Schmalz SGM-HP 40x121 User manual

Magnetic Gripper SGM-HP 40x121 / SGM-HT-HP 40x121
Assembly Instructions
WWW.SCHMALZ.COM EN-US · 30.30.01.02582 · 00 · 11/20

Note
The Assembly instructions were originally written in German. Store in a safe place for future reference.
Subject to technical changes without notice. No responsibility is taken for printing or other types of er-
rors.
Published by
© J.SchmalzGmbH, 11/20
This document is protected by copyright. J.SchmalzGmbH retains the rights established thereby. Repro-
duction 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 writ-
ten agreement from J.SchmalzGmbH.
Contact
J. Schmalz GmbH
Johannes-Schmalz-Str. 1
72293 Glatten, Germany
T: [phone]
[email protected]
www.schmalz.com
Contact information for Schmalz companies and trade partners worldwide can be found at:
www.schmalz.com/salesnetwork
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Contents
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Contents
1 Important Information ...................................................................................................................................5
1.1 The technical documentation is part of the product ........................................................................ 5
1.2 Note on Using this Document ............................................................................................................ 5
1.3 Warnings in This Document................................................................................................................ 5
1.4 Symbol.................................................................................................................................................. 5
1.5 Type Plate ............................................................................................................................................ 5
1.6 Other Applicable Documents ............................................................................................................. 6
2 Fundamental Safety Instructions...................................................................................................................7
2.1 Intended Use........................................................................................................................................ 7
2.2 Non-Intended Use ............................................................................................................................... 7
2.3 Danger Zone ........................................................................................................................................ 7
2.4 Environmental and Operating Conditions......................................................................................... 8
2.5 Personnel Qualifications ..................................................................................................................... 8
2.6 Technical Condition............................................................................................................................. 8
2.7 Responsibility of the Integrator ......................................................................................................... 8
2.8 Country-Specific Regulations for the Operating Company .............................................................. 9
3 Product Description ......................................................................................................................................10
3.1 Description of the Magnetic Gripper ............................................................................................... 10
3.2 Variants and Type Key ...................................................................................................................... 10
4 Technical Data ...............................................................................................................................................11
4.1 General Parameters........................................................................................................................... 11
4.2 Dimensions......................................................................................................................................... 12
5 Transport and Storage..................................................................................................................................13
5.1 Checking the Delivery ....................................................................................................................... 13
5.2 Reusing the Packaging...................................................................................................................... 13
6 Installation.....................................................................................................................................................14
6.1 Installation Instructions..................................................................................................................... 14
6.2 Mechanical Attachment.................................................................................................................... 14
6.3 Pneumatic connection....................................................................................................................... 15
7 Start of Operations .......................................................................................................................................16
7.1 Personnel Qualification..................................................................................................................... 16
7.2 Before Initial Start of Operations..................................................................................................... 16
8 Operation ......................................................................................................................................................17
8.1 Preparations....................................................................................................................................... 17
9 Troubleshooting............................................................................................................................................18
9.1 Safety ................................................................................................................................................. 18
9.2 Faults, Causes, Solutions ................................................................................................................... 18
10 Maintenance..................................................................................................................................................20
10.1 Safety ................................................................................................................................................. 20
10.2 Maintenance Schedule...................................................................................................................... 20

Contents
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10.3 Cleaning the Magnetic Gripper........................................................................................................ 21
10.4 Accessories, Spare Parts and Wearing Parts..................................................................................... 21
11 Disposing of the Product..............................................................................................................................23

Important Information
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1Important Information
1.1The technical documentation is part of the product
1. For problem-free and safe operation, follow the instructions in the documents.
2. Keep the technical documentation in close proximity to the product. The documentation must be ac-
cessible to personnel at all times.
3. Pass on the technical documentation to subsequent users.
ðFailure to follow the instructions in these Assembly instructions may result in injuries!
ðSchmalz is not liable for damage or malfunctions that result from failure to heed these instructions.
If you still have questions after reading the technical documentation, contact Schmalz Service at:
www.schmalz.com/services
1.2Note on Using this Document
J.SchmalzGmbH is generally referred to as Schmalz in these Assembly instructions.
These Assembly instructions contain important notes and information about the different operating
phases of the product:
• Transport, storage, start of operations and decommissioning
• Safe operation, required maintenance, rectification of any faults
The Assembly instructions describe the product at the time of delivery by Schmalz.
1.3Warnings in This Document
Warnings warn against hazards that may occur when handling the product. The signal word indicates the
level of danger.
Signal word Meaning
WARNING Indicates a medium-risk hazard that could result in death or serious injury if
not avoided.
CAUTION Indicates a low-risk hazard that could result in minor or moderate injury if
not avoided.
NOTE Indicates a danger that leads to property damage.
1.4Symbol
This symbol indicates useful and important information.
üThis symbol represents a prerequisite that must be met prior to an operational step.
4This symbol represents an action to be performed.
ðThis symbol represents the result of an action.
Actions that consist of more than one step are numbered:
1. First action to be performed.
2. Second action to be performed.
1.5Type Plate
The type plate is permanently attached to the product and must always be clearly legible.
The type plate contains the following data:

Important Information
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• Company logo/address
• Part sales designation/type
• Manufacturing date
• Serial number
• Permitted pressure range
• QR code
4Please specify all the information above when ordering replacement parts, making warranty claims
or for any other inquiries.
1.6Other Applicable Documents
The following operating instructions must also be observed when setting up the magnetic gripper:
• The operating instructions 30.30.01.01624 for the proximity switch.

Fundamental Safety Instructions
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2Fundamental Safety Instructions
2.1Intended Use
WARNING
The product contains a permanent magnet that generates a continuous magnetic
field.
Danger for persons with pacemakers. Devices and data carriers can be damaged.
4Keep persons with pacemakers away from the product.
4Keep sensitive electrical devices and data carriers away from the product.
The magnetic gripper is used for handling ferromagnetic workpieces, such as perforated plates, complex
laser-cut workpieces, plates with drill holes and apertures.
The operator is required to document the static strength and holding force and to adhere to safety fac-
tors.
For system designs, a safety factor of S=3 should be applied.
The loads to be lifted must be rigid enough to ensure they are not destroyed during lifting.
The magnetic gripper is built in accordance with the latest standards of technology and is shipped in safe
condition. However, hazards can arise during use. Observe the warnings in these operating instructions.
The maximum lift capacity must not be exceeded (> See ch. Technical Data).
Do not operate the device in environments where there is a risk of explosion.
Do not operate the product in aggressive environments (e.g. ambient air containing solvent fumes).
2.2Non-Intended Use
Schmalz accepts no liability for damage caused by the use of the gripper for purposes other than those
described under Intended Use. Use of the gripper for loads that are not specified in the order confirma-
tion or that have different physical properties than those specified in the order confirmation shall be con-
sidered non-intended use. In particular, the following are considered non-intended use:
• Use as a climbing aid
• Lifting people or animals
• Storing loads when active
• Supporting the lifting process by applying external forces
• Freeing building components or immovable equipment
2.3Danger Zone
Persons in the danger zone of the gripper may suffer life-threatening injuries.
The system integrator must carry out a risk assessment of the entire system and define the danger zone
precisely. In doing so, country-specific provisions and regulations must be observed.
Automatic operation on the industrial robot or gantry
• During automatic operation of the handling system, no persons or animals may be present in the
danger zone.
• In other operating modes, ensure that no unauthorized persons or animals are present in the dan-
ger zone.
• Ensure that collisions with the surrounding environment and objects do not occur to prevent the
load from breaking off.
During automatic operation of the handling system, the danger zone must be secured to prevent access
by persons (protective barrier or sensor system).

Fundamental Safety Instructions
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The danger zone of the gripper includes the following areas:
• The area directly below the gripper and load.
• The area immediately surrounding the gripper and load.
• The working area of the automatic handling system.
2.4Environmental and Operating Conditions
The gripping system must not be operated under the following conditions:
• In potentially explosive atmospheres
• Use in an environment with acidic or alkaline media
The gripping system must be operated only under the following conditions:
• The gripping system must be sufficiently dimensioned for the loads to be lifted.
4If in doubt, consult Schmalz before the start of operations.
2.5Personnel Qualifications
Unqualified personnel cannot recognize dangers and are therefore exposed to higher risks!
The operating company must ensure the following points:
• The personnel must be commissioned for the activities described in these instructions.
• The staff must be at least 18 years of age and physically and mentally capable.
• The product must be operated only by persons who have undergone appropriate training.
• Personnel must receive regular safety briefings (frequency as per country-specific regulations).
• Installation, maintenance, and repairs must be carried out only by specialists from J.SchmalzGmbH
or by persons who can prove that they have undergone appropriate training at Schmalz.
The following target groups are addressed in these instructions:
• Mechanical and electrical specialists who are responsible for installing, troubleshooting and main-
taining the product.
The operator of the system must comply with country-specific regulations regarding the age, ability and
training of the personnel.
Valid for Germany:
A qualified employee is defined as an employee who has received technical training and has the knowl-
edge and experience – including knowledge of applicable regulations – necessary to enable him or her to
recognize possible dangers and implement the appropriate safety measures while performing tasks. Qual-
ified personnel must observe the pertinent industry-specific rules and regulations.
2.6Technical Condition
If the product is operated while in a defective state, safety and function will be impaired.
• Only operate the gripper when in perfect working order as originally delivered.
• Follow the maintenance schedule.
• Use only original spare parts from Schmalz.
• If the operating behavior changes, check the gripper for faults. Rectify faults immediately!
• Do not independently modify or alter the gripper.
• Safety features must not be disabled under any circumstances.
Schmalz assumes no liability for consequences of modifications over which it has no control.
2.7Responsibility of the Integrator
The integrator is obligated to perform a risk assessment for the environmental conditions at the installa-
tion location.

Fundamental Safety Instructions
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The integrator is also responsible for third parties in the working area of the gripper. The operating com-
pany must ensure that they have the appropriate qualifications and skills.
• Ensure that regular breaks are taken.
• Ensure that the gripper cannot be started up by unauthorized persons.
• During maintenance or repair work, ensure that the gripper cannot be operated.
• Clearly define the responsibilities for the various activities performed with the gripper.
• Ensure that these responsibilities are observed.
• When handling unfamiliar loads, carry out tests where necessary to ensure safe operation:
– The load is sufficiently rigid that it cannot be damaged during handling.
2.8Country-Specific Regulations for the Operating Company
1. Observe the country-specific regulations regarding accident prevention, safety testing and environ-
mental protection.
2. The gripper is to be used in combination with an automated handling system (gantry/robot). Ensure
that the appropriate country-specific regulations and safety regulations are adhered to.

Product Description
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3Product Description
3.1Description of the Magnetic Gripper
Magnetic grippers lift ferromagnetic workpieces using magnetic force. They are used for handling sheet
metal, perforated plates, complex laser-cut workpieces, sheets with drill holes as well as apertures, corru-
gated sheets, and pipes.
By applying compressed air, the permanent magnets are moved towards the gripping surface (gripping
the workpiece) or away from the gripping surface (depositing the workpiece).
The bistable mode of operation allows safe gripping even during a power failure.
The gripper is available in two different versions:
• Magnetic gripper SGM-HP 40x121 with very high holding forces
For demanding applications with an operating temperature of up to 70° C
• Magnetic gripper SGM-HT-HP 40x121 with very high holding forces
For demanding high-temperature applications with an operating temperature of up to 150° C and
workpiece temperature of up to 350° C
The (external) compressed air generation is not included in the scope of delivery. If you have any ques-
tions about the design, please contact the Schmalz service team at:
www.schmalz.com/services
2
1
3
4
5
6
1 1/8" compressed air connection
(depositing workpiece)
2 1/8" compressed air connection
(gripping workpiece)
3 M5 mounting thread (6x)
for universal connection
4 M5 mounting thread (4x)
for lateral holder systems (> See ch. Acces-
sories)
5 M6 mounting thread (4x)
for front holder systems (> See ch. Acces-
sories)
6 Support rail (2x)
3.2Variants and Type Key
The magnetic gripper is available in two different versions. The version is indicated in the item designa-
tion. The item designation is composed as follows:
Part number Type name High-tempera-
ture
High power Gripping sur-
face
10.01.17.00566 SGM-HP 40x121 --- HP 121 x 40 mm
10.01.17.00544 SGM-HT-HP 40x121 HT HP 121 x 40 mm

Technical Data
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4Technical Data
4.1General Parameters
Parameter Gripper type Unit
SGM-HP 40x121 SGM-HT-HP 40x121
Operating medium Air or neutral gas, 40 µm filtered, with or without oil, class 7-4-4 com-
pressed air quality acc. to ISO 8573-1
Holding force 1 ≥ 0.5 mm,
sheet metal
65 75 N
Holding force 1 ≥ 0.7 mm,
sheet metal
120 140 N
Holding force 1 ≥ 1 mm,
sheet metal
270 230 N
Holding force 1 ≥ 2 mm,
sheet metal
580 600 N
Max. holding force 11070 1170 N
Lateral force, dry 2210 190 N
Lateral force, oily 2160 175 N
Residual holding force ≤ 2.5 N
Opt. operating pressure 2.5 ... 6.0 bar
Ambient temperature 5 ... 70 max. 150 °C
Contact temperature max. 70 max. 3503°C
Mode of operation bistable
Mounting position any
Weight 1500 g
1 All holding forces are static and unsecured when gripper active surfaces are fully covered on steel plate
S235 at +20°C.
2 2 mm steel plate
3 Can be used for workpiece temperatures up to 350° C (depending on process conditions). The influence
of temperature can reduce holding forces by up to 30%.
As the operating temperature increases, the holding force of the grippers decreases. We rec-
ommend performing tests before continuous operation.
The specified values apply to clean, smooth surfaces for low-carbon steel sheets. Dirty, rough,
and highly alloyed steel sheets reduce the holding force.
For maximum holding forces, the component to be handled must completely cover the grip-
ping surface.
Due to the design of the gripper, it is not possible to centrally grip parts that are smaller than
the gripping surface.

Technical Data
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4.2Dimensions
L B H H2 H3 H4 X1 X2 X3 Y1
121 40 102 36.7 33.6 2.6 57 20 60 40
Y2 Y3 Y4 G2 LG2 G4 LG4 G5 LG5 W
81 16 30 1/8" in-
ternal
thread
7 M5 in-
ternal
thread
7 M6 in-
ternal
thread
6.5 30°
All specifications except angles given in mm.

Transport and Storage
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5Transport and Storage
5.1Checking the Delivery
The scope of delivery can be found in the order confirmation. The weights and dimensions are listed in
the delivery notes.
1. Compare the entire delivery with the supplied delivery notes to make sure nothing is missing.
2. Damage caused by defective packaging or occurring in transit must be reported immediately to the
carrier and J.SchmalzGmbH.
5.2Reusing the Packaging
The product is delivered in cardboard packaging. The packaging should be reused to safely transport the
product at a later stage.
Keep the packaging for future transport or storage.

Installation
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6Installation
6.1Installation Instructions
WARNING
The product contains a permanent magnet that generates a continuous magnetic
field.
Danger for persons with pacemakers. Devices and data carriers can be damaged.
4Keep persons with pacemakers away from the product.
4Keep sensitive electrical devices and data carriers away from the product.
CAUTION
Improper installation or maintenance
Personal injury or damage to property
4Prior to installation and before maintenance work, the product must be disconnected
from the power supply, depressurized (vented to the atmosphere) and secured against
unauthorized restart.
2
1
3
4
5
1 1/8" compressed air connection
(depositing workpiece)
2 1/8" compressed air connection
(gripping workpiece)
3 M5 mounting thread (6x)
for universal connection
4 M5 mounting thread (4x)
for holder systems (> See ch. Accessories )
5 M6 mounting thread (4x)
for holder systems (> See ch. Accessories )
6.2Mechanical Attachment
The gripper is adapted to the handling system either directly or by using interchangeable holder systems.
The holder systems can be chosen from the range of accessories. (> See ch. Accessories)
The gripper may be installed in any position.

Installation
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6.3Pneumatic connection
1. Shorten the hoses and pipelines as much as possible.
2. Keep hose lines free of bends and crimps.
3. Lay hose lines in such a way that they do not rub.

Start of Operations
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7Start of Operations
7.1Personnel Qualification
Unqualified personnel cannot recognize dangers and are therefore exposed to higher risks!
1. Only instruct qualified personnel to perform the tasks described in these operating instructions.
2. The product may only be operated by persons who have undergone appropriate training.
3. Electrical work and installations may only be carried out by qualified electrical specialists.
4. Assembly and maintenance work must only be carried out by qualified personnel.
7.2Before Initial Start of Operations
Before the initial start of operations following the installation, repair, servicing or maintenance work, you
must check the following:
• All mechanical connectors are properly attached and secured.
• All screws and nuts are tightened to specified torques.
• All components are installed.
• The safety distances have been maintained.
• The supply hoses are properly routed.
• The EMERGENCY STOP switch for the overall system is working.
• The type plate and “Warning of Magnetic Field” sign are present and easy to read.
CAUTION
Noise pollution due to incorrect installation of the pressure and vacuum connec-
tions
Hearing damage
4Correct installation.
4Wear ear protectors.
CAUTION
Risk of crushing if workpiece is abruptly attached
4Do not place any body parts between the gripping surface and workpiece.

Operation
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8Operation
8.1Preparations
4The product must be operated only by persons who have undergone appropriate training.
WARNING
The product contains a permanent magnet that generates a continuous magnetic
field.
Danger for persons with pacemakers. Devices and data carriers can be damaged.
4Keep persons with pacemakers away from the product.
4Keep sensitive electrical devices and data carriers away from the product.
To avoid injury, always use appropriate protective equipment that is suitable for the situation. The protec-
tive equipment must meet the following standards:
• Protective work shoes in safety class S1 or higher
• Ear protection class L or higher
• Sturdy work gloves in safety category 2231 or higher
• Eye protection class F
Before each activation of the gripping system, the following measures must be taken:
1. Check the device for visible damage. Correct any faults or report them to the supervising personnel.
2. Ensure that only authorized persons are present in the working area of the machine or system in or-
der to prevent any hazard from switching on the machine.
3. Ensure that the danger zone of the machine or system is free of persons during automatic opera-
tion.

Troubleshooting
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9Troubleshooting
9.1Safety
Maintenance work may only be carried out by qualified personnel.
WARNING
Risk of injury due to incorrect maintenance or troubleshooting
4Check the proper functioning of the product, especially the safety features, after every
maintenance or troubleshooting operation.
CAUTION
Improper installation or maintenance
Personal injury or damage to property
4Prior to installation and before maintenance work, the product must be disconnected
from the power supply, depressurized (vented to the atmosphere) and secured against
unauthorized restart.
9.2Faults, Causes, Solutions
Fault Possible cause Solution
Workpiece is not
gripped
Magnets are not in the corresponding
end position
Check compressed air supply
Check hose connections and plug-in
screw unions
Pressure too low
Magnetic gripper
leaks when com-
pressed air is ap-
plied
Sealing elements damaged; use at too
high contact or ambient temperature
Maintain defined temperature ranges
for the HP and HT-HP variants.
Workpiece is only
gripped with re-
duced holding
force
The workpiece to be handled does not
completely cover the gripping surface.
For maximum holding forces, the work-
piece to be handled must completely
cover the gripping surface.
Support rail damaged Replace damaged support rails.
Ferromagnetic pollutants on the grip-
ping surface (e.g. iron shavings)
Clean the gripping surface.
Support rails have no or insufficient
contact to the pole shoes
When mounting the support rails, en-
sure that the contact to the pole shoes
is flat.
The workpiece to be gripped has a dirty
and/or rough surface or is highly al-
loyed.
If possible, only handle low-carbon
workpieces (steel sheets) with a clean
and smooth surface.
The operating or ambient temperature
is too high.
Maintain defined temperature ranges
for the HP and HT-HP variants; if neces-
sary, perform tests before continuous
operation.
When using sensors (for 10.01.17.00566 only)
Sensor (for moni-
toring the piston
position) cannot
be taught
Sensor defective Replace the sensor.

Troubleshooting
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Fault Possible cause Solution
Sensor cannot be
taught or can only
be taught with er-
rors
Teaching is performed using a magneti-
zable tool (e.g. ballpoint pen refill,
hexagon wrench, etc.).
Use the teach-in tool supplied with the
sensor or a comparable plastic pen.
Sensor signal is
lost or faulty
Sensor not fully inserted into the corre-
sponding sensor slot; sensor fastening
screw is loose
Push sensor in as far as possible and
tighten fastening screw with specified
torque.
Magnetic interference fields Avoid magnetic interference fields and
maintain minimum distances.
Ferromagnetic pollutants in the area of
the sensor slot (e.g. iron shavings)
Check the sensor slot(s) at regular inter-
vals and clean them if necessary.

Maintenance
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10Maintenance
10.1Safety
Maintenance work may only be carried out by qualified personnel.
WARNING
Risk of injury due to incorrect maintenance or troubleshooting
4Check the proper functioning of the product, especially the safety features, after every
maintenance or troubleshooting operation.
CAUTION
Improper installation or maintenance
Personal injury or damage to property
4Prior to installation and before maintenance work, the product must be disconnected
from the power supply, depressurized (vented to the atmosphere) and secured against
unauthorized restart.
10.2Maintenance Schedule
Schmalz stipulates the following checks and check intervals. The operator must comply with
the legal regulations and safety regulations applicable at the location of use. These intervals
apply to single-shift operation. For heavier use, such as multi-shift operation, the intervals
must be shortened accordingly.
Maintenance task Daily Weekly Monthly Every six
months
Yearly
Check the level of wear on the support
rails
X
Replacing the support rails
The wearing part set contains the following single components:
• Support rails (2x)
• Locking washers (8x)
• Machine screws (8x)