kind.

SAFETY INSTRUCTIONS
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WARNING
Failure to comply with the general safety instructions
Personal injuries and damage to the system
►
Compressed air or a vacuum could cause closed containers to explode or
implode. Check the products before use.
►
Do not apply suction to any dangerous dusts, oil mists, vapors, aerosols, etc.
►
Only use suitable and approved vacuum filters.
►
Do not look into the exhaust air flow of the vacuum generator.
Intended Use1.6
The gripper is used to lift and transport cardboard boxes or similar materials that allow suction. Neutral
gases in accordance with EN 983 are approved as evacuation media. Neutral gases include air, nitro-
gen and inert gases.
The device may only be used with robot systems that comply with the provisions of DIN IST/TS 15066,
DIN EN ISO 10218-1 and DIN EN ISO 10218-2.
Operation as part of a collaborative system is only permitted when the entire system meets the corre-
sponding legal requirements for collaborative robot systems. The system integrator is responsible for
ensuring that these requirements are complied with.
The possibilities to do this include:
- The use of redundant vacuum/compressed air generation
- The use of battery-operated audio-visual warning devices to monitor the input pressure and
vacuum value
- Safety-oriented vacuum generation and monitoring with a corresponding performance level
WARNING
Suspended loads
Personal injuries and damage to the system
►
Never stand under suspended loads.
The system is mounted on the load suspension provided by the customer using the flanges designat-
ed for this purpose. The customer also provides a control device.

PRODUCT DESCRIPTION
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Note on the Type Plate1.7
The type plate contains important information about the device. The type plate is firmly attached to the
exterior of the device.
The type plate contains the following information:
- Name
- Part number
- Production date
- Serial number
The designation and part number are important for identifying the device. They must always be speci-
fied when ordering replacement parts, making warranty claims or making other inquiries about the
device.
2 Product Description
Functional Principle2.1
The system uses vacuum to lift the defined products. The system can be used to lift one or more
cardboard boxes or similar workpieces of various sizes without adapting the suction area to the specif-
ic workpiece.
The system achieves its maximum load-bearing capacity when the complete suction area is engaged
with an airtight workpiece with a smooth surface.
The robot system, to which the customer’s system was attached, is responsible for the motion in the
various axes.
When being applied to the workpiece, the foam must be compressed by at least
50%.

PRODUCT DESCRIPTION
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Design of the FXCB with Integrated Vacuum Generation2.2
Item
Description
A
Housing cover
B
Machine screw M4x10
C
Silencer
D
Valve
E
Retaining cap SHC
F
Ejector module SEP
G
Ejector block
H
Pneumatic interface Ø 10 mm
I
Machine screw M4x20
J
Electrical interface M12 8-pole
K
Housing right
L
Flange module
M
Housing left
N
Suction trough
O
Vacuum switch VSi
P
Masking film
Q
Sealing plate
A
C
E
G
F
M
I
Q
D
L
B
H
J
K
O
P
N

PRODUCT DESCRIPTION
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Design of the FMCB for External Vacuum Generation2.3
Item
Description
A
Housing cover
B
Machine screw M4x10
C
Hose connector
D
Pneumatic interface Ø 10 mm
E
Machine screw M4x20
F
Electrical interface M12 8-pole
G
Housing right
H
Flange module
I
Housing left
J
Suction trough
K
Vacuum switch VSi
L
Masking film
M
Sealing plate
A
C
I
E
M
H
B
D
F
G
K
L
J

TECHNICAL DATA
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3 Technical Data
ATTENTION
Non adherence to the performance limits of the gripper
Malfunction and damage to the gripper and the attached
components.
►
Only operate the gripper within the specified performance limits
FXCB
With integrated vacuum generation
FMCB
For external vacuum generation
Number of suction cells
45
45
Optimal input pressure
5.5 bar1
-
Permitted pressure range
4.5 to 7.0 bar
Max. 7.0 bar2
Maximum degree of evacua-
tion
53%4
90%4
Compressed air consumption
161.5 l/min4
-
Suction flow
525.9 l/min
-
Required suction flow rate
-
372.3 l/min3.4
Permissible load
80 N
80 N
Weight
1.9 kg
1.5 kg
Operating voltage
24V DC
24V DC
Permitted temperature range
+5 to +40° C
+5 to +40° C
Sound level at full coverage
67.5 dB(A)4
-
Protection class
IP40
IP40
1At this pressure, the integrated ejectors have optimal energy efficiency.
2For this gripper version, the compressed air is only used to more quickly deposit loads.
3At a vacuum of –0.15 bar, the vacuum generator must provide the
specified suction flow rate (at the vacuum connection pieces of the FMCB).
4Attention: this refers to real measured values without additional safety
NFC tags in the gripper
Two NFC tags are integrated into the gripper. The first is located under the type
plate and links to the gripper page in the Schmalz app. The second is located in the
vacuum switch and links to the vacuum switch page.
To use the tags, hold an NFC-enabled device over the place where the NFC logo is
attached.
The linked pages contain data, part numbers and the operating instructions for the
respective parts.
Vacuum in the gripper
For workpieces typical for the application (e.g. cardboard boxes), a vacuum be-
tween 250 and 300 mbar is recommended.
A vacuum lower than 200 mbar is not recommended.
The overpressure in the gripper must be limited to a maximum of 0.2 bar.
Consult the manufacturer before operating it at higher or lower ambient tempera-
tures.

TECHNICAL DATA
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TECHNICAL DATA
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Dimensions:
L
B
H
L11
L2
L3
B11
H1
300
130
131.4
331
99
102
159
137.4
H2
d
D2
20
10
32
1Exact dimensions vary based on the circumferential foam
2Only for the FMCB

TECHNICAL DATA
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Center of mass
FXCB
FMCB
ATTENTION
Using vacuum hoses that are too rigid with cobots (FMCB only)
Stopping the robot by interpreting the resistance of the hose as a collision with the
person
►
Before operation, check whether the resistance force of the vacuum hose causes the
robot to stop

TRANSPORT AND ASSEMBLY
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4 Transport and Assembly
WARNING
Improper securing of the load
Improper unloading and transport can result in personal injuries and damage to
property. Moving loads can tip over, fall or crush people. When lifting transport
units, parts can fall over, move or fall out. Danger to life and limb.
►
Only transport loads that are sufficiently secured against slipping.
►
Ensure that all persons leave the hoist danger zone before the transport units
are lifted.
►
Wear protective footwear and additional safety equipment if necessary.
►
Only trained personnel who have received safety instructions may unload and
transport the product.
Delivery4.1
4.1.1Items Included in Delivery
For the exact items included in delivery, please refer to the order confirmation.
In addition to the gripper, the following is included in delivery:
4 pcs. M6x12 machine screw according to DIN 7984 for mounting the gripper on the robot
4 pcs. Safety washers to secure against accidental release of the gripper during operation
1 pc Dowel pin Ø 6 mm for exact position locking
1 pc Allen key, size 4, for tightening the screws
1 pc Quick Reference Guide
1 pc Electrical connection cable for connecting the gripping system to the robot (optional)
1 pc Hose clamp (only for FMCB)
Note
The operating instructions are part of the system and must be kept with the system every time it is
relocated.
4.1.2Checking for Completeness
Using the enclosed delivery documents, check the entire shipment to ensure that it is complete. Also
refer to our Terms and Conditions of Sale and Delivery.
ATTENTION
Incorrect disposal of the system or individual components
Environmental damage
►
Disposal according to national guidelines.

TRANSPORT AND ASSEMBLY
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4.1.3Reporting Damage
After delivery of the shipment, damage due to faulty packaging or transport must be reported immedi-
ately to the carrier and J.Schmalz GmbH.
Packaging4.2
The system is shipped in a transport box made specifically for the system.
Storage4.3
The system must be stored in its original packaging as long as it is not being used and is to be stored
for any period of time.
ATTENTION
Incorrect storage of the system
Material damage to the system
►
The system may only be stored as described in the operating instructions.

START OF OPERATIONS AND SETUP
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5 Start of Operations and Setup
CAUTION
General notes on the start of operations
Risk of injuries
►
The system integrator must secure the danger zone.
►
The production system must be stopped in the area where the system is
being set up.
►
The system may only be set up at the workplace in accordance with the
operating instructions.
►
The system must be disconnected and depressurized during setup.
►
The production system must be secured to prevent activation during
setup.
Approach of a moving element to a fixed part/machinery mobili-
ty/moving elements
Body parts could be crushed, sucked in or caught if the flat suction cup
is abruptly attached to a workpiece or a surface.
►
Do not place any body parts between the bottom of the gripper and a
surface.
High pressure
Placement/release of compressed air lines
►
The system integrator must secure the danger zone.
►
Regularly inspect the gripper and perform regular maintenance in order
to detect and replace porous compressed air lines in good time. Re-
place defective connectors.
Stored energy/vacuum
Body parts could be crushed, cut, sucked in, caught or sliced if the flat
suction cup is abruptly attached to a workpiece or a surface.
►
Do not place any body parts between the bottom of the gripper and a
surface.
►
Eyes can be sucked in; do not look into open vacuum openings.
Conductive parts/parts that have become live in an error
state/short circuits
Electric shock
►
Regularly inspect and perform maintenance on the gripper to detect and
repair wear or faulty connections in good time.

START OF OPERATIONS AND SETUP
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CAUTION
Noise hazards due to the exhaust system or gas flowing at high
speeds or worn parts
Discomfort, tinnitus, stress, exhaustion due to constant/
high noise levels
►
If possible, switch off vacuum generators (only FMCB) and the blow-off
function when not in use in order to reduce noise pollution.
►
Wear personal protective equipment e.g. ear protectors
►
If possible, position vacuum generators (only FMCB) far enough away
from machine operators; use additional silencers
►
Regularly inspect and perform maintenance on the system in order to
ensure that it works properly.
Careless use of personal protective equipment
Danger to the operator
►
Adapt and wear appropriate personal protective equipment based on
the task being performed.
WARNING
System setup by untrained personnel
Serious personal injury
►
The system must only be set up by trained personnel who have read and un-
derstood the operating instructions.
Non-compliance with work safety instructions
Personal injuries and damage to the system
►
Never lift loads at an angle and never drag them.
►
Do not tear off stuck loads.
►
Only pick up and lift suitable loads (check inherent stability and surface densi-
ty).
►
Only set workpieces down on clear, even surfaces due to the danger of slip-
ping.
►
Do not release the load until it rests completely and safely on a secure surface.
►
Do not come close to the load when releasing/depositing it and do not touch it.

START OF OPERATIONS AND SETUP
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DANGER
General safety notes on the start of operations
Danger to life and limb
►
The system must only be set up by trained personnel who have read and un-
derstood the operating instructions.
►
The system integrator must secure the danger zone.
►
The production system must be stopped in the area where the system is being
set up
►
The system may only be set up at the workplace in accordance with the operat-
ing instructions.
►
The system must be disconnected during setup.
►
The production system must be secured to prevent activation during setup.
Acceleration/deceleration/kinetic energy
Danger to life and limb
►
See general safety notes on the start of operations
Danger of falling objects/gravity:
Danger to life and limb
►
See general safety notes on the start of operations
►
Never stand under suspended loads.
Human error
Danger to life and limb
►
Adhere to the operating instructions